HMC Maintenance - CNCzone

Machine Tools

HMC Maintenance (HP5100)

124

HP5100 HP51MTE87

Contents

No. Alarm

number Alarm Name Page

1 2001 OP Emg. Stop PB or LS Off 126

2 2002 Main Spindle Servo Alarm 128

3 2003 Circuit Protector Trip 130

4 2004 Hyd. Pump Motor Overload 132

5 2005 Hyd. Pressure Down Alarm 134

6 2009 ATC Servo or Inverter Alarm 137

7 2010 Spindle Tool Unclamp Cmd. Fault 138

8 2015 Spindle Tool Unclamp Alarm 140

9 2020 Coolant & Lub. Pump Overload 142

10 2021 Air Pressure Down Alarm 175

11 2023 M06 Command Overtime Alarm 162

12 2036 Magazine Rotation or Matrix Illegal Position Alarm 167

13 2037 M06 Command Illegal Pos. 171

14 2041 APC Overtime Alarm 173

15 2042 M61 / M62 Command Illegal Position 176

16 2048 ATC Door Open 180

17 2050 Lub. Level Low or Pressure Down 184

18 2051 Oil cooling Unit Alarm 186

19 2052 Filter Change Alarm For TSC Unit 195

20 2060 Spindle Tool CL/UNCL Overtime Alarm 196

21 2063 ATC Arm Pin Alarm 198

22 2064 Waiting Tool Pot Spindle/Magazine Side Alarm 200

23 2065 Changer Arm Position Check Alarm 203

24 2073 Pallet or Table CL/UNCL Switch Alarm 207

25 2074 ATC Overtime Alarm 211

26 2075 ATC Magazine Rotation Over Time Alarm 215

27 2077 Waiting Pot & Spindle Tool No. Zero 218

28 2078 ATC OP Manual Mode 220

29 2080 ATC or APC Interlock Alarm 222

30 2081 ATC Magazine Guard Door Open 226

31 2084 APC Set-Up Station Door Open 228

125

HP5100 HP51MTE87

No. Alarm

number Alarm Name Page

32 2085 APC Set-Up Location S/W Unpush 229

33 2086 APC OP Manual Mode 231

34 2090 Table Or Pallet Clamp Alarm 233

35 2094 Chip or Screw Conveyor Alarm 236

36 2107 Operator’s Door Open 238

37 2118 Operator’s Door Open Alarm 239

38 2120 Y-Z Interference Zone Alarm 241

39 2126 APC Up / Down Alarm 243

40 2127 APC Changer 180CW/CCW Alarm 246

41 2154 Waiting Pot Clamp Alarm 249

42 2155 Tool Magazine Pot Detect Switch Alarm 251

43 2158 Waiting Pot Spindle/Magazine Side Command 254

44 2160 APC Pallet Check Switch Alarm 256

45 2163 ATC Door Open/Close Alarm 258

46 2200 T-code Or M06 Commanded Status 260

47 2215 VPF Off Of Tool Magazine 261

Appendix1 X-Y Signal Address 263

Appendix2 M-CODE LIST 268

Appendix3 Repairing Method of Spindle Amp Alarms 274

Appendix4 ATC Main Changer Sequence Chart 280

Appendix5 Pallet Change Sequence Chart 281

Appendix6 Recovering ATC Breakdowns 283

Appendix7 Repairing Method of Servo Driver Alarms 286

126

HP5100 HP51MTE87

OP Emg. Stop PB or LS Off

Either the Emergency Stop Push Button Switch has been pressed on the

operation panel, or more than one of Emergency Stop Axis Limit Switches

of each axis have been activated.

① The Emergency Stop Push Button Switch has been pressed on the

operation panel (Main O.P, ATC O.P).

② The Axis (X,Y,Z Axis) Emergency Stop Limit Switch has been pressed.

③ The operation panel Emergency Stop Switches, axis emergency stop

Limit Switches, or other related parts are faulty.

④ The connecting cable has been disconnected.

① Check if the red spade-shaped push button switch has been pressed on

the operation panel (Main O.P, ATC O.P). If it is pressed, turn the

switch clockwise to release it.

② When each axis's(X, Y, Z Axis) emergency stop Limit Switch has been

activated, simultaneously press the operation panel Machine Ready

Switch and the Emergency Release Switch to set the machine at

Machine Ready. (If the switch is released, the machine returns to

emergency status.) Transfer the problem axes in Jog or Handle Mode

to release it from the axis emergency stop Limit Switch.

③ Check the operation panel Emergency Stop Switches, axis emergency

stop Limit Switches, or other related parts for problems. Make any

necessary replacements or repairs.

④ Connecting Cable Disconnection: Refer to the Electric drawings and use

a Electric tester to check the Terminal Block for each terminal to find

the problem area. Connect the cable or replace with a new cable.

Part Name Part Number Symbol Model Maker

Switch, Emergency P/B

(for Main) ESWPB0439 SB1 B130-81L 2B KACON


(for ATC) ESWPB0226 SB7 KH-3046ER-RED Kunhung


(for APC) ESWPB0248 SB9 AH30-VR02 Fuji

Solution

Cause

Status

2001

127

HP5100 HP51MTE87

Signal Address Symbol I/O Status Connector

(Pin)

Numbering

Tube

Emergency Stop

X8.4 ESP.M

-SB1,124,SEMG, SL1,2,3,12A,13A,

15ª

Input Module Slot 02

T/Block(31) ESP

Machine

Ready

X32.4

MRD.M -SB11

Distributed I/O

Module A XC56A(A04) SB11

ddress Symbol Coil Comment

A0.0 2001 OP Emg. Stop or LS Off

R650.2 APONI Auto Power On Initial Flag

R652.7 ARST Upper Alarm Reset

X8.4 ESP.M Emergency Stop

X32.4 MRD.M Machine Ready

OP Emg. Stop PB or LS Off

128

HP5100 HP51MTE87

Main Spindle Servo Alarm

The Alarm shows on the Main Spindle Drive Unit

① Main Spindle Drive Unit troubled

② The Spindle Motor, power cable, or signal cable troubled

Check the Alarm number appearing in the Main Spindle Drive Unit on ①

the operation panel

Take appropriate ② actions according to the alarm number.

Refer to appendix (Repairing Spindle Amp Alarms)☞

Check the spindle motor three③ -phase power and Feedback cable

connections

Actions

Cause

Status

2002

129

HP5100 HP51MTE87

Address Symbol Coil Comment

A0.1 2002 Main Spindle Servo Alarm

F45.0 ALMA Spindle Alarm

R652.7 ARST Alarm Reset

Main Spindle Servo Alarm

130

HP5100 HP51MTE87

Part Name Part Number Symbol Model Maker

Protector, Auxiliary ENFBX0290S QF14,15,22,

QF23,27,28,81

5SX9100

INO+1NC(6.0A) Siemens

Protector, Circuit ENFBX0283S QF14 5SX2216-7 Siemens



Protector, Circuit ENFBX0264S QF22,81 5SX2101-7 Siemens

Protector, Circuit ENFBX0551 QF28 5SX2125-7 Siemens


Signal Address Tool Symbol I/O Connector

(Pin)

Numbering

Tube

Circuit Protect Trip X2.3

TRIP.M

-QF 14,15,21,22,

23,81,27,28

Input

Module

Slot 07

T/Block(07) TRIP

Circuit Protector Trip

Circuit Protect has been activated in the electrical cabinet.

① Circuit Protect has been activated. (Detection of abnormal electric

current)

② Control power faulty

③ Circuit protect faulty

① Find the reason for tripping the Circuit Protector.

☞ (ex) If QF22 has been tripped, first check for short-circuiting in the

QF22's secondary L+ cable. After repairing, replace the tripped Circuit

Protector.

② If the alarm shows without tripping the circuit protector, measure

resistance at each auxiliary a contact to find the short-circuited Circuit

protector, and replace it with a new one.

☞ The normal resistance measure for contact points when Circuit

Protect is On is “0”Ohm.

③ Check the I/O board: If ①~② are normal, the I/O board is faulty.

Solution

Cause

Status


2003

131

HP5100 HP51MTE87


A0.2 2003 Circuit Protector Trip


X2.3 TRIP.M Emergency Stop

TRIP -Q F23 AC 100V Control

-Q F14 Transe Form er Power TRIPE

TRIPA -Q F81 ATC Motor Brake

-Q F21 DC 24V Control TRIPD TRIPF

TRIPC -Q F28 Solenoid DC Power Source

-Q F22 Tool Magazine Motor Brake TRIPH

1L+


15

X2.3 (TRIP.M )

Input M odule(AID32E) : Slot 7


Input Module(AID32E) :Slot

X2.3 (TRIP.M)

15

132

HP5100 HP51MTE87

Hyd. Pump Motor Overload

Overcurrent detected in the Hyd. Pump Motor.

① Burnout of the Hyd. Pump Motor or power Cable

② Fault in the Load Setting value of the Overcurrent Detecting circuit

breaker or the Circuit Breaker itself

① Check the Hyd. Pump Motor or Power Cable. If there are problems,

repair or replace with a new one.

② Check the load Setting value of the Overcurrent Detecting circuit

breaker. If it is wrong, reset it. If the circuit breaker itself is faulty,

replace with a new one. (The problem circuit breaker can be found by

the KA11 contact and and 1L+ contact and resistance check)

☞ QM31 Setting Overload: 2.2Kw : 9.6A

QM32 Setting Overload: 2.2Kw : 10.0A

QM36 Setting Overload: 2.2Kw : 10.0A, 3.7Kw : 17A

Product Product # Symbol Model Maker

Breaker, Auxillary ENFBX0290R QM31, 32 3RV1901-1F(2NO) Siemens

Breaker, Circuit ENFBX0285R QM31, 32 3RV1011-1KA10(9-

12A) Siemens

Signal Address Tool

Symbol I/O

Connector

(Pin)

Numbering

Tube

Hydraulic Motor

Overload

X2.1

HOL.M -QM31 Input Module Slot 07 XJ411 (32) HOL

z


A0.3 2004 Hyd. Pump Motor Overload

R652.7 ARST Upper Alarm Reset

X2.1 HOL.M Hydralic. Motor Overload

Solution

Cause

Status

Hyd. Pump Motor

Overload

2004

133

HP5100 HP51MTE87

-QM31 Hyd. Pump Motor(Main)

HO LA

-QM32 Hyd. Pump Motor(PMG )

HO LB

-QM36 Fixture Hyd. Pum p Motor

1L+

32

X2.1 (HO L.M)

Input M odule(AID32E) : Slot 7

Hyd. Pump M otor Overload

Input Module(AID32E) : Slot7

X2.1 (HOL.M)

XJ411 (32)


134

HP5100 HP51MTE87

Hyd. Pressure Down Alarm

The Hyd. Pressure Switch has been activated because the pressure in the

Hyd. Power Unit has fallen below the Hyd. Pressure Switch set point.

① Hyd. Power Unit malfunction, or the oil pressure has fallen below 20

kg/㎠.

② Hyd. Pressure Switch or other parts faulty

① Turn the Hyd. Power Unit pressure adjustment valve clockwise to set

the pressure at 50Kg/㎠.

② Hyd.Power Unit, Pressure Switch itself,cables, or related parts faulty.

Check Hyd. Power Unit, Pressure Switch, all cables between Switch and

the operation panel and input modules. Repair or replace with new

ones.

Signal Address Tool

Symbol I/O

Connector

(Pin)

Numbering

Tube

Hyd.Pressure

Check

(Main)

X3.0

HPRS.M -SP01

Input Module Slot

07 XJ411 (12) SP01

Hydraulic 1,2,3

Motor Run

Y38.4

HYDM.R -KA31

Distributed I/O

Module B XCE57B(A18) KA31

Solution

Cause

Status

Aux. Hyd. Pressure

OK Flag

Hyd. Pressure

Down Alarm

2005

135

HP5100 HP51MTE87


A0.0 2001 OP Emg. Stop PB or LS Off

A0.1 2002 Main Spindle Servo Alarm

A0.2 2003 Circuit Protector Trip

A0.3 2004 Hyd, Pump Motor Overload

A0.4 2005 Hyd. Pressure Down Alarm

A0.6 2007 Spindle Stop Signal Alarm

A0.7 2008 -

A1.0 2009 Spindle Servo or Inverter Alarm

A1.6 2015 Spindle Tool Unclamp Alarm

F0.6 SA Servo Ready

F1.0 AL NC Alarm

K5.0 KHPRS Hyd. Pressure Switch Not Used

K11.7 KFXHYD When Motor Of Hyd. Fixture Used

Hyd. Pump On

Check Time

Hyd. Pressure

Check Time (Main)

Hyd. Pressure OK

136

HP5100 HP51MTE87


R440.2 TMB99 Hyd. Pressure Check Time (Fixture)

R441.2 KMB107 Hyd. Pressure D-Time Initial

R625.3 TMB20 Hyd. Motor On Check Time Delay

R629.2 KMB51 Hyd. Pressure Check Time (Main)

R630.0 MRYA Aux. Machine Ready

R630.3 HPOK Hyd. Pressure OK

R647.0 APOFF Auto Power Off


R763.6 MAPCFG Man APC Command Flag

R841.0 APOKF Aux. Hyd. Pressure OK Flag

R1420.7 PMGSEL PMG Operation Selected

X3.0 HPRS.M Hyd. Pressure Check (Main)

Y38.4 HYDM.R Hyd. 1,2,3 Motor Run

137

HP5100 HP51MTE87

ATC Servo or Inverter Alarm

The alarm shows on the inverter of the Servo Motor driving the ATC

① Servo Motor Inverter troubled

② Servo Motor or Connection cable troubled

Refer to the Servo Motor Manual and Repair troubled part or replace with

new ones.☞ Refer to the Appendix (Repairing method by Servo Driver

Alarms)

Signal Address Tool

Symbol I/O

Connector

(Pin)

Numbering

Tube

ATC Servo or

Inverter Alarm

X9.6

TALM.M -A81

Input Module Slot

08 XJ412 (01) TALM


A1.0 2009 ATC Servo or Inverter Alarm

K7.6 KATC ATC Not Used


X9.6 TALM.M ATC Servo or Inverter Alarm

Solution

Cause

Status

ATC Servo or

Inverter Alarm

2009

138

HP5100 HP51MTE87

Spindle Tool Unclamp Cmd. Fault

The clamp/unclamp command signal in the spindle tool during M06

troubled. The tool clamp command signal is confirmed before the

unclamp command signal.

① Fault in the unclamp command signal from ATC servo amp.

② Error in the ATC Servo amp parameters input

①. Check the signal cable connections for unclamp command from

ATC servo amp

②Check the parameters for the ATC Servo Amp Unclamp command

location control

Signal Address Tool

Symbol I/O

Connector

(Pin)

Numbering

Tube

Tool Clamp

Command

X8.5

(CLMD.M) -SX51

Input Module Slot

08 XJ412 (38) SX51

Tool Unclamp

Command

X8.6

(ULMD.M) -SX52

Input Module Slot

08 XJ410 (22) SX52

Solution

Cause

Status

2010

▣PARAMETERS FOR ATC SERVO

67 CLAMP POSITION (*1) 1~360 289 D 277 (270)

68 UNCLAMP POSITION 1~360 25 D 25

NO.67 "289" -> "277" : CHANGE DC24V SOL. (INCLUDE DIODE)

NO.69 "289" -> "284" : CHANGE DC24V SOL. (INCLUDE DIODE)

note *1) ( ) used HSK Tool

NO.ATC SERVO

DEF. TYPEFUNCTION RANGE

HP51

HP41

139

HP5100 HP51MTE87


A1.1 2010 Spindle Tool Unclamp Cmd. Fault



R0705.5 TCFLT Tool Clamp Command Fault

F0.6 SA Servo Ready

R652.6 ERST External Reset

R705.4 TUCCFG ATC Unclamp Command Flag

R705.5 TCFLT Tool Clamp Command Fault

R2409.0 M06CDF M06 Command Flag

X8.5 CLMD.M Tool Clamp Command

F0.6 SA Servo Ready

R705.4 TUCCFG ATC Unclamp Command Flag


X8.6 ULMD.M Tool Unclamp Command

Tool Clamp

Command Fault

Tool Clamp

Command Fault

Tool Clamp

Command Fault

Spindle Tool Unclamp

Cmd. Fault

140

HP5100 HP51MTE87

Spindle Tool Unclamp Alarm

The Spindle Tool Clamp Detection Switch in the Spindle Tool Clamp Status

(Spindle Tool Unclamp Output Off) is off, or the Spindle Tool Unclamp

Detection Switch is On

① Fault in the adjustment of the Spindle Tool Clamp Detection Switch or

the Spindle Tool Unclamp Detection Switch

② Fault in the Switch itself or the connection cable, or related parts

① Readjust the Switch

② Check the proximity Switch, connecting cable, and I/O board. Repair

faulty part or replace with new ones.

Product Product # Symbol Model Label

Switch, Proximity / PNP

ESWPX0265 - BES516-325-E5-C-S4 Balluff

Cable, Proximity S/W ECBLS0170F -SX11/12 BKS B20-1-03 Balluff

Signal Address Tool

Symbol I/O

Connector

(Pin)

Numbering

Tube

Spindle Tool Clamp X6.4

TCL.M -SX11

Input Module Slot

08 XJ412 (31) SX11

Spindle Tool

Unclamp

X6.5

TUCL.M -SX12

Input Module Slot

08 XJ411 (47) SX12

Solution

Cause

Status

2015

0.8~1.2mm

Proximity Switch Dog

Spindle Tool

Clamp

Spindle

Tool

Unclamp

Spindle Tool

Unclamp Alarm

141

HP5100 HP51MTE87


A1.6 A1.6 Spindle Tool Unclamp Alarm


R841.2 SPTCLF Spindle Tool Clamp Flag

X6.4 TCL.M Spindle Tool Clamp

X6.5 TUCL.M Spindle Tool Unclamp

142

HP5100 HP51MTE87

Coolant & Lub. Pump Overload

Overcurrent detected in the coolant or lubricant Pump Motor.

① Burnout of the coolant or lubricant Pump Motor or power cable

② Fault in the Overcurrent detecting Circuit Breaker Load settting value ,

or the circuit breaker itself

① Check the coolant or lubricant Pump Motor and power Cable. Repair

faulty part or replace with new ones.

② Check the Overcurrent detecting Circuit Breaker Load settting value

and reset it. If there is a problem with the circuit breaker itself, replace

with a new one.

☞ QM10 (Spindle & Y-Axis Servo Fan Motor Use) Setting Overload: 1.5A

QM40 (Flushing Coolant Pump Motor Use) Setting Overload: 8.0A

QM41 (Flood Coolant Pump Motor Use) Setting Overload: 8.0A

QM51 (Lub. Pump Motor Use) Setting Overload: 0.9A


Breaker, Motor Circuit ENFBX0255R QM10 3RV1011-1AA10

(1.0-1.6A) Siemens

Breaker, Motor Circuit ENFBX0258R QM40 3RV1011-1GA10

(4.5-6.3A) Siemens

Breaker, Motor Circuit ENFBX0259R QM41 3RV1011-1JA10

(7.0-10.0A) Siemens

Breaker, Motor Circuit ENFBX0254R QM51 3RV1011-0JA10

(0.7-1.0A) Siemens

Breaker, Auxillary ENFBX0290R QM10,40,41,51 3RV1901-1F(2NO) Siemens

Signal Address Tool

Symbol I/O

Connector (Pin)

Numbering Tube

Coolant & Lub. Motor

Overload

X2.2 MOL.M

-QM10~ -QM185

Input Module Slot 07 XJ410 (48) MOL

Solution

Cause

Status

Coolant & Lub. Pump

Overload

2020

143

HP5100 HP51MTE87


A2.3 2020 Coolant & Lub. Pump Overload


X2.2 MOL.M Coolant & Lub. Pump Overload

-QM10 Spindle&Y-Axis Servo Fan motor

MOLA

-QM40 Flushing Coolant Pump Motor

MOLB

-QM41 Flood Coolant Pump Motor

MOLC

1L+

-QM51 Lubrication Pump Motor

MOLM

1L+

48

X2.2 (MOL.M)

Input Module(AID32E) : Slot 7


Input Module(AID32E) : Slot 7

X2.2 (MOL.M)

XJ411 (48)


144

HP5100 HP51MTE87

145

HP5100 HP51MTE87

(Reference) Servo ATC Recovery

1) ATC Structure

Drive Cam Ass’y

Spline Shaft Reduction Gear

ATC Servo

Motor

Unique Tool

Locking Device

Air Cylinder

Changer Arm

Home Position

Detection

Proximity S/W

-. Magazine

Servo Motor

With Brake

-. Reduction Gear

-. Tool Pot Guide

& Clamp Device

146

HP5100 HP51MTE87

2) ATC Main Sequence

Changer Arm Home Position

☞Input Signal : X8.7(CAHP.M),SX53, Input Module Slot8(Pin37) On

Spindle Tool Clamp

☞ Output : Y39.6(STUN.R), KAR11-YV11,Distribute I/O B (A23)

☞ Completion : X6.4(TCL.M), SX11, Input Module Slot8(Pin31)

X6.5 (TUCL.M), SX12, Input Module Slot8(Pin47)

Initial Condition

Arm & Servo Home Position①

2nd Reference Point & M19②

Pot Spindle Si③ de

& Clamp

Arm Pin Release④

X8.7 (SX53) CAHP.M

X7.0 (SX5A) WPSS.M

X7.2 (SD32) WPCL.M

X15.5 (SD56) ATAR.M


☞Output : Y39.6(STUN.R), KAR11-YV11,Distribute I/O B (A23)

☞Completion : X6.4(TCL.M), SX11, Input Module Slot8(Pin31)


On

Off

On

Changer Arm Pin Locking

☞ Output : Y 0.2(ATAL.R), YV55,Output Module Slot01(Pin04)

☞ Completion : X15.3(ATAL.M), SD55, Input Module

Slot06 (Pin11)

X15.5(ATAR.M), SD56, Input Module Slot06(Pin43)

On

On

Off

Changer Arm Pin Release

☞ Output : Y 0.2(ATAL.R), YV55,Output Module Slot01(Pin04)

☞Completion:X15.3(ATAL.M),SD55, Input Module Slot06(Pin11)

X15.5 (ATAR.M), SD56, Input Module Slot06(Pin43)

On

On

Off

Changer Arm

Gripping Tool

Spindle Tool

Tool Change

Spindle Tool Clamp

Changer Arm Home

Arm

Forward

Arm Out

&

Rotation

Arm In

Arm

Forward

Arm Pin

Locking

Arm Pin

Release

Off

On

Off

147

HP5100 HP51MTE87

3) Trouble Shooting

(1) Operating the Maintenance screen (ATC manual operation)

Select "JOG” Mode on the Main O.P.①

Press the“CUSTOM” Key.②

The“CUSTOM WINDOW”sceen appears.☞

③ Press the“MANUAL”Function Key.

☞ The ATC, APC Manual screen appears.

148

HP5100 HP51MTE87

Press“ATCON". ④

The“ATC MANUAL MODE”is ☞ On.

149

HP5100 HP51MTE87

☞ Step Selecting method: Use the cursor keys to move the cursor up and down

on the Main O.P, and select.

Manual operation: After selecting ⑤ the designated command and pushing Cycle Start, the

step operates and is completed when an "*" appears in the "status" space on the right.

(2) Canceling the AL2065 (Verifying the Arm Home Position)

① Meaning of the Alarm : The alarm becomes activated when there is a change in t

he Main Changer Arm Home Position due to the Servo System or from other causes.

That is, the case where there is a difference between the reference point (X7.6)

memorized in the servo system and the reference point that recognizes

proximity switches (X8.7) by the present arm position.

② Objective of the Alarm: The alarm aims to increase the stability of the Servo

Mechanisms (e.g. Clamping/Unclamping), which must work based on the Arm's

actual location, by maintaining the same Arm position setting regardless of

continuous tool exchanges.

③ Troubleshooting the Alarm

☞ Checking for Problems with the Changer Arm Home Position Detection Proximity

S/W

After checking for problems with switch looseness/ Dog looseness/

contamination/firing range, proceed normally.

Initial Condition Status

150

HP5100 HP51MTE87

☞In case of alarm, when the changer arm home dog is deflected or even if the

position is normal, observe inside the Cam to see if the Turret Can Follower

Bearing is positioned on the Cam's Center area. Since this area is very small, it is

convenient to use a mirror and worklight.

☞After verifying the Cam Follower Bearing location, use those observations to

cancel the #2065 Alarm by Origin Initialization from the Servo Drive..

Case Cam

Follower S/W & Dog align Solution

Normal Faulty Reorder the Switch, secure, and Initialize

A Normal Normal Initialize

Faulty Normal B

Faulty Faulty

Realign the Changer Arm using Inching, reorder the Switch, and Initialize

Mirror

A

A

A B≒

Is the Cam Follower

Bearing in the middle of

the central area?

Central

Area

151

HP5100 HP51MTE87

(2) -1 Case “A”

① Press the "MODE" Key once on the Servo Drive start

screen [r 0000]

② Press the "DOWN" Key once on the

[rd-oFF] screen

③ Press the "SET" Key for five seconds on the

[Or9.S--] screen. The letters will blink, then complete

Servo Origin Initialization.

④ Power Off → On

⑤ Move back to Maintenance Mode. Execute the

remaining Recovery processes. Verify normal ATC

activity, and close Maintenance Mode.

152

HP5100 HP51MTE87

(2)-2 Case “B”

① Press the MODE Key once and the "DOWN" Key

four times on the Servo Drive start screen[r 0000] to

display the [JOG run]. Press the "SET" Key once to

display the [Jr.0000].

② Appropriately use the "UP/DOWN" Key (which

drives the Arm 20rpm every time it is pressed) to

position the Cam Follower Bearing in the center of the

middle section. If necessary, reorder the S/W and press

the "Set" Key once to exit to the [JOG run] screen.

③ Press the "UP" key three times on the [JOG run] screen.

④ Press the "SET" Key for five seconds on the

[Or9.S--] screen. The letters on the screen will blink,

and then complete the Servo Origin Initialization.

⑤ Power Off → On

⑥ Move back to Maintenance Mode. Execute the



153

HP5100 HP51MTE87

3) Ordinarily, ATC related trouble shooting that could possibly occur during ordinary

arm driving

Case Status

1 Power interruption before unclamp or after clamp, emergency situation

2 Power interruption during arm driving after unclamp and before clamp, or

emergency situation

Power interruption during unclamp or right after clamp, emergency

situation 3

Arm gets jammed during unclamp or right after clamp (in most cases)

(2)-3 Case “1”

Power ① On → Machine Ready Operation

Maintenance Mode ② On

③ Use Reverse Step operation to return to the

Arm Home Position

☞ If the problem occurred after Clamping,

use the available Forward Step control. The

point at which the problem occurred can be

judged based on the Forward Step control's

availability, and is the D450=D452 status.

That is, the PMC Ladder is set so that the for

ward step control is only available after clam

ping is verified.

Maintenance Mode ④ Off

⑤ Take necessary measures after confirming whether AL2065 ooccurred or not

⑥ If there is a record of turning off Power, manually recover the reference point (not

necessary for emergency).

⑦ M19 / G91 G30 X0 Y0 Z0 in MDI Mode

⑧ Check the tool number (D450 / D452) on the G.Data Table and make any necessary

changes.

Maintenance Mode ⑨ On

⑩ Execute 1 Cycle several times to accurately judge the cause of the problem, and to

check for any additional problems.

Maintenance Mode ⑪ Off

⑫ Insert the tool that was to be exchanged before the problem arose. Recheck the

program, and continue the original process.

Case “1”

154

HP5100 HP51MTE87

(2)-4 Case “2”

① Power ON à Machine Ready operation

② Maintenance Mode On

③ With the reverse step operation,

returns to arm home position

☞ Remove all the tools clamped to the

changer arm and reverse operate. At

this time, in the figure below, in

position A, when the tool is removed

it is very dangerous therefore it must

be done at B.

④ Maintenance Mode Off

⑤ Take necessary measures after

confirming whether AL2065 ooccurred

or not.

⑥ If there is any history of power OFF,

manual return to the reference point

(not necessary for emergency).

⑦ M19 / G91 G30 X0 Y0 Z0 based on

MDI

⑧ Check the tool number (D450 / D452)

on the G.Data and change it if

necessary.

⑨ Maintenance Mode On

⑩ Accurately check the cause by

executing 1 cycle several times and

check if there are any additional

problems.

⑪ Maintenance Mode Off

⑫ After changing the tool that was to be

changed before the problem re-check

the program and continue operating.

A

B

①

②

Case “2”

Press the locking pin on the back of the arm as hard as possible and then remove the tools clamped to the arm.

①

② CT/DIN Shape Check the

state of roller rotation and degree of wear, etc. and take proper measures if necessary.

155

HP5100 HP51MTE87

(2)-5 Case “3” (Machine is Jammed) Trouble Shooting Process

Case Tool Data Status

3-1 D450≠D452 Cannot pull out tools after Unclamping.

3-2 D450=D452 Cannot rotate Changer Arm because it is jammed in

tools after Clamping.

☞ It is very important to distinguish the two states, and it is accurate to

determine using the position of the changer arm home position dog.

① Power ON à Machine Ready operation

☞ Even if it is due to being mechanically jammed and not power

interruption, the probability that AL2009 will occur from the servo system

is very high. AL2009 caused by overload is power OFF level, so for

release power OFF / ON operation is essential.

② Maintenance Mode On

Case “3”

Case 3-2

C. Arm home position

dog is located above

the proximity switch

▶ Forward operation

Case 3-1

C. Arm home position

dog is located below

the proximity switch

▶ Reverse operation

156

HP5100 HP51MTE87

③ Distinguish the occurred situations and perform the trouble shooting.

(Refer to the next page)

.

Case Tool Data Status

3-1 D450≠D452

▪ If the Changer Arm falls out easily during Reverse Step

Control, return it to the Cam Home Position and execute

the next step.

▪ If the Arm does not fall out and the Overload Alarm(#2009)

is set off, turn on the power and press the Changer Arm

Roller using a screwdriver. Carefully recover using Reverse

control and execute the following step.

3-2 D450=D452

▪ If the Changer Arm falls out easily during Forward Step

Control, return it to the Cam Home Position and execute

the next step.

▪ If the Arm does not fall out and the Overload Alarm(#2009)

is set off, turn on the power and press the Changer Arm

Roller using a screwdriver. Carefully recover using Forward

control and execute the following step.

Finding the origin of jamming and Troubleshooting (see below)④

Maintenance Mode Off⑤

Check for AL2065 activati⑥ on and take appropriate steps.

If there is a record of turning off Power, manually recover the reference point⑦

(unnecessary in the case of emergency).

M19 / G91 G30 X0 Y0 Z0 in MDI Mode⑧

Check the tool number (D450 / D452) on the G.Data Table and make any necessary ⑨

changes.

Maintenance Mode On⑩

Execute 1 Cycle several times to accurately judge the cause of the problem, and to⑪

check for any additional problems.

Maintenance Mode Off⑫

Insert the tool that was to be exchanged before the problem arose. Recheck the ⑬

program, and continue the original process.

☞ Notes to be checked when removing jams

Do not carelessly use manual ⓐ Unclamp operation.

(Note) If the jam occured during Unclamping, be careful of tools falling from the

Spindle.

157

HP5100 HP51MTE87

If the tool had not fallen due to weak Kicking, send the Arm to its home position. ⓑ

Carefully hit with a rubber hammer and repeat the manual unclamping

process to pull out the tool. After completion, it is recommended to reset the

tool push amount.

Release the Collet and check for any damage/abrasion/loosening.ⓒ

Recheck the Centering in order to check the M19, change in the 2nd reference poiⓓ nt,

and change or Slip in the Changer Arm.

Check for any abration, dents, or scratchers on the Changer Arm Roller. Also check the ⓔ

spring strength of the Release Pin.

Remove any contamination on the ATC main drive, and check for any abnormal noise.ⓕ

Rⓖ epeatedly move the standby Pot in/out to decide its location and to check for any

speed disorder.

Check the Customer Use Tools and Pull Stud for any wear, standard disorder, or ⓗ

loosening.

In the case of CT/DIN Tools, make sure that it has been loaded iⓘ nto the magazine in

the right direction.

4) ATC Centering

☞ If the Tool Change is not smooth directly after installation or during use, the ATC and

Main Spindle must be aligned(centered).

Centering Tools for ATC Centering

(1)Preparation for ATC Centering

Remove the tool from the Main Spindle to empty the Spindle, and release the two ①

Driving Keys attached on the side of the Spindle.

Attach the Centering Tool(1) to the Spindle.②

Tool 1

Tool 2

Tool 3

158

HP5100 HP51MTE87

Send each Axis to the Tool Change③ Position.

B☞ -Axis: X, Y, Z Axis: 2nd reference point (G91 G30 X0. Y0. Z0.)

Execute Spindle Orientation.④

M19;☞

Confirm the Pot number of the tool missing rom the Tool Magazine and call the tool.⑤

ex) Tool No. 15 : “MDI” Mode T15; “Cycle Start”☞

O⑥ pen the ATC Door.

ex) “MDI” Mode M222 ; “Cycle Start☞

(2) Insert the ATC Centering Tool(2) into the Changer Arm Gripper.

Manually control the ATC from“Maintenance” Mode.①

Select“JOG” Mode.②

Press the “CUSTOM” Key.③

Press "MAN" from among the Functi④ on Keys.

Press“ATCON".⑤

Manually select the Toggle S/W from the manual ATC menu.⑥

Use the arrow keys to move the curosr to “ATC ARM FORWARD STEP,”then press‘Cycle ⑦

Start’to rotate the Changer Arm towards the Spindle until just before the

Arm Out position.

Insert the Centering Tool(2), fitting it to the Arm Gripper Key.⑧

(4) Adjusting the gap between Tool(1) and Tool(2): Set the gap to the front and back of

the Changer Ass'y.

Objective : DIN: 3.2mm, BT: 2.0mm☞

(5) Adjusting the Center Location of Tool(2) and Tool(1)

If Centering is incorrect, remove Centering Tool(3), change Keep Relay K 7.6 from “1” ①

Centering Tool (2)

Centering Tool (3)

Gap

Measurement

Area

(3) Check the alignment between the

Changer Arm and Spindle.

① Check the gap between Tool(1) and

Tool(2) using a gap gauge.

☞ Objective : DIN: 3.2mm, BT: 2.0mm

② Insert Tool(3) into the center hole to

check if the locations of Tool(2) and

Tool(1) are accurate.

159

HP5100 HP51MTE87

to“0, then use MPG to move the X and Y Axes and check Centering.

Do not use Keep Relay K7.6 “0” ATC☞ →

When Centering is microadjuste② d, enter the coordinates into the X, Y Axis 2nd

reference point.

2nd reference point Parameter: N1241☞

Remove Centering Tool(3) and change the Keep Relay K7.6 back from “0” to “1”.③

Use Forward Step to return the Changer Arm to its Home position, then ④ remove

Centering Tool(1) from the main axis.

Execute tool exchange once in unloaded "MDI” Mode, then manually send the Changer ⑤

Arm to Tool Exchange position and reconfirm Centering.

160

HP5100 HP51MTE87

Air Pressure Down Alarm

The Air Pressure Switch has been activated because the pressure in the

Air Equipment for Tool Change has fallen below the Air Pressure Switch

set point.

The factory air pressure has fallen ① below standard (below 4kg).

Breakage of the Air Pressure Switch or other parts②

Raise the factory air pressure to above 4kg/① ㎠ (normally to about

6kg/㎠).

Check the pressure recorded on the Air pressure gauge attached to the

Air Service Unit at the back of the machine. If the air pressure is below

4kg/㎠, turn the pressure control handle to the right. If the air pressure

does not rise, the factory air pressure is weak. Check the factory air

pressure.

② Fault in cables or other parts: make any necessary repairs or

replacements.

Signal Address Tool

Symbol I/O

Connector (Pin)

Numbering Tube

Air Pressure Check X3.1

EPRS.M -SP12 Input Module Slot 07 XJ410 (28) SP12

Pallet Air for Table Y1.5

PAIR.R -YV63

Output Module Slot

01

T/Block

(18) YV63

Solution

Cause

Status

2021

Air Pressure Check

Time

Air Pressure Down

Alarm

161

HP5100 HP51MTE87


A2.4 2021 Air Pressure Down Alarm

F0.6 SA Servo Ready

K5.1 KAPRS Air Pressure S/W Not Used

R629.0 TMB49 Air Pressure Check Time


X3.1 APRS.M Air Pressure Check

Y1.5 PAIR.R Pallet Air For Table

162

HP5100 HP51MTE87

M06 Command Overtime Alarm

The Tool Change Command(M06) could not be completed within 5 seconds.

This is generally an alarm set off when the Changer Arm and Tool jam

during Tool Change.

This is generally an alarm set off when the Changer Arm and Tool jam

during Tool Change.

M06 Initial Position☞

Address X7.6 X7.2 X7.1 X7.0 X8.7

Status 1 1 0 1 1

T☞ -Code Initial Position

Address K61.1 X7.6 X7.3 X7.1 X8.7

Status 1 1 1 1 1

(Reference) Recovering ATC Breakage

If the Changer Arm stopped in the middle of Tool Change(M06), you must

manually return the Changer Arm to its home position. Because the necessary

measures differ with each situation, you must accurately find the cause of the

problem and take appropriate measures.

Since this is done with tools attached to the Chang☞ er Arm, be careful not to drop

the tools. Just in case tools fall, set up a wooden pallet to protect tools or the

machine cover below the ATC.

(1) Changer Arm stop during Spindle Tool Clamp Status

The Changer Arm stopped between the Home Position and the Spindle.

(2) Changer Arm stop during Spindle Tool Unclamp Status

The Changer Arm stopped after falling out from the Spindle and before rotating

180˚ to insert the tool into the Spindle.

(3) Arm Jam during Unclamping or directly following Clamping

The Changer Arm stopped while stuck in the Spindle.

(4) Alarm 2065 (“Changer Arm Position Check Alarm”) activated

despite having returned the Changer Arm to Home Position

The Changer Arm has been returned to Home Position, but for some reason

this position does not match the Servo reference point or the ATC machine

reference point set in the Cam bundle.

Solution

Cause

Status

2023

163

HP5100 HP51MTE87

(1) Recovery Process for when the Changer Arm has stopped during

Spindle Tool Clamp Status

1) In Emergency Stop status, or in Power Off

status, remove the stop cause and turn the

machine on to Ready mode.

2) Select "JOG" mode from the main operation panel.

3) Press the "CUSTOM" NC Function Key.

The“CUSTOM WINDOW”screen appears.

4) Press the "PMC-SW”soft key. The ATC, APC

Manual screen appears.

5) When the ATC, APC Manual screen appears,

press the “ATC-ON”soft key to select the ATC.

The ATC Manual Mode changes from

“DISABLE”to “ON”.

164

HP5100 HP51MTE87

6) Move the cursor keys to choose "ATC ARM

REVERSE STEP,”and repeatedly press the

main operation panel's cycle start button to

move the Changer Arm to Home Position.

7) Repeatedly press the main operation panel's

Cycle Start button to move the Changer Arm to

Home position, where it no longer moves. (If

the Changer Arm stops moving, it has been

returned to Home Position.)

If the Changer Arm jams after ※ replacing

tools and Spindle Tool Clamping, select

"ATC ARM FORWARD STEP”to manually

send it to other sections.

Verification : D450 = D452 in PMC G.DATA

mode

8) Move the cursor Key to select“ATC ARM 1

CYCLE,”and press the main operation panel's

Cycle Start button. The Changer Arm will

execute Tool Change once, and the inner Cam

and Changer Arm will be reordered.

9) At completion, press the “OFF”soft key. The

ATC Manual Mode will change

from“ON”to“DISABLE.”

165

HP5100 HP51MTE87

10) Press (in order)“SYSTEM” => PMC => PMC DATA => G.DATA, confirm the tool

numbers of the Spindle and Standby Port from D450, D452, and reset.

D450 : Spindle tool number

D452 : Standby port tool number

11) When each axis is returned to its reference point, the ATC breakage recovery

is complete.

166

HP5100 HP51MTE87


A2.6 2023 M06 Command Overtime Alarm

A4.3 2036 T-Code Command Illegal Pos.

A4.4 2037 M06 Command Illegal Pos.

A9.4 2077 Wait.Pot & Spdl Tool Data Zero

A9.5 2078 ATC Op Manual Mode

F0.5 STL Cycle Start

F218.5 MTC-FM Man Tool Pot Call From Matrix

F218.6 MTR-FM Man Tool Pot Return From Matrx

F45.7 ORARA Spindle Orientation Complete

K0.3 KHP5500,KHP6300 If It Is A Ace-Hp5500,Hp6300

K10.3 KATCDR ATC Door Not Used

K16.7 KMTM19 Used Variable Orientation Func

K6.0 KMATRX Matrix Tool Magazine Is Used


R2401.5 RTCCMF Re-Change T-Code Command Flag

R2401.7 TCCMDF T-Code Command Flag

R2410.7 2081F

R600.3 M06 ATC Change Macro Call

R625.6 TMB23 M06 Command Overtime

R625.6 TMB23 M06 Command Overtime

R631.3 CYSTP Cycle Stop


R705.7 ATCSER ATC Clamp Command Switch Error

R721.0 MANM06 Manual 1 Cyc ATC Start

R749.6 ATCAUT ATC Mag. Auto Mode

X8.0 ATDO.M ATC Door Open

Y1.2 MTO2.R Mag. 2 Tool Pot Tool Out

Y1.3 MTPO.R Mag.1 Tool Pot Tool Out

167

HP5100 HP51MTE87

Magazine Rotation or Matrix Illegal Position Alarm

(Check Condition for T-code Command

(M6INPA,TFINP))

Tool Change was attempted in a different position from the default

position.

Faulty adjustment of the switch that confirms the default ① position of

the ATC or Tool Magazine

② Fault in pertinent parts

. Check the switch with PMC① -DGN and adjust the position with the Dog.

. ② Check the Limit Switch, connection cable ,I/O Module to find the faulty

area.

☞ M06 Initial Position

Address X7.6 X7.2 X7.1 X7.0 X8.7

Status 1 1 0 1 1

☞ T-Code Initial Position

Address K61.1 X7.6 X7.3 X7.1 X8.7

Status 1 1 1 1 1

Signal Address Tool

Symbol I/O

Connector

(Pin)

Numbering

Tube

Waiting Pot Spindle

Side

X7.0

WPSS.M -SX5A Input Module Slot 08 XJ412 (12) SX5A

Waiting Pot

Magazine Side

X7.1

WPMS.M -SX5B Input Module Slot 08 XJ412 (28) SX5B

Waiting Pot Clamp

Check

X7.2

SD32.M -SD32 Input Module Slot 08 XJ412 (44) SD32

Waiting Pot

Unclamp

Check

X7.3


ATC Servo Home

Position

X7.6

MCAH.M -A81 Input Module Slot 08 XJ412 (10) THOMEI

ATC Home Position

Check

X8.7

CAHP.M -SX53 Input Module Slot 08 XJ412 (37) SX53

Solution

Cause

Status

2036

168

HP5100 HP51MTE87

(Reference) DGN (Diagnostic) Check Process

1) Finding the DGN

(1) Press the "SYSTEM" key from the right side of the Main operation panel CRT.

▪ The following will appear in the Soft Key space below the CRT.

〔PARAM〕〔DGNOS〕〔PMC〕〔SYSTEM〕〔(OPRT)〕

(2) Press the〔PMC〕Soft Key.


〔PMCLAD〕〔PMCDGN〕〔PMCPRM〕

(3) Press the〔PMCDGN〕Soft Key.


〔TITLE〕〔STATUS〕〔ALARM〕〔TRACE〕

(4) Press the〔STATUS〕Soft Key.


〔NO.SRH〕〔〕〔〕〔〕〔〕

(5) Enter the intended DGN number. Ex) When looking for X4.1 : “X”, “4”, “.”, “1”,

(6) Press the〔NO.SRH〕among Soft Key.

▪ A diagnostic screen showing the needed number will appear.

2) How to read the DGN

Ex) X 003 0 0 1 1 0 0 1 0

Of Address X3, Bit 1, 4, and 5 are On, and Bit 0, 2, 3, 6, and 7 are Off.

Shown As 0 0 1 1 0 0 1 0

Bit No Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0

Changer Arm

Home Position

Proximity S/W

(SX53--X8.7)

Waiting Pot

Spindle side

(SX5A—X7.0)

169

HP5100 HP51MTE87


A4.3 2036 T-code Command Illegal Pos.

F212.4 TMN-FM ATC Manual Mode From Matrix


F218.6 MTR-FM Man Tool Pot Return From Matrx

F1212.2 L-OP LCB Auto Operate



K16.5 KTBU Used Tool Broken Unit (LCB)

R411.3 M255 Spindle Tool Number Set

R411.4 M256 Next Tool Number Set

R460.0 TTF T-code Strobe


R700.2 WPTNCM Same T Is Comd With Wait Pot

R700.7 TCMDFA T-code Command Flague Aux.

R701.5 M6INPA M06inp Aux.

R701.5 M6INPA M06inp Aux.

R701.6 TFINP T-code Initial Position

Magazine Rotation or Matrix Illegal Position

Alarm

(Check Condition For T-code Command

(M6INPA, TFINP))

170

HP5100 HP51MTE87


R708.2 STSECH Spindle Tool Search

R710.1 WPTZER Wait. Pot Tool Data Zero

R749.6 ATCAUT ATC Mag. Auto Mode

R842.1 ATCALM ATC Alarm

R2401.5 RTCCMF Re-change T-code Command Flag

R2408.6 MAG.1F Mag.1 Flag

R2408.7 MAG.2F Mag.2f


R2410.7 2081F

171

HP5100 HP51MTE87

M06 Command Illegal Pos.

There is an error in reading the Waiting Port Tool number.

Problems with the ATC Initial Position (X, Y, Z Axis returned to 2nd

reference point) and the Changer Arm Location

The tool is not detected by the Waiting Port. (PMC Parameter D452)①

The X, Y, ② Z Axes are not located at their 2nd reference points.

The Changer Arm is not in its home position.③

Check for ① the existence of tools in the Waiting Port.

Check the status of the Waiting Port Tool Clamp. (SD32② --X7.2)

Check if the X,Y,Z Axes are each at its 2nd reference point.(G91 G30 ③

X0.Y0.Z0.)

If each is at its 2nd reference point, the reference point confirmation ☞

LED blinks.

M0☞ 6 Initial Position

Address X7.6 X7.2 X7.1 X7.0 X8.7

Status 1 1 0 1 1

Check the position of the Changer Arm, and reposition it referring to ④

the release of AL2065.

Signal Address Tool

Symbol I/O

Connector

(Pin)

Numbering

Tube

Waiting Pot Spindle

Side

X7.0


Waiting Pot

Magazine Side

X7.1


Waiting Pot Clamp

Check

X7.2


ATC Servo Home

Position

X7.6

MCAH.M -A81 Input Module Slot 08 XJ412 (10) THOMEI

ATC Home Position

Check

X8.7

CAHP.M -SX53 Input Module Slot 08 XJ412 (37) SX53

Solution

Cause

Status

2037

172

HP5100 HP51MTE87


A4.4 2037 M06 Command Illegal Pos.



F218.6 MTR-FM Man Tool Pot Return From Matrix





R702.0 TCCMDA T-code Command Aux.

R704.1 ATCS2 Do.2(pot Spindle Side Check)

R708.2 STSECH Spindle Tool Search

R708.6 ATDRCL ATC Door Close Comd

R709.0 ATCMST ATC Macro Start

R709.2 M06INP M06 Initial Position

R710.1 WPTZER Wait. Pot Tool Data Zero


R842.1 ATCALM ATC Alarm


R2401.7 TCCMDF T-code Command Flag




R2410.7 2081F

M06 Command Illegal Pos.

173

HP5100 HP51MTE87

APC Overtime Alarm

The M60(pallet Change) or M61(APC Unload), M62(APC Load) commands

could not be completed within 30 seconds.

Faulty adjustment of each sequence's process completion detection

switch, or disorder in the process Solenoid Valve, connection cable, or

other related parts.

If there is a problem with each sequence's process completion detection

switch or with related parts, each sequence's alarm should be set off.

Check the parts corresponding to the activated alarms and take necessary

measures.

Refer to the“Pallet Change Sequence" chart☞


A5.0 2014 APC Overtime

A9.0 2073 Pallet or Table CL/UNCL S/W Alarm

K7.7 KAPC APC Not Used

R626.3 TMB28 APC Overtime Check


Solution

Cause

Status

APC

Overtime

Check

APC Overtime

Alarm

2041

174

HP5100 HP51MTE87

☞ Pallet Change Sequence

START (M60 Command)

Y,Z-Axis 2nd Ref. Position

Y,Z-Axis 2nd Ref. POS.？

B-Axis Ref. Position

B-Axis Ref. Position.？

APC Initial Position？

Pushed Set-Up Button？

Pallet Unclamp

Pallet Unclamp

？

APC Up

APC Up O.K？

A

①

②

③

④

Yes

Yes

Yes

Yes

Yes

Yes

▶ Return to Y,Z-Axis 2nd reference point Program : G00 G91 G30 Y0. Z0.;

▶ Executing Return to X,Y,Z-Axis 2nd reference point

Program : G00 G91 G30 Y0. Z0.;

▶ Return to B-Axis Reference point Program : G00 G91 G28 B0.;

▶ Return to B-Axis Reference point Program : G00 G91 G28 B0.;

Output Signal : Y39.2 APUP.R -KAR75/-YV75 Completion Signal : X11.6 ACUP.M -SX81

★ 2042 M61/M62 Command Illegal POS occur.

X10.0 PCL.M -SP61 X10.1 TACL.M -SL62

X11.1 PNO1.M -SX75, X11.2 PNO2.M -SX76

X11.6 APUP.M -SX81 X11.7 APDN.M -SX82

X12.1 ACUP.M -SX81

On

On

Off

On

Off

On/Off

Output Signal : Y7.2 PUCL.R -KAR62/-YV62 Completion Signal : X10.0 PCL.M -SP61

On

Off

★2085 APC Set-Up Location S/W Unpush occur

Verification Signal : X16.6 SETU.M -SB93

On

Verification Signal: X10.0 PCL.M -SP61

★ 2073 Table or Pallet CL/UNCL Switch Alarm

Off

No

No

No

No

No

No Verification Signal : X11.6 ACUP.M -SX81

★ 2126 APC Up/Down Alarm occur

On

175

HP5100 HP51MTE87

⑤

APC Arm 180 CW Rot.

End？

⑥

APC Down O.K？

⑦

Pallet Clamp O.K？

Pallet 2 Position？

⑤

APC Arm 180 CCW Rot. End？

Yes

APC Arm 180 CW Rotation Output Signal : Y39.0 PCW.R -KAR73/-YV73 Completion Signal : X11.2 PNO2.M -SX76

No Verification Signal : X11.2 PNO2.M

★ 2127 APC Changer 180CW/180CCW Alarm

Yes

APC Down Output Signal : Y39.3 APDN.R -KAR76/-YV76 Completion Signal : X11.7 APDN.M -SX82

No Verification Signal : X11.7 APDN.M -SX82

★ 2126 APC Up/Down Alarm occur

Yes

Pallet Clamp Output Signal : Y7.2 PUCL.R -KAR62/-YV62 Completion Signal : X10.0 PCL.M -SP61

No Verification Signal : X10.0 PCL.M -SP61

★ 2073 Table or Pallet CL/UNCL Switch Alarm

Yes

On

End

2

Pallet 1 Position？ GO TO No

1

A

1

Yes

APC Arm 180 CCW Rotation Output Signal : Y39.1 PCCW.R -KAR74/-YV74 Completion Signal : X11.1 PNO1.M -SX75

No Verification Signal : X11.1 PNO1.M -SX75

★ 2127 APC Changer 180CW/180CCW Alarm

Verification Signal : 1 POS. X11.1 PNO1.M -SX75 2 POS. X11.2 PNO2.M -SX76 On

Off

Yes

2

On

On

176

HP5100 HP51MTE87

M61 / M62 Command Illegal Position

The M61 or M62 command was given in a condition other than the APC

initial condition.

Faulty adjustment of the APC intial condition detection switch ①

② Fault in the detection Switch, connection cable, or related parts

Faulty adjustment of the APC initial condition detection switch①

Check the Ladder Diagram or D.G.N to find the problem Switch and to

adjust and fix it.

Check (in order) each section's② Switch, connection cable, and I/O board

to find and repair or replace the faulty part.

APC ☞ Initial Condition

Address X5.4 X10.3 X10.1 X10.0 X11.7 X11.6 X11.2 X11.1 X11.0

0 1 Status 1 0 1 1 1 0

1 0 1

Signal

(APC Initial Condition) Address Symbol I/O

Connector

(Pin)

Numbering

Tube

Set Up Door Interlock X5.4

SUIT.M -S91


XJ411 (19) S91

Pallet Clamp (Index/Rotary) (ON)

X10.0 PCL.M

-SP61 Input Module

Slot 09 XJ413 (16) SP61

Table Clamp (Index/Rotary) (ON)

X10.1 TACL.M

-SL62 Input Module

Slot 09 XJ413 (32) SL62

Table Unclamp (Index/Rotary) (OFF)

X10.3 TAUL.M

-SL64 Input Module

Slot 09 XJ413 (15) SP64

Pallet Rot. Lock

(Setup S-D.O.)

X11.0

PLOC.M

(SSDC.M)

-SX89 Input Module

Slot 09 XJ413 (12) SX89

Pallet No.1 Detection (ON/OFF)

X11.1 PN01.M

-SX75 Input Module

Slot 09 XJ413 (28) SX75

Pallet No.2 Detection (OFF/ON)

X11.2 PN02.M

-SX76 Input Module

Slot 09 XJ413 (44) SX76

APC Up Check (OFF)

X11.6 APUP.M

-SX81 Input Module

Slot 09 XJ413 (10) SX81

APC Down Check (ON)

X11.7 APDP.M

-SX82 Input Module

Slot 09 XJ413 (42) SX82

Solution

Cause

Status

M61/M62 Command Illegal Pos.

2042

177

HP5100 HP51MTE87


A5.1 2042 M61/M62 Command Illegal Pos.


R629.6 TMB55 M60 Illegal Pos. Check Time

A5.1 2042 M61/M62 Command Illegal Pos.

A9.0 2073 Pallet Or Table Cl/Unclamp SW Al

A10.3 2084 APC Set-up Station Door Open

A10.4 2085 APC Set-up, location S/W Unpush

F102.3 MV4 B-axis Moving Signal

K10.2 KAUTDR Auto Door For Setup Door Is Us

K10.5 KSETDR Set-up Door Interlock Not Used

K16.2 KSSPDR Setup Supplier Door Not Use

R430.7 TM32 APC Auto Door Close Check Time

R452.0 TMB193 Setup Supplier Door Close C-tm

R607.2 M61 APC 1 Load Macro Call


R629.6 TMB55 M60 Illegal Pos. Check Time


M60 Illegal Pos. Check

Time

178

HP5100 HP51MTE87


R757.2 APCINP APC Initial Position

R760.0 M61CD Pallet1 Load Command


R762.0 M61MEN M61 Finish


R1011.2 PDTB.MR Pallet Detection In Buffer



X5.4 SUIT.M Front(set Up) Door Interlock

(Reference) Adjusting the Table and Pallet Switch

① Pallet Clamp / Unclamp Check

☞ Pallet Clamp Adjusted Pressure : 35kg/㎤

Pallet Unclamp Adjusted Pressure : 8kg/㎤

② Pallet No 1 Detection / No 2 Detection

APC Up / Down Check

Table Clamp / Unclamp Check③

APC Down Check

Pallet No.1

Pallet No.2

APC UP Check

Proximity

Switch

2~2.5mm

Dog

179

HP5100 HP51MTE87

For the Table Clamp, change the B Axis reference point by about 0.5 degrees so that it ☞

rests where the Curvic Coupling does not normally sit, execute Tool Clamp, and verify the

DGN. At this point both switches must be turned off.

Table Unclamp

Table Clamp

180

HP5100 HP51MTE87

ATC Door Open

The ATC Door is open

The ATC Door is open.①

Faulty adjustment of the ATC Door Close ② Check Reed Switch

③ Fault in the ATC Door Close Detection Switch or related parts

Manully operate the ATC, or command“M222”(ATC Door Close) in MDI ①

mode.

Loosen the Reed Switch Holder security Screw and move it towards the ②

Shaft. Find the location where the Sensor LED lights up, and secure.

Check (in order) the Reed Switch, connection cable, and I/O board. ③

Make any necessary repairs or replacements.

Signal Address Symbol I/O Connector

(Pin)

Numbering

Tube

ATC Door Open X8.0

ATDO.M -SD51 Input Module Slot 08 XJ412 (07) SD51

ATC Door Close X8.1

ATDC.M -SD52 Input Module Slot 08 XJ412 (24) SD52

Cycle Start X32.5

ST.M -SB12

Distributed I/O

Module A XC56A(B04) SB12

Solution

Cause

Status

2048

ATC Door Close

Check

Reed Switc

ATC Door Open

Check

Reed Switc

181

HP5100 HP51MTE87


A5.7 2048 ATC Door Open Alarm

A20.2 2163 ATC Door Open/Close Alarm



R628.4 TMB45 ATC Door Open Alarm D-time

R635.7 AUT Auto Mode


R707.0 M1CYLE Man 1 Cycle Operation

R733.1 MM Maintenance Mode For ATC/APC

X32.5 ST.M Cycle Start

F0.6 SA Servo Ready


R407.2 M222 ATC Door Open

R407.3 M223 ATC Door Close

R628.4 TMB45 ATC Door Open Alarm D-time


R718.0 TMB45A ATC Door Open Alarm D-time

R721.0 MANM06 Manual 1 Cycle ATC Start

ATC Door Open Alarm

D-time

ATC Door Open Alarm

182

HP5100 HP51MTE87



R2410.7 2081F

R4005.3 TMB45B ATC Door Open Alarm In Matrix

X8.1 ATDC.M ATC Door Close

(Reference) Operating the Maintenance screen (ATC manual operation)

Select the "JOG" Mode from the Main O.P.①

Press the“CUSTOM” Key.②

▪ The“CUSTOM WINDOW”screen appears.

Press the "MANUAL③ " Function Key“MANUAL".

▪ The ATC, APC Manual screen appears.

Press“ATCON.” ④

▪ The“ATC MANUAL MODE”is On.

183

HP5100 HP51MTE87

☞ Choosing a Step: Use the cursor keys

to move the cursor up and down on

the Main O.P and select.

⑤ Manual operation : Select the

appropriate command and Push

Cycle Start button to begin the

corresponding Step. The process is

complete when an "*" appears in the

"Status" space on the right. Initial Condition Status

184

HP5100 HP51MTE87

Lub. Level Low or Pressure Down

There is not enough lubricant in the lubricant tank connected to the

various Guide Ways or Ball Screw and Bearing, the pressure does not rise

to the standard level(15Kg/㎠) even after the lubricant motor is activated,

or the pressure did not fall within ten seconds of rising.

There is not enough lubricant in the lubricant Tank.①

The lubricant supply Line (Lub. Hose, Lub. Pipe, Lub. Tube etc.) has ②

burst or has slipped.

Breakage of the Distributor Valve③

Breakage of the lubric④ ant tank or disorder in the connection cable or

related parts

Add lubricant to the lubricant tank in the back of the machine.①

It is recommended to regularly supplement lubricant every 3~4 ☞

days (when the machine is active for 8 hours a day).

Find the ② faulty lubricant supply Line (Lub. Hose, Lub. Pipe, Lub. Tube

etc.) and repair the problem area.

If lubricant is being supplied only to a specific area despite all lubricant ③

supply Lines being normal, the distributor valve is malfunction. Make

necessary repairs or replace with a new one.

Differentiate between the lubricant Tank, from the Tank to the ④

electrical cabinet terminal, or by Input Module. Check each group and

make necessary repairs or replacements.

Signal Address Tool

Symbol I/O

Connector (Pin)

Numbering Tube

Lub.Level Low X5.0

LUB.M -SV51


XJ411 (03) SV51

Lub.Pressure Check X5.1

LPRS.M -SP51


XJ411 (20) SP51

Lub. Manual Start X5.2

LMS.M -M51


XJ411 (35) SB51

Lubrication For Guideway

Y2.4 LUBM.R

-QM51 Output Module Slot

02 T/Block(07) KM51A

Solution

Cause

Status

2050

Lub. Level Switch

Lub. Pressure

Switch

Lub. Level

Lub. Pressure

Gage

185

HP5100 HP51MTE87


A6.1 2050 Lub.Level Low Or Pressure Down

R620.0 TM01 Guideway Lub.Motor On Time

R623.3 TMB4 Lub.Pressure Check D-time



R691.0 NO-MOV No Movement Each Axis

R691.6 AL50R AL50 Reset

R841.6 LPRSAL Lub.Pressure Alarm

R841.6 LPRSAL Lub.Pressure Alarm

X5.0 LUB.M Lub.Level Low

X5.1 LPRS.M Lub.Pressure Check

X5.2 LMS.M Lub.Manual Start

Y2.4 LUBM.R Lubrication For Guideway

Lub.Level Low Or

Pressure Down

Lub.Pressure Alarm

186

HP5100 HP51MTE87

Oil cooling Unit Alarm

There is a problem with the Oil Cooling Unit, which cools the Main Spindle.

Fault in the Oil Cooling Unit

Refer to the Oil Cooling Unit Manual to find the meanings and measures for

each Alarm, and take necessary measures.

Signal Address Tool

Symbol I/O

Connector

(Pin)

Numbering

Tube

Oil Cooling Alarm X2.5

OCFT.M -OCFT Input Module Slot 07 XJ411 (47) OCFT

Oil Cooling

Alarm(Special)

X4.0

SOCF.M -M73 Input Module Slot 07 XJ411 (07) OCFT1


A6.2 2051 Oil Cooling Unit Alarm

K19.5 KSOCU Special Oil Cooling Unit


R652.3 TMB20 Hyd. Pump On Check Time

X2.5 OCFT.M Oil Cooling Unit Fault

X4.0 SOCF.M Oil Cooling Alarm (Special)

Solution

Cause

Status

Oil Cooling Unit

Alarm

2051

187

HP5100 HP51MTE87

1) There is a problem, but no alarm is activated

No. Status Cause Solution

1

It does not

function at all.

(The operation

panel's power

lamp does not

turn on.)

① There is no main power, or the

electric connection of the power

(L1, L2) is faulty.

• Check the wiring to see if

power is being supplied to the

power terminals.

① The remote control

input【10】,【11】is turned off.

• Check the connection of

remote control input. 2

The pump

cannot be

activated ② Operation is locked. (Operation is

locked when shipped.)

• Disable the Lock rom the

operation panel.

① The pump's absorption pipe is

loosened.

• Check the pipe packing, and

tighten as necessary.

② The absorption strainer is

clogged.

• Clean the absorption strainer.

• If the oil inside the oil tank is

contaminated, please replace

the oil.

③ The oil level inside the oil tank is

low.

• Fill in more oil.

④ The oil discharge pipe has

suffered significant pressure

damage, and the pump relief is

activated.

3

The pump

operates, but

there is no oil

flow.

The oil flow is

weak and the

pump is very

loud.

⑤ The oil absorption pipe has

suffered significant pressure

damage, and the pump has

developed cavitation.

• Replace the inner rim of the

oil pipe with a larger rim, and

shorten the pipe length.

① The machine stops according to

the temperature adjustment

control.

---

② The compressor reset prevention

timer(30 seconds) is active.

• Check if the compressor

resets after the timer runs

out.

③ Low oil temperature protection

(entry oil temperature is ２℃

or less) is operating.

• Check to see if it works

normally when the entrance

oil temperature is above 5℃.

4

The pump

operates,

but the

compressor

does not.

④ Low outer air protection（room

temperature is －２℃ or

• Check to see if it works

normally when the room

188

HP5100 HP51MTE87


less）is operating. temperature is above 0℃.

⑤ Mode 9 is set at 10%. • Reset to a more

approrpriate operation

mode.


① There is blockage near the

absorption pipe or exhaust

pipe.

• Remove the blockage.

② The air filter is

contaminated.

• Clean the air filter.

③ The room temperature is

high, and the machine is

underoperating.

④ There is a high temperature

load.

• heck the operation

capacity according to

temperature range from

the catalogue, and

choose a model with the

appropriate capacity.

⑤ The set temperature is

high.

• Reset to an appropriate

temperature.

5

The pump and

compressor operate,

but the oil does not

cool.

⑥ Even if the compressor

operates, there is a lack of

refrigerant gas if expelled

gas is the same

temperature as room

temperature.

• Recharge refrigerants.

① If the Data line is shown as

“---,“ the sensor using that

operation mode is not

connected.

• Connect the temperature

sensor.

6 The function cannot

be set. ② When the ENT key (right

key) is pressed, a

momentary display of “---

“ is simply error protection

being turned on.

• Turn off the error

protection SW (SW1) on

the control board.

7

The【64】,【65】alar

m output is diferent

from previous signal

outputs.

① The signal connection of

alarm output is partially

altered.

• Output from

【60】,【63】are

compatible with previous

models (AKS5 series and

AKZ6 series), but the

189

HP5100 HP51MTE87

signals and connections

has been changed for

【64】, 【67】in the 7

series. See details in the

"Using Previous Models"

section at the end of the

guide.

190

HP5100 HP51MTE87

2) When an alarm is activated (To release Alarm, turn off the power and turn it

back on.)

Alarm

Code

Alarm

Level Status Cause Solution

In the case of AKZ ①

models, there is no oil

flow.

Check if the oil pressure circuit is

correctly connected, and if the

pump is operating normally.

AA 2 Overheating the

heater

(S4B1:CN4)

(limited to

models with

heater

attached)

In the case of AKZJ ①

models, there is not

enough oil in the tank.

Supplement oil.

① Faulty DC Fan Motor Replace the DC Fan Motor A6 2

Faulty DC Fan

Motor Lock

① There is faulty

communication between

the Fan Motor and the

control engine

Check the connection for any

disconnection, and replace the

control engine.

E1 1 System

problem

① Internal Parameter

problem.

Replace the control board

① The oil temperature or

room temperature

exceeds the allowed

range.

Operate only within the usage

range.

② There is blockage near

the absorption or

exhaust pipe.

Do not place anything that might

block ventilation within 500 mm

of the absorption pipe or

exhaust pipe.

③ The filter is clogged or

the condenser is

contaminated.

Refer to the repair and

inspection in #8 to clean the air

filter.

E3 2

High pressure

problem (High

pressure

alteration(S3PH

:CN6)

activated)

④ Other Contact the Daikin service team.

① The oil temperature or

room temperature

exceeds the allowed

range.

Operate only within the usage

range.


the absorption or

exhaust pipe.




exhaust pipe.

E5 2

Compressor

Overheating

(Discharge Pipe

Thermer TH6

activated)

(Compressor

Head Thermer

(S2B:CN)

activated)

③ The filter is clogged or

the condenser is

contaminated.

Refer to the repair and

inspection in #8 to clean the air

filter.

E6 2 Compressor(M

2C) Lock

① Compressor

breakage.(needing

replacement)

Replace the compressor.

191

HP5100 HP51MTE87

Alarm

Code

Alarm


① Overload due to viscous

oil use.

Use oil that has 4~200 mm2/s

viscosity in the permitted

temperature range.

② Pump motor electric

current increased

because the power

electric pressure is lower

than the usage range.

Check if the power electric

pressure is lower than the usage

range. Check if the electric

pressure drops between

myelination when other

machines are activated.

③ Disconnection of the

pump's electric motor

wiring

Replace the pump's electric

motor

EH 1

Pump high

electric current

circuit breaker

(S1B:CN3)

activated

④ The pump is jammed or

the electric motor breaks

because of foreign

substances.

Replace the pump's electric

motor

EJ 1/2

Field Additional

Protection

Activated(OP.)

① Protection machinery

connected to the field (In

the case of Unit Form,

there are cases in which

it is connected upon

shipping) is activated

Check what the activated

machinery has detected.

H1 2 Disorder in the

Air Temperature

sensor

(TH5:air

temperature

conformity

sensor)

(TH3:room

temperature

sensor)

① Disconnection or short-

circuiting in the air

channel sensor needed

for control.

Confirm the problem sensor

from the control panel's monitor

mode (problem sensor showing

"99.9"), then check the wiring.

① The air's exothermic

amount exceeds the oil

con's cooling capacity.

(wrong model chosen)

If the compressor is working at

100% capacity in normal mode

(can be confirmed in monitor

mode), choose a model one size

bigger.


the absorption or

exhaust pipe, lowering

cooling ability.




exhaust pipe.

FH 2

Entrance oil

temperature

exceeds 60℃

③ Underperformance due to

exceeding nominal

temperature (Room

If the nominal temperature is

exceeded, undercontrol lowers

cooling ability below nominal

192

HP5100 HP51MTE87

Alarm

Code

Alarm


temperature 35 , Oil ℃

temperature 35 ).℃

ability. Check to see if the oil

con's cooling ability exceeds the

exothermic amount.

④ Temperature cannot be

controlled because

operating in Mode

9(capacity directly

specified)

Use a proper mode (When the

capacity is directly specified,

there is no temperature

feedback control.)

⑤ Refrigerant gas is

leaking.

If the expelled gas is the same

temperature as room

temperature while the

compressor is operating,

refrigerant gas may leak.

Contact our company's service

team.

JH 2 Disorder of Oil

temperature

sensor

(TH2:Exit oil

temperature

sensor)

(TH4:Entrance

oil temperature

sensor)


circuiting of the oil

temperature channel

sensor needed for

control.

Confirm the problem sensor

from the control panel's monitor

mode (problem sensor showing

"99.9"), then check the wiring.

J3 2 Disorder of the

discharge Pipe

temperature

thermister

Disconnection or short-

circuiting of the

discharge Pipe

temperature thermister.

Check the wiring of the

thermister.


EV Valve Exit

temperature

thermister


circuiting of the EV Valve

Exit temperature

thermister.


thermister.


Condenser

temperature

thermister


circuiting of the

Condenser temperature

thermister.


thermister.

L0 2 Disorder of the

Invertor or

Compressor

channel

① Compressor or Inverter

Breakage

Replace the Control Engine or

Compressor

LC 2 Transfer

disorder

between the

INV-

① Communication problem

between the

temperature control

computer and the

Replace the control engine or

reform the power environment

(noise alleviation needed)

193

HP5100 HP51MTE87

Alarm

Code

Alarm


temperature

control CPUs

invertor computer.

P3 2 Disorder of the

Electric Field

Box

temperature

thermister

Disconnection or short① -

circuiting of the Electric

Field Box temperature

thermister


thermister.

P4 2 Disorder of the

Heat Protection

Fin

Temperature

thermister


circuiting of the Heat

Protection Fin

Temperature thermister


thermister.

U0 2

Not enough

gas

① Excessive transfer

movement has damaged

the refrigerant pipe, and

refrigerant gas is leaking.

Repair the refrigerant pipe and

recharge the refrigerant gas

① The electric connection is

on the wrong side.

The wiring must be reconnected. U1 1

Power

Reversal ② The L3 is defecitvely

connected

Check to see if the L3 is

connected properly to the power

terminal.

U2 2 Momentary

blackout/Insuffi

cient voltage

① Power voltage is below

70V.

Check to see if the voltage is

rated, or if the voltage suddenly

drops when surrounding

machines are activated.

U9 2 Unable to

transfer to

separate

system

(Problem in

transferring

between Slave

system and

Master system)

① Error in communicating

with wireless system.

Check to make sure that the

wireless system and the

communication line are well

connected. (Only applicable to

cases in which the wireless

system does not respond to the

main system.)

UH 2 System Channel

Problem

(EEPROM

Problem)

① Error in the parameter

recorded in the Control P

Board.

Replace the Control Engine

UJ 1/2

OP2 Activated

① Connection Protector is

activated (In the case of

uniform, it may be

connected upon

shipment).

Verify the information detected

by the Protector.

194

HP5100 HP51MTE87

Alarm

Code

Alarm


1E - Above the

permitted

temperature

range

Warning 1

~

5E - Above the

permitted

temperature

range

① he temperature being

watched has exceeded

the preset permitted

range.(Not a problem

with the oil cone.)

Check the Warning setting.

195

HP5100 HP51MTE87

Filter Change Alarm For TSC Unit

Alarm indicating that the high-pressure coolant equipment(TSC) Filter is

clogged and needs to be replaced

The high① -pressure coolant equipment(TSC) Filter is clogged.

② Fault in the Filter clog detection sensor or parts related to the

connection cable to the electrical cabinet terminal block.

Replace with a new Filter.①

②Divide into areas - Filter Unit, from the Filter Unit to the electrical

cabinet terminal block, and Input Module - and check for problems.


Signal Address Tool

Symbol I/O

Connector

(Pin)

Numbering

Tube

TSC Filter or

Pressure Check

X3.3

CPOC.M -SP16 Input Module Slot 07 XJ411 (11) M222


A6.3 2052 Filter Change Alarm of TSC Unit

F0.6 SA Servo Ready

K4.4 KFILT Filter Status Check Not Used

K9.2 KHTSC High Pressure (TSC) Coolant Used

K12.7 KCO&MD Coolant Dual and Middle TSC

R436.2 TMB67 Filter Abnormal Status Check-Time


X3.3 CPOC.M TSC Filter or Pressure Check

Solution

Cause

Status

Filter Abnormal

Status Check-Time

Filter Change Alarm

of TSC Unit

2052

196

HP5100 HP51MTE87

Spindle Tool CL/UNCL Overtime Alarm

The Spindle Tool Unclamp Cylinder Location Detection Switch has been

set differently from the command signal for more than ten seconds.

Faulty adjustment of the location detection Switch ①

Problems with cables or ② related parts


Adjust the Switch, reading the detection Lamp on the proximity switch

attached to the back of the Spindle Tool Unclamp motion Cylinder.

Problems with cables or parts②

Check (in order) the Proximity Switch, From the Proximity Switch to

the Spindle Head terminal box, cables from the Spindle Head Terminal

box to the electrical cabinet, and the Input Module. Make any

necessary repairs or replacements.


Cable,

Proximity/Switch ECBLS0170F - BKS B20-1-03 Balluff

Switch, Proximity/PNP ESWPX0265F -SX11/12 BES516-325-E5-C-S4 Balluff

Signal Address Tool

Symbol I/O

Connector

(Pin)

Numbering

Tube


TCL.M -SX11

Input Module Slot

08 XJ412 (31) SX11

Spindle Tool

Unclamp

X6.5

TUCL.M -SX12

Input Module Slot

08 XJ412 (76) VPF2

Spindle Tool

Unclamp

Y39.6

STUN.R

-KAR11

-YV11

Distributed I/O

Module (B)

Mini Relay (DC

24V)

XC57B(A23)

KAR11(11)

KAR11

YV11

Solution

Cause

Status

2060

0.8~1.2mm

Proximity Switch

Dog

Spindle Tool

Clamp

Spindle

Tool

Unclamp

197

HP5100 HP51MTE87


A1.6 2015 Spindle Tool Unclamp Alarm

A7.3 2060 Spindle Tool Cl/Uncl Overtime Alarm

F0.6 SA Servo Ready

R626.5 TMB30 Spindle Clamp/Unclamp Check Time


X6.4 TCL.M Spindle Tool Clamp

X6.5 TUCL.M Spindle Tool Unclamp

Y39.6 STUN.R Spindle Tool Unclamp

Spindle Tool CL/UNCL

Check Time

Spindle Tool CL/UNCL

Overtime Alarm

198

HP5100 HP51MTE87

ATC Arm Pin Alarm

The Tool Change command (M06) has been given without the ATC Arm

Pin being released, or the ATC Arm Pin Location Detection Sensor has

been set differently from the command signal for more than 3 seconds.

The ATC Arm Pin is locked. ①

Faulty adjustment of the ATC Arm Pin position ② detection Reed Switch

③ Fault in the ATC Arm Pin position detection Reed Switch or in related

parts

Manually operate the ATC or command "M235”(ATC① Arm Pin Release)

in MDI mode.

Loosen the Reed Switch Holder security Screw and move it towards the ②

Shaft. Find and secure in the location in which the Sensor's LED lights

up.

Check (in order) the Reed Switch, connection cable, and I/O board. ③



(Pin)

Numbering

Tube

ATC Arm Pin Locking X15.3

ATAL.M -SD55

Input Module Slot

06 XJ414 (11) SD55

ATC Arm Pin Release X15.5

ATAR.M -SD56

Input Module Slot

06 XJ414 (43) SD56

ATC Arm Pin Locking Y0.2

ATAL.R -YV55

Output Module Slot

01

T/Block

(04) YV55

Solution

Cause

Status

2063

ATC Arm

Pin Locking

ATC Arm

Pin Release

199

HP5100 HP51MTE87


A7.6 2063 ATC Arm Pin Alarm

F0.6 SA Servo Ready


K61.1 KATCSV ATC Used Servo

R443.1 TMB122 ATC Arm Pin Alarm Check Time



R721.0 MANM06 Manual 1 Cycle ATC Start


X15.3 ATAL.M ATC Pin Locking

X15.5 ATAR.M ATC Pin Release

Y0.2 ATAL.R ATC Pin Locking

Y12.6 TST.R ATC Servo Start

ATC Arm Pin Alarm

ATC Arm Pin Alarm

Check Time

200

HP5100 HP51MTE87

Waiting Tool Pot Spindle/Magazine Side Alarm

The Waiting Port Location Detection Switch has been set differently from

the command signal for more than 15 seconds.



Faulty adjustment of the location detection S① witch

Manually activate the Waiting Port and adjust the Location Detection

Switch.


Check (in order) the Limit Switch, from the Limit Switch to the Tool

Magazine terminal box, cables from the Tool Magazine terminal box to

the electrical cabinet, and the Input Module. Make any necessary

repairs or replacements.

Signal Address Tool

Symbol I/O

Connector

(Pin)

Numbering

Tube

Waiting Pot Spindle Side

X7.0 WPSS.M

-SX5A Input Module

Slot 08 XJ412 (12) SX5A

Waiting Pot Magazine Side

X7.1 WPMS.M

-SX5B Input Module

Slot 08 XJ412 (28) SX5B

Waiting Pot Spindle Side

Y39.4 WPSS.R

-KAR53 -YV53

Distributed I/O Module (B) Mini Relay (DC 24V)

XCE57B(A22) KAR53(09)

KAR53 YV53

Waiting Pot Magazine Side

Y39.5 WPMS.R

-KAR54 -YV54

Distributed I/O Module (B) Mini Relay (DC 24V)

XCE57B(B22) KAR54(10)

KAR54 YV54

Solution

Cause

Status

2064

201

HP5100 HP51MTE87

Waiting

Pot

Spindle

Waiting Pot

Magazine Side

Tool

Magazine

Pocket Detect

Waiting Tool POT

SPD/MAG Side Alarm

Waiting Tool POT

Check Time

202

HP5100 HP51MTE87


A7.7 2064 Waiting Tool Pot SPD/MAG Side AL

F0.6 SA ATC Not Used

K6.0 KMATRX Matrix Tool Magazine is Used


R627.1 TMB34 Waiting Tool Pot Check Time


R2410.7 2081F

R4005.0 TMB34A Waiting Tool Pot Check Time

X7.0 WPSS.M Waiting Pot Spindle Side

X7.1 ATAL.M Waiting Pot Magazine Side

Y39.4 WPSS.R Waiting Pot Spindle Side

Y39.5 WPMS.R Waiting Pot Magazine Side

203

HP5100 HP51MTE87

Changer Arm Position Check Alarm

When the ATC Arm was in its Home Position, there was no Servo Home

Position signal from the Home Position Detection Switch or the Servo Motor

Faulty adjustment of the ATC Home Position Check Detection Switch or ①

faulty parts

Faulty adjustment of the Servo Motor or Drive, or faulty parts.②

Confirm and insepct the following signal from the ATC changer home ①

location.

ATC Changer Initial Position☞

Address X7.6 X8.7 X8.6 X8.5

Status 1 1 0 0

② Refer to “Canceling the AL2065”below.

Signal Address Tool

Symbol I/O

Connector (Pin)

Numbering Tube

ATC Servo Home Position

X7.6 MCAH.M

-A81 Input Module

Slot 08 XJ412 (10) THOMEI

Tool Clamp Command

X8.5 CLMD.M

SX51 Input Module

Slot 08 XJ412 (38) SX51

Tool Unclamp Command

X8.6 ULMD.M

-SX52 Input Module

Slot 08 XJ410 (22) SX52

ATC Home Position Check

X8.7 CAHP.M

-SX53 Input Module

Slot 08 XJ412 (37) SX53

(Reference) Canceling the AL2065 (Verifying the Arm Home Position)

1) Meaning of the Alarm : The alarm becomes activated when there is a change in t

he Main Changer Arm Home Position due to the Servo System or from other causes.

That is, the case where there is a difference between the reference point (X7.6)

memorized in the servo system and the reference point that recognizes

proximity switches (X8.7) by the present arm position.

2) Objective of the Alarm: The alarm aims to increase the stability of the Servo

Mechanisms (e.g. Clamping/Unclamping), which must work based on the Arm's

actual location, by maintaining the same Arm position setting regardless of

continuous tool exchanges.

3) Troubleshooting the Alarm

☞ Checking for Problems with the Changer Arm Home Position Detection Proximity

S/W

After checking for problems with switch looseness/ Dog looseness/

contamination/firing range, proceed normally.

Solution

Cause

Status

2065

204

HP5100 HP51MTE87

☞In case of alarm, when the changer arm home dog is deflected or even if the

position is normal, observe inside the Cam to see if the Turret Can Follower

Bearing is positioned on the Cam's Center area. Since this area is very small, it is

convenient to use a mirror and worklight.

☞After verifying the Cam Follower Bearing location, use those observations to

cancel the #2065 Alarm by Origin Initialization from the Servo Drive..

Case Cam

Follower S/W & Dog align Solution

Normal Faulty Reorder the Switch, secure, and Initialize

A Normal Normal Initialize

Faulty Normal B

Faulty Faulty

Realign the Changer Arm using Inching, reorder the Switch, and Initialize

Mirror

A

A

A B≒

Is the Cam Follower

Bearing in the middle of

the central area?

Central

Area

205

HP5100 HP51MTE87

(1) Case “A”

① Press the "MODE" Key once on the Servo Drive start

screen [r 0000]

② Press the "DOWN" Key once on the

[rd-oFF] screen

③ Press the "SET" Key for five seconds on the

[Or9.S--] screen. The letters will blink, then complete

Servo Origin Initialization.

Power ④ Off → On

⑤ Move back to Maintenance Mode. Execute the



206

HP5100 HP51MTE87

(2) Case “B”

① Press the MODE Key once and the "DOWN" Key

four times on the Servo Drive start screen[r 0000] to

display the [JOG run]. Press the "SET" Key once to

display the [Jr.0000].

② Appropriately use the "UP/DOWN" Key (which

drives the Arm 20rpm every time it is pressed) to

position the Cam Follower Bearing in the center of the

middle section. If necessary, reorder the S/W and press

the "Set" Key once to exit to the [JOG run] screen.

③ Press the "UP" key three times on the [JOG run] screen.

④ Press the "SET" Key for five seconds on the

[Or9.S--] screen. The letters on the screen will blink,

and then complete the Servo Origin Initialization.

Power Off ⑤ → On

⑥ Move back to Maintenance Mode. Execute the



207

HP5100 HP51MTE87

Pallet or Table CL/UNCL Switch Alarm

The Pallet or Table Location Detection Switch doest not correspond to the

command signal.

Faulty adjustment of the location de① tection switch

The Table Angle Index Use Curvic Coupling is not in its correct position ②

but has been pushed up.

Faulty Cables or Parts③

Faulty adjustment of the location detection switch①

Adjust the Switch, reading the detection switch on the proximity switch

attached to the back of the Spindle Tool Unclamp Activation Use Cylinder.

Refer to“Setting the Table Reference Point”to reset the B Axis refrence ②

point.

Faulty Cables or Parts③

Check (in order) the proximity switch, from the proximity switch to the

Spindle Head terminal box, cables from the Spindle Head terminal box to

the electrical cabinet, and the Input Module.

Signal Address Tool

Symbol I/O

Connector

(Pin)

Numbering

Tube

Pallet Clamp X10.0

PCL.M -SP61 Input Module Slot 09 XJ413 (16) SP61

Table Clamp X10.1

TACL.M -SL62 Input Module Slot 09 XJ413 (32) SL62

Pallet

Unclamp(Rotary)

X10.2

PUCL.M -SP63 Input Module Slot 09 XJ413 (48) SP63

Table Unclamp X10.3

TAUL.M -SL64 Input Module Slot 09 XJ413 (15) SP64

Pallet Unclamp Y7.2

PUCL.R

-KAR62

-YV62

Output Module Slot

03

Mini Relay (DC 24V)

XJ400 (44)

KAR62(11)

KAR62

YV62

Table Unclamp Y39.7

TUCL.R

-KAR61

-YV61

Distributed I/O

Module (B)

Mini Relay (DC 24V)

XCE57B(B23)

KAR11(11)

KAR11

YV11

Solution

Cause

Status

2073

Pallet Clamp

Check Table

Unclamp

Table

Clamp

208

HP5100 HP51MTE87

(Reference) Adjusting the hydraulic pressure and Switch of the Table and Pallet

1) Pallet Clamp / Unclamp Check

Pallet Clamp Adjusted Pressure: 35kg/① ㎤

Pallet Unclamp Adjusted Pressure: 8kg/② ㎤

2) Table Clamp / Unclamp Check

In case of the Table Clamp, change the B Axis reference point about 0.5 ①

degrees to dislocate the Curvic Coupling, clamp, then check the DGN. At this

point, both switches should be in the 'OFF' position.

When Keep Relay K8.1 is forcibly set while AL2073 is activated, (“0”② ->”1”) the

table becomes unclamped.

(Reference) Resetting the B Axis Reference Point

☞ If the B Axis Servo Motor has been disassembled and then reassembled, or the B

Axis stops at a different location after executing CW or CCW, or if the "2073 Pallet or

Table CL/UNCL Switch Alarm”is activated, the B Axis reference point must be reset.

1) Set the B Axis at 0 degrees and unclamp the table.

ex) “MDI” Mode: G90 B0.; M11;

2) Attach the Test Indicator to the Spindle Head and move the X Axis to match the

parallelism of the Edge Locator.

Set the Mode to“Handle”and set the selection① switch to B Axis and select 0.01.

Slowly rotate the Handle by degrees to set the parallelism between the edge ②

locator and the X Axis as accurately as possible.

3) When the parallelism is set, set Parameter N1815's #4 Bit (APZ) to “0,”then return it

to "1”and turn off the power.

When the N1815 #4 Bit (APZ) Parameter is changed, "P/S Alarm 000 Must Turn ☞

Off Power” and “P/S Alarm 300 nAxis Need ZRN”are activated.

4) When the power is turned back on, the alarm is canceled and the B Axis position on

the screen changes to "0".

5) Check the accurate clamp position of the table.

With the B Axis as the standard for 0 degrees, activate from 90 degrees to 0 ①

degrees, and from -90 degrees from 0 degrees. Verify on the angle indicator the

amount that the table moves when the table is clamped (when the teeth of the

curvic coupling fit with each other).

After unclamping the table, move the B Axis by degrees using the Handle in the ②

direction that the B Axis moves during clamping after CW or CCW (ex: ±0.03

degrees 0.05 degrees). Then repeat steps 3) and 4) above.∼

6) Repeat the above process to make the amount of table movement during clamping

equal on both sides.

The amount of movement is the backlash of the machine☞ itself.

209

HP5100 HP51MTE87

Lub.Pressure Alarm

Angle

Pallet or Table

CL/UNCL Switch Alarm

210

HP5100 HP51MTE87


A9.0 2073 Pallet or Table CL/UNCL Switch Alarm

F0.6 SA Servo Ready

K7.5 K4THA 4th-Axis Not Used

R626.4 TMB29 B-Axis (Table) CL/UNCL Check Time


K8.5 KROTA Rotary Table Used

R600.7 M10 B-Axis (Rotary) Clamp

R601.0 M11 B-Axis (Rotary) Unclamp

R653.0 MEND M-Function End

R752.1 RTCLP B-Axis (Rotary) Clamp

R841.5 BACLPF B-Axis (Table) Clamp Flag

X10.0 PCL.M Pallet Clamp (Index/Rotary)

X10.1 PCL.M Pallet Unclamp (Index/Rotary)

X10.2 PUCL.M Pallet Unclamp

X10.3 TAUL.M Table Unclamp (Rotary Table)

Y39.7 TUCL.R Table Unclamp (Rotary Table)

Y7.2 PUCL.R Pallet Unclamp

211

HP5100 HP51MTE87

ATC Overtime Alarm

For some reason, the tool search (T__ ;) or the tool change

command(M06) was not completed within 45 seconds.

The machine was stopped due to a problem from among the Tool Search

or Tool Change Sequence.

▪ Normally, the particular sequence overtime alarm will activate before

this alarm, indicating the problematic sequence.

Resolve the problem by referring to the corresponding Sequence chart or

Alarm chart.


(Pin)

Numbering

Tube

Waiting Pot Spindle

Side

X7.0

WPSS.M -SX5A

Input Module Slot

08 XJ412 (12) SX5A

Waiting Pot

Magazine Side

X7.1

WPMS.M -SX5B

Input Module Slot

08 XJ410 (28) SX5B

ATC Arm Pin

Locking

X15.3

ATAL.M -SD55

Input Module Slot

10 XJ414 (11) SD55

ATC Arm Pin

Release

X15.5

ATAR.M -SD56

Input Module Slot

10 XJ414 (43) SD56

ATC Arm Pin

Locking

Y0.2

ATAL.R -A41

Output Module

Slot 01 T/Block(04) YV55

TMG.2 Servo ON Y9.0

(SV02.R) -A41

Output Module

Slot 03 XJ400 (03) SV02

Tool Mag. S-Motor

Brake Rel.

Y11.0

TMBK.R -KA85

Output Module

Slot 04 XJ401 (12) KA85

TMG Servo On

Table

Y11.5

SVON.R -A41

Output Module

Slot 10 XJ401 (43) SVON

Solution

Cause

Status

2074

212

HP5100 HP51MTE87

1) ATC Main Sequence


▪ Input Signal : X8.7(CAHP.M), SX53, Input Module Slot8(Pin37) On

Spindle Tool Clamp

▪ Output : Y39.6(STUN.R), KAR11-YV11,Distribute I/O B (A23)

▪ Completion : X6.4(TCL.M), SX11, Input Module Slot8(Pin31)


Initial Condition

Arm & Servo Home Position①

2nd Reference Point & M19②

Pot Spindle Side③

& Clamp

Arm Pin Release④

X8.7 (SX53) CAHP.M

X7.0 (SX5A) WPSS.M

X7.2 (SD32) WPCL.M

X15.5(SD56) ATAR.M


▪ Output : Y39.6(STUN.R), KAR11-YV11,Distribute I/O B (A23)

▪ Completion : X6.4(TCL.M), SX11, Input Module Slot8(Pin31)


On

Off

On


▪ Output : Y 0.2(ATAL.R), YV55,Output Module Slot01(Pin04)

▪Completion: X15.3(ATAL.M), SD55, Input Module Slot06(Pin11)

X15.5 (ATAR.M), SD56, Input Module Slot06(Pin43)

On

On

Off


▪ Output : Y 0.2(ATAL.R), YV55,Output Module Slot01(Pin04)

▪Completion :X15.3(ATAL.M), SD55, Input Module Slot06(Pin11)

X15.5 (ATAR.M),SD56, Input Module Slot06(Pin43)

On

On

Off

Changer Arm

Gripping Tool

Spindle Tool

Tool Change

Spindle Tool Clamp

Changer Arm Home

Arm

Forward

Arm Out

&

Rotation

Arm In

Arm

Forward

Arm Pin

Locking

Arm Pin

Release

Off

On

Off

213

HP5100 HP51MTE87


A9.1 2074 ATC Overtime Alarm


R445.5 TMB142 ATC Overtime In Matrix

R628.1 TMB42 ATC Overtime




R628.1 TMB42 ATC Overtime


R648.6 M250A Door Interlock Bypass On Aux.

R649.6 DCL Operator Door Close Confirm

ATC Overtime

ATC Overtime Alarm

214

HP5100 HP51MTE87


R702.0 TCCMDA T-code Command Aux.

R749.6 ATCAUT ATC MAG. Auto Mode






R2410.7 2081F

Y9.0 SVO2.R TMG. 2 Servo On

Y11.0 TMBK.R Tool Mag. S-motor Brake Rel.

Y11.5 SVON.R TMG Servo On Table

215

HP5100 HP51MTE87

ATC Magazine Rotation Over Time Alarm

The tool magazine rotation was not completed within 50 seconds of the

command signal(TMG Servo On: Y11.5 or TMG2 Servo On:Y9.0) being sent

out, either manually or automatically.

Fault in the Tool Magazine Driving Servo Motor or Servo Drive

Refer to the Servo Motor or Servo Drive maintenance guide to make

necessary repairs or replacements.

☞ Refer to the appendix (Repairing Servo Driver Alarms)

Signal Address Tool

Symbol I/O

Connector

(Pin)

Numbering

Tube

TMG.2 Servo ON Y9.0

(SV02.R) -A41

Output Module

Slot 03 XJ400 (03) SV02

Tmg.2 Servo Motor

Break Rel.

Y9.7

TMB2.R -KA185

Output Module

Slot 03 XJ400 (33) KA185

Tool Mag. S-Motor

Brake Rel.

Y11.0

TMBK.R -KA85

Output Module

Slot 04 XJ401 (12) KA85

TMG Servo On

Table

Y11.5

SVON.R -A41

Output Module

Slot 10 XJ401 (43) SVON

Solution

Cause

Status

2075

ATC Magazine Rot.

Overtime Alarm

ATC Magazine Rot.

Overtime Check

216

HP5100 HP51MTE87


A9.2 2075 ATC Magazine Rot. Overtime Alam


K7.6 KAPC ATC Not Used

R445.6 TMB143 Man. ATC Mag. Rot. Overtime Check

R628.2 TMB43 ATC Magazine Rot. Overtime Check


Y9.0 SVO2.R TMG2 Servo On Table

Y9.7 TMB2.R TMG2 Servo Motor Brake Release

Y11.0 TMBK.R TMG Servo Motor Brake Release


217

HP5100 HP51MTE87

HP50/63 ATC SERVO DRIVE Adjust/Operation/PARAMETERS

1. PARAMETER SETTING METHOD

41POT 61POT 1) Press "MODE" on SERVO DRIVE.

00 0 0 MOTOR POWER CAPACITY 2) Change to parameter fixing mode as the following display.

01 0 0 MOTOR RUNNING DIRECTION

02 0 0 RESERVE PARAMETER

03 1 1 FIX-DIRECTION, JOG FUNCTION SELECTION The first two segments are the parameter NO.

04 0 0 RESERVE PARAMETER The last four segments are the setting value.

05 41 41 ATC 41 TOOLS POT 3) Search parameter NO. to be changed by pressing "UP" or "DOWN".

61 61 ATC 61 TOOLS POT 4) Press "SET" after searching parameter NO. to be changed.

06 GEAR RATIO - MOTOR SIDE 5) The dot below the first two segments will disappear.

106 106 AH5P/AH6P 6) Press "UP" or "DOWN" to adjust 4 segments to value to be set.

7) Press "SET" after completion of adjusting.

07 GEAR RATIO - MACHINE SIDE 8) The dot will appear below the first two segments.

9 9 AH5P/AH6P 9) The data will be stored.

10) Some parameters will display the former data after setting.

08 * * TOOL POT NUMBER OF HOME 11) The parameters will display the stored data after power on/off.

09 0 0 RESERVE PARAMETER 2. INITIAL TOOL NO. SET OR MANUAL HOME SETTING METHOD

10 256 256 POSITION LOOP PROPORTIONAL GAIN 1) Normally clamp the Tool No. to any position.

11 250 250 SPEED LOOP PROPORTIONAL GAIN 2) Set current position NO. to parameter NO.8

12 1 1 SPEED LOOP INTEGRAL GAIN 3) The display will turn to the former setting value after setting.

13 10 5 BRAKE OFF DELAY TIME (When power is turned off and then turned on again, it will display

14 2 1 BRAKE OFF CONTROL DELAY TIME the stored data)

15 10 5 BRAKE ON DELAY TIME 4) Press "MODE" and change the display of the servo ON/OFF mode.

16 0 0 MONITOR OFFSET VOLTAGE

17 0 0 MONITOR SELECTION

18 200 200 POSITIONING COMPLETE RANGE

19 6000 6000 REMAINING PULSE ALLOWANCE

20 0 0 POSITION LOOP FEED-FORWARD GAIN

21 0 0 FEED-FORWARD FILTER TIME CONSTANT

22 250 250 POSITIVE TORQUE LIMIT 1

23 250 250 NEGATIVE TORQUE LIMIT 1

24 100 100 POSITIVE TORQUE LIMIT 2

25 100 100 NEGATIVE TORQUE LIMIT 2

26 2050 2050 SPEED LIMIT

27 80 100 JOG SPEED AT SET HOME

28 2000 2000 TOOL MAGAZINE INDEX SPEED

29 200 200 ACCLERATION TIME 5) Press "SET" for 7 seconds and display will set parameter

30 200 200 DECELERATION TIME automatically and the turn back the display to zero-point setting

mode.

31 3000 3000 SPEED MONITOR OUTPUT VOLTAGE 6) Turn the power OFF and the ON again and the setting of the zero

32 1500 1500 TORQUE MONITOR OUTPUT VOLTAGE point is now completed.

33 6 6 INITIAL STATUS DISPLAY 3. NOTE

34 ENCODER COORDINATES COMPENSATION (LOW) 1) Don't change parameters during indexing.

35 ENCODER COORDINATES COMPENSATION (UP) 2) Adjusted parameters operated as the following.

36 SET VALUE OF MACHINE ZERO-POINT (LOW) ① Parameter NO.00~09

37 SET VALUE OF MACHINE ZERO-POINT (UP) : Adjusted parameters are only valid when power is off → on.

38 750 750 CURRENT LOOP PROPORTIONAL GAIN You can adjust the parameters under the servo is off

39 510 510 CURRENT LOOP INTEGRAL GAIN ② Parameter NO.10~18

40 2048 2048 ENCODER PULSE PER ONE ROTATION : You can adjust the parameters under the servo is off or on.

41 FEEDBACK PULSE(LOWER) ③ Parameter NO.19~33

42 FEEDBACK PULSE(UPPER) : You can adjust the parameters under the servo is off.

43 ACCELERATION RATE OF REMAINING VALUE ④ Parameter NO.34~45

44 DECELERATION RATE OF REMAINING VALUE : These parameters will be set automatically by home setting.

45 RESERVE PARAMETER Do not change these parameters.

3) Do not turn the power while mounting or dismounting the

operator panel of turret servo drive.

VERSION DATE REVISED CONTENT1.1 010504

DAEWOO HEAVY INDUSTRIES LTD.

AUTO SET

AUTO SET

AUTO SET

NO.

AUTO SET

REMARK

AUTO SET

AUTO SET

AUTO SET

AUTO SET

AUTO SET

AH5P,AH6P

0.0.0 0 0 0

rd.oFF origin modeMODE ▲▼

jog.run Jog Operation Mode Change▲▼

r d - o F F Jog Operation Ready Condi.MODE

jr.0.1.0.0 Jog MAG. CCW Rotation▲

jr.0000 Jog Operation ModeSET

jog.run Jog Operation Mode ReturnSET

jr.0.-1.0.0 Jog MAG. CW Rotation▼

Or 9.5 "SET" 7 Sec Push▲▼

rd-oFF ORIGIN ModeMODE

Or 9.5 "SET" 7 sec push▲▼

218

HP5100 HP51MTE87

Waiting Pot & Spindle Tool No. Zero

All of the Tool Data in the Waiting Pot and Spindle are set to "0".

The Waiting Pot was emptied due to command T00; sent out from a ①

Program.

The Spindle Tool was emptied due to command M06 T00; sent out ②

from a Program.

The data in the③ D452 (Waiting Tool No.) or D450(Spindle Tool No.) has

been erased.

Search for another tool.①

Just in case, make sure to check that there are no tools in the Waiting ☞

Pot.

(It must be empty.)

Change another tool.②

Just in☞ case, make sure to check that there are no tools in the Spindle.

(It must be empty.)

Enter“SYSTEM” “PMC” “DATA” “G DATA” and input the D452 ③ → → →

(Waiting Tool No.) D450 (Spindle Tool No.) data, after checking the

actual tool numbers.


R711.0 WSZERO Wait.& Spdl Pot Zero

R710.4 STZERO Spindle Tool No.Zero


A9.4 2077 Wait.Pot & Spdl Tool Data Zero

Solution

Cause

Status

2077

Wait.Pot & Spdl Tool Data Zero

219

HP5100 HP51MTE87

(Reference) Verifying the Spindle or Waiting Pot Tool Numbers

1) From the Main Control panel, press the "SYSTEM" Key from the right side of the CRT.

▪ The following appears in the Soft Key space below the CRT.


2) Press the〔PMC〕Soft Key.



3) Press the〔PMCPRM〕Soft key.


〔TIMER〕〔COUNTR〕〔KEEPRL〕〔DATA〕〔SETING〕

4) Press the〔DATA〕Soft Key.


〔G.DATA〕〔G.CONT〕〔NO.SRH〕〔〕〔INIT〕

5) Press the〔G.DATA〕Soft Key.

▪ The following appears in the Soft Key space below the CRT, and the DATA screen

appears.

〔C.DATA〕〔G-SRCH〕〔SEARCH〕

6) The following Tool Data appears when the Page Down button is pressed once from

the control board.

No Address Data

0000 D0450 3 Spindle Tool No.→

0001 D0452 5 Waiting Tool No.→

0002 D0454

0003 D0456

0004 D0458

The data shown in #D0450 is the Spindle Tool No., and the data shown in #D0452 is

the Waiting Pot Tool No.

220

HP5100 HP51MTE87

ATC OP Manual Mode

The selection switches in the main control board were set to EDIT,

MEMORY, TAPE, or MDI Mode while the Manual/Auto Selection Toggle

Switch in the ATC Manual control board was set to "Manual."

Set the Manual/Auto Selection Toggle Switch in the ATC Manual control

board to “AUTO”.

Signal Address Tool

Symbol I/O

Connector

(Pin)

Numbering

Tube

ATC Main Mode

Select

X15.6

TSMD.M -SA81

Input Module

Slot 10 XJ414 (10) SA81

Solution

Status

2078

ATC OP Manual Mode

ATC Manual Control Board

221

HP5100 HP51MTE87


A14.5 2118 Machine Maintenance Mode


K6.0 KMATRX Matrix Tool Magazine is Used



R1484.0 RT_MANMD ATC Manual Mode From Executer

X15.6 TSMD.M ATC Manual Mode Select

222

HP5100 HP51MTE87

ATC or APC Interlock Alarm

Either the ATC or the APC is not set to its initial position in Auto Mode

(Edit, Memory, Tape, MDI Mode).

ATC : Faulty adjustment of the ATC Home Position Check ① Proximity

Switch, or faulty parts

Faulty Home Position signal due to disorder in the ATC Servo Motor or

Drive

APC : Faulty adjustment of the APC Up/Down Check ② Proximity Switch,

or faulty parts

Faulty adjustment of the Pallet No. Check Proximity Switch or faulty parts

① (Reference) Refer to Below

Find the ② faulty signal from the PMC DGN or the Ladder and reset the

faulty Switch, or replace the faulty part.

☞ M06 Initial Position

Address X7.6 X7.2 X7.1 X7.0 X8.7

Status 1 1 0 1 1

☞ T-Code Initial Position

Address K61.1 X7.6 X7.3 X7.1 X8.7

Status 1 1 1 1 1

APC ☞ Initial setting


0 1 Status 1 0 1 1 1 0

1 0 1


(Pin) Numbering

Tube

ATC Servo Home Position

X7.6 MCAH.M

-A81 Input Module Slot 08 XJ412 (10) THOMEI

Tool Clamp Command

X8.5 CLMD.M

-SX51 Input Module Slot 08 XJ412 (38) SX51

Tool Unclamp Command

X8.6 ULMD.M


ATC Home Position Check

X8.7 CAHP.M


APC Up Check (OFF)

X11.6 APUP.M


APC Down Check (ON)

X11.7 APDP.M


Pallet No.1 Detection (ON/OFF)

X11.1 PN01.M


Pallet No.2 Detection (OFF/ON)

X11.2 PN02.M


Solution

Cause

Status

2080

223

HP5100 HP51MTE87

(Reference) Adjusting the ATC / APC Confirmation Switch

1) ATC Home Position Check

2) Pallet No 1 Detection / No 2 Detection, APC Up / Down Check

(Reference) DGN(Diagnostic) Check Process

1) Finding the DGN

From the Main ① Operation Panel, press the "SYSTEM" Key from the right side

of the CRT.



Press the② 〔PMC〕Soft Key.

ATC Home

Position Check

2~2.5mm

Proximity

Switch Dog

APC Down Check SX82

Pallet No.1 SX75

Pallet No.2 SX76

APC UP Check SX81

224

HP5100 HP51MTE87



press the③ 〔PMCDGN〕Soft Key.


〔TITLE〕〔STATUS〕〔ALARM〕〔TRACE〕

Press the④ 〔STATUS〕Soft Key.


〔NO.SRH〕〔〕〔〕〔〕〔〕

Input the DGN number being searched. Ex) When searching for X4.1: “X”, “4”, “.”, “1”,⑤

Press the⑥ 〔NO.SRH〕Soft Key.

▪ A Diagnostic screen appears with the number being searched.

2) Reading the DGN

Ex) X 003 0 0 1 1 0 0 1 0

Of Address X3, Bit 1, 4, 5 are On, and Bit 0, 2, 3, 6, 7 are Off.

Shown

as

0 0 1 1 0 0 1 0

Bit No. Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0

ATC Interlock

ATC or APC

Switch Alarm

225

HP5100 HP51MTE87


A9.7 2080 ATC or APC Switch Alarm



K61.0 KATCIV ATC Used Inverter

K61.1 KATCSV ATC Used Servo

R534.3 MDI MDI Mode





R718.7 ATCINT ATC Interlock

R769.7 APCINT APC Interlock


X7.6 THOMEI.M ATC Servo Home or Man. Home Pos.

X8.5 CLMD.M Tool Clamp Command

X8.6 ULMD.M Tool Unclamp Command

X8.7 CAHP.M ATC Home Position Check

R628.7 TMB48 Pallet Unclamp Interlock Time

R756.0 AHPOS1 APC Changer Position (CW)

R756.1 AHPOS2 APC Changer Position (CCW)

X11.6 APUP.M APC Up Check

X11.7 APDN.M APC Down Check

APC Interlock

226

HP5100 HP51MTE87

ATC Magazine Guard Door Open

The ATC Magazine Guard Door is open.

ATC Magazine Guard Door is open, or the Door Op① en Detection Safety

Switch is improperly adjusted.

Close the ATC Magazine Guard Door.①

Differentiate and check the Safety Switch and cables from the Switch ②

to the electrical cabinet. Make any necessary repairs or replacements.


(Pin)

Numbering

Tube

Tool Magazine Door

Interlock

X8.2

MDIT.M -S85

Input Module

Slot 08 XJ412 (39) S85

Tool Magazine Door

Interlock

X10.6

MDI2.M -S85A

Input Module

Slot 09 XJ413 (30) S85A

Solution

Cause

Status

Safety Switch

2081

227

HP5100 HP51MTE87

Tool Mag. Door Interlock Check


A10.0 2081 ATC Magazine Guard Door Open

F212.6 AL81-FM Door Open Alarm Of Matrix MAG.



K8.3 KDCLAR Alarm Reset By Door Close

K9.6 KMDINI Tool MAG.Door Interlock Not Use

R635.6 MAN Manual Mode




R717.7 MDIT Tool Magazine Door Open

R719.2 MATCST Manual ATC Start

R719.3 MATSTF Man ATC Start Flag




R436.4 TMB69 Tool Mag. Door Interlock Check

ATC Magazine

Guard Door Open

Tool Mag. Door

Interlock Check

228

HP5100 HP51MTE87

APC Set-Up Station Door Open

The APC Set-Up Station Door is Open.

The APC Set-Up Station Door is Open, or the Door Open Detection Safety

Switch or related parts are faulty.

Close the APC Door.①

Differentiate and Check the Door Open Detection Safety Switch, cables ②

from the Safety Switch to the electrical cabinet, and the Input Module.



(Pin)

Numbering

Tube

Set Up Door Interlock X5.4

SUIT.M -S91

Input Module

Slot 07 XJ411 (19) S91

Set Up Door Interlock 2 X17.5

SUIT.M -S91A

Input Module

Slot 10 XJ414 (34) S91A

Solution

Cause

Status

2084

229

HP5100 HP51MTE87

APC Set-Up Location S/W Unpush

When the M60(Pallet Change) or M61(APC 1 Load), M62(APC 2 Load)

commands were given, the Set-Up Switch in the APC Manual Control

board was not pressed.

After setting the workpiece on the Table, the Set-Up Switch was not

pressed.

After setting the ① workpiece on the Pallet, close the Splash Door and

press the Set-Up Push Button on the APC Manual Control board.

The yellow light comes in on the Set☞ -up Switch Lamp.

Check the switches re② lated to Set-up. Differentiate and check the

switch, cables from the switch to the electrical cabinet, and the Input

Module in the problematic area. Make any necessary repairs or

replacements.


(Pin)

Numbering

Tube

Set Up(APC),

Set-up Mode2(PMG)

X16.6

SETU.M -SB93

Input Module Slot

10 XJ414 (22) SB93

Solution

Cause

Status

Set-Up Switch

APC Manual control board

2085

230

HP5100 HP51MTE87


A10.4 2085 APC Set-up,location S/W Unpush


R607.1 M60 APC Macro Call



R755.7 SETUP Set Up

R759.0 APCMST APC Macro Start




APC Set-up,location

S/W Unpush

231

HP5100 HP51MTE87

APC OP Manual Mode

The Moode selection switches in the main operation panel were set to

EDIT, MEMORY, TAPE, or MDI Mode while the Manual/Auto Selection

Toggle Switch in the ATC Manual control board was set to "Manual."

Set the ① Manual/Auto Selection Toggle Switch in the ATC Manual control

board to “AUTO”.

Differentiate and check the Manual / Auto Selection Toggle switch, ②

cables from the switch to the electrical cabinet, and the Input Module.



(Pin)

Numbering

Tube

APC Manual Mode

Selection

X16.7

PMMD.M - SA91

Input Module Slot

10 XJ414 (37) SA91

Solution

Status

Manual/Auto Selection

Toggle Switch Toggle Switch

APC Manual Control board

2086

232

HP5100 HP51MTE87


A10.5 2086 APC Op Manual Mode


A22.1 2178 Commanded Pallet Can Not Find

A22.2 2179 Commanded Pallet Is On The Table



R1050.0 PMGOFF Pallet Magazine Off Mode

R1053.0 PMGOFF Pallet Magazine Off Mode

R1054.0 SETOFF Set-up Off Mode

R1420.7 PMGSEL Pmg Operation Selected

R1420.7 PCHOFF Pallet Change Off Mode Pmg

R1484.7 PMMD.MR APC Manual Mode

X16.7 PMMD.M APC Man Mode,set-up Mode3(PMG)

X41.5 PAUT.M Pmg Auto Mode Selection

APC Op Manual Mode

APC Manual Mode

233

HP5100 HP51MTE87

Table Or Pallet Clamp Alarm

The Pallet or Table Clamp Switch cannot be detected

Faulty adjustment of the Table Clamp Detection Limit Switch or ①

disorder in related parts

Lowered oil pressure or disorder in the Pallet Clamp Check Pressure ②

Switch or related parts

Refer below “Table & Pallet Clamp Check”

Signal Address Symbol I/O Conector

(Pin)

Numbering

Tube

Pallet Clamp X10.0

PCL.M -SP61

Input Module Slot

09 XJ413 (16) SP61

Table Clamp X10.1

TACL.M -SL62

Input Module Slot

09 XJ413 (32) SL62

Table Unclamp X10.3

TAUL.M -SL64

Input Module Slot

09 XJ413 (15) SP64

Pallet Unclamp Y7.2

PUCL.R

-KAR62

-YV62

Output Module Slot

03

Mini Relay

(DC 24V)

XJ400 (44)

KAR62(11)

KAR62

YV62

Table Unclamp Y39.7

TUCL.R

-KAR61

-YV61

Distributed I/O

Module(B)

Mini Relay

(DC 24V)

XCE57B(B23)

KAR11(11)

KAR61

YV61

(Reference) Table & Pallet Clamp Check

1) Faulty adjustment of the Table Clamp Detection Limit Switch or disorder in related

parts

Separate the Z-Axis Sliding cover near the Column, then manually press the Table

Solution

Cause

Status

2090

Pallet Clamp

Check Table

Unclamp

Table

Clamp

234

HP5100 HP51MTE87

Clamp use Micro Switch to check the DGN. If there is no problem, adjust using the

Micro Switch security Bolt or Switch Bracket security Bolt. If the DGN does not operate,

differentiate and check the Micro Switch, cables from the Switch to the Table terminal

box, cables from the terminal box to the electrical cabinet, and the Input Module. Make

any necessary repairs or replacements.

2) Lowered oil pressure, disorder in the Pallet Clamp Check Pressure Switch or related

parts

▪ Lowered oil pressure : The oil pressure in the Pallet Unclamp use oil pressure Line has

fallen below 8kg/㎠.

☞ Pallet Clamp Check(x10.0) : 35kg/㎠ /Pallet Unclamp Check(x10.2) : 8kg/㎠

3) Faulty Pallet Unclamp use Solenoid Valve prevents normal oil pressure supply

If the block in the oil pressure supply is judged to be caused by damage to a Spring inside

the Pallet Unclamp use Solenoid Valve or a jam in the Spool, use a small screwdriver or

wrench to push the spool to check the problem. When the faulty part is found, repair or

replace with a new part.

▪ If there are no problems with the Pallet Unclamp Check Pressure Switch or related parts,

differentiate and check the Press. Switch, the cables from the Switch to the electrical

cabinet, and the Input Module. Make any necessary repairs or replacements.

B-axis Or Pallet

Unclamp Inter

Table Or Pallet Clamp

Alarm

235

HP5100 HP51MTE87


A11.1 2090 Table Or Pallet Clamp Alarm

F0.4 SPL Feed Hold

F0.5 STL Cycle Start



R607.5 M64 Pallet Load Macro Call

R628.3 TMB44 Table(B-axis) Clamp Alarm D-time

R628.3 TMB44 Table(B-axis) Clamp Alarm D-ti

R752.4 TMBINT Table/Pallet Unclamp Interlock

R752.6 TMBINT1 Table Unclamp Interlock

R752.7 PALINT B-axis or Pallet Unclamp Inter

R759.0 APCMST APC Macro Start




X10.0 PCL.M Pallet Clamp(Index/Rotary)

Table(B-axis) Clamp

Alarm D-time

236

HP5100 HP51MTE87

Chip or Screw Conveyor Alarm

Faulty Chip Conveyor or Screw Conveyor

The protective brake has been stopped or rotation is blocked due to over

current.

(1) In the case of the Chip Conveyor

Check the status of the ① -QM1 brake inside the Control Box attached

within the main body of the Chip Conveyor.

if the ☞ -QM1 is stopped, inspect the three-phase cables first.

If ② -TM1 or -TM2 is activated, the rotation confirm signal (-SX1) sent

after the motor command signal is not being detected. The chain

connected to the motor and the -SX1 switch must all be checked.

(2) In the case of the Screw Conveyor

Check to see if the ① -QM62/63 inside the electrical cabinet is stopped.

Check fo② r disconnection of the three-phase main cable, magnet (-

KM62/63), and motor.


(Pin)

Numbering

Tube

Screw Conveyor

Overload

X2.4

SCOL.M

-QM63~

-QM62 Input Module Slot 07 XJ411 (37) SCOL

Chip Conveyor

Alarm

X3.6

CCFT.M -M61 Input Module Slot 07 XJ411 (10) M241

☞ QM62,63 Setting Overload 치: 3.0 A


Breaker, Circuit ENFBX0257R QM62,63 3RV1011-1EA10(2.8-4A) Siemens

Breaker, Auxillary ENFBX0290R QM62,63 3RV1901-1F(2NO) Siemens


K9.1 KCHIP Chip Conveyor is Used

X2.4 SCOL.M Screw Conveyor Overload

X3.6 CCFT.M Chip Conveyor Alarm

Solution

Cause

Status

Chip or Screw

Conveyor Alarm

2094

237

HP5100 HP51MTE87

-QM63

SCOLA

-QM62

1L+

Inout Module(AID32E) :Slot 7

X2.4 (SCOL.M)

15

Screw Coveyor Overload

SCOL

Screw Conveyor Overload

15

Inout Module(AID32E) : Slot 7

X2.4(SCOL.M)

238

HP5100 HP51MTE87

Operator’s Door Open

The Door near the operator is open.

The Door near the operator is open.① Faulty Adjustment of the Door Open Detection Safety Switch or ② fault in related parts

Close the door near the operator.① Differentiate and check the Safety Switch, the cables from the ② switch to the ATC terminal box, and the cables from the ATC terminal box to the electrical cabinet. Make any necessary repairs or replacements.


(Pin) Numbering

Tube

Operator’s Safety door Interlock

X5.3 OSDI.M

-KA02 Input Module Slot

07 XJ411 (02) S13

Cycle Start X32.5 ST.M

-SB12 Distributed I/O

Module A XC56A(B04) SB12


A12.3 2100 Machine In Service Mode

A13.2 2107 Operator’s Door Open Alarm



X5.3 OSDI.M Operator’s Safety door Interlock

X32.5 ST.M Cycle Start

Solution

Cause

Status

ATC Servo or

Inverter Alarm

2107

Safety Switch

239

HP5100 HP51MTE87

Operator’s Door Open Alarm

Keep R① elay is selected.

Maintenance Mode is commanded.②

Maintence Mode is selected.

If Keep Relay K5.7 had been intentionally selected, return to the ①

original setting after the intended process is complete.

If M239 had been commanded, ② cancel by commanding M240.



F0.6 SA Servo Ready

K5.7 KMAINT Operating Maintence For ATC/APC

R409.3 M239 ATC/APC Maintenance Mode On

Solution

Cause

Status

Maintenance Mode for ATC/APC

Operating Maintence for ATC/APC

Machine Maintenance Mode

2118

240

HP5100 HP51MTE87


R409.4 M240 ATC/APC Maintenance Mode Off

R458.0 M239-M Maintenance Mode For ATC/APC


R643.3 MDI MDI Mode


R761.0 M62CD M62cd

241

HP5100 HP51MTE87

Y-Z Interference Zone Alarm

The Axis has entered reciprocal interference area.

The Y Axis and/or Z Axis has entered into reciprocal interference ① area.

Transfer the axis in the opposite direction ① which it entered ,to transfer

it out of reciprocal interference area.

Check the program to see② if there are problems with the stroke.

If Keep Relay K8.4 is set ③ to “1,”the command is nullified.


(Pin)

Numbering

Tube

Tool Length

Sensor Up

X17.0

TLUP.M -SD61 Input Module Slot 10 XJ414 (03) SD61

Tool Length

Sensor Down

X17.1

TLDN.M -SD62 Input Module Slot 10 XJ414 (20) SD62

Tool Length

Sensor Up

Y1.7

TLUP.R -YV67 Output Module Slot 01

T/Block

(20) YV67

Solution

Cause

Status

Y-Z Interference Zone Alarm

Y-Z Interference Zone

2120

242

HP5100 HP51MTE87


A14.7 2120 Y-Z Interference Zone Alarm

K0.7 KTLENG Moving Type Tool Meas.Is Used

K8.4 KMCIFZ Machine Interference Zone

R642.5 YAZONE Y axis Interference Zone

R642.6 ZAZONE Z axis Interference Zone

R642.7 YZZONE Y-Z Interference Zone

R692.2 SEON Work Measure Sensor On

X17.0 TLUP.M Tool Length Sensor Up

X17.1 TLDN.M Tool Length Sensor Down

Y1.7 TLUP.R Tool Length Sensor Up

243

HP5100 HP51MTE87

APC Up / Down Alarm

A completion signal was not received within ten seconds after the APC

Up or Down command is sent out, the APC Up Check and Down Check

signals were turned on or off simultaneously and sustained for over ten

seconds.

① Faulty adjustment of the detection switch

② Problems with the detection Switch, activation Solenoid Valve,

connecting cables, or related parts

Faulty adjustment of the switch①

Check the location of the proximity switch and dog attached to the top

of the APC Up/Down use Hyd. Cylinder, and in the case of a problem

with adjustment, loosen the proximity switch security nut and adjust

the switch.

Problems with the detection Switch, ② activation Solenoid Valve,

connecting cables, or related parts

Differentiate and check the proximity switch, cables from the switch to

the APC terminal box, cables from the terminal box to electrical cabinet,

and the Input Module. Make any necessary repairs or replacements.

Also differentiate and check the activation Solenoid Valve, cables from

the Valve to the APC terminal box, cables from the terminal box to the

electrical cabinet, and Output Module. Make any necessary repairs or

replacements.

☞ APC Initial Condition


0 1 Status 1 0 1 1 1 0

1 0 1


(Pin)

Numbering

Tube

APC Up Check X11.6

APUP.M -SX81

Input Module Slot

09 XJ413 (10) SX81

APC Down Check X11.7

APDP.M -SX82

Input Module Slot

09 XJ413 (42) SX82

APC Changer Up Y39.2

APUP.R

-KAR75

-YV75

Distributed I/O

Module (B)

Mini Relay (DC 24V)

XCE57B(A21)

KAR75(11)

KAR75

YV75

APC Changer

Down

Y39.3

APDN.R

-KAR76

-YV76

Distributed I/O

Module (B)

Mini Relay (DC 24V)

XCE57B(B21)

KAR76(11)

KAR76

YV76

Solution

Cause

Status

2126

244

HP5100 HP51MTE87

APC Down Check

Pallet No.1

Pallet No.2

APC UP Check

APC Up APC Up

APC CCW APC CW

245

HP5100 HP51MTE87


A15.5 2126 APC Up/Down Alarm


R627.7 TMB40 APC Up/Down Check Time


R763.4 MAPCSP Manual APC Stop

R1056.2 MCHASP Manual Pallet Changer Stop

R1420.7 MPFSEL PMG Operation Selected


X11.7 APDN.M APC Down Check

Y39.2 APUP.R APC Changer Up

Y39.3 APDN.R APC Changer Down

APC Up / Down

Check Time

APC Up/Down Alarm

246

HP5100 HP51MTE87

APC Changer 180CW/CCW Alarm

The APC Changer CW or CCW command was not completed within 15

seconds, or the CW and CCW detection signals were detected

simultaneously.

Faulty adjustment of the detection switch ①

Problems with the detection Switch, activ② ation Solenoid Valve,

connection cables or related parts

Faulty adjustment of the Switch①

Check the location of the proximity switch and dog attached to the top

of the APC. In the case of a problem with adjustment, loosen the

proximity switch security nut and adjust the switch.

☞ Adjustment of the distacne between the proximity Switch and Dog:

2 2.5mm∼

② Troubled in the detection Switch, activation Solenoid Valve, connection

cables or related parts

APC Initial Condition③

Address X11.7 X11.6 X11.2 X11.1

1 0 Status 1 0

0 1


(Pin)

Numbering

Tube

Pallet No.1

Detection

(On/Off)

X11.1

PN01.M -SX75

Input Module Slot

09 XJ413 (28) SX75

Pallet No.2

Detection

(Off/On)

X11.2

PN02.M SX76

Input Module Slot

09 XJ413 (44) SX76

APC Up Check

(Off)

X11.6

APUP.M -SX81

Input Module Slot

09 XJ413 (10) SX81

Pallet Changer

CW. Rotation

Y39.0

PCW.R

-KAR73

-YV73

Distributed I/O

Module B

Mini Relay (DC 24V)

XCE57B(A20)

KAR73(09)

KAR73

YV73

Pallet Changer

CCW. Rotation

Y39.1

PCCW.R

-KAR74

-YV74

Distributed I/O

Module B

Mini Relay (DC 24V)

XCE57B(B20)

KAR74(10)

KAR74

YV74


APUP.R

-KAR75

-YV75

Distributed I/O

Module B

Mini Relay (DC 24V)

XCE57B(A21)

KAR75(11)

KAR75

YV75

Solution

Cause

Status

2127

247

HP5100 HP51MTE87

APC Changer

CW/CCW Alarm

APC Up APC Up

APC CCW APC CW

APC Down Check

Pallet

No.1

APC UP Check

Pallet

No.2

248

HP5100 HP51MTE87


A10.3 2084 APC Set-up Station Door Open

A15.6 2127 APC Changer CW/CCW Alarm






R430.7 TM32 APC Auto Door Close Check Time

R452.0 TMB193 Setup Supplier Door Close C-tm

R627.6 TMB39 APC 180cw/180ccw Check



R756.0 AHPOS1 APC Changer POS.(Cw)

R756.1 AHPOS2 APC Changer POS.(CCw)

R763.4 MAPCSP Man APC Stop

R1056.2 MCHASP Man Pallet Changer Stop



Y39.0 PCW.R Pallet Changer CW.Rotation

Y39.1 PCCW.R Pallet Changer CCW.Rotation

Y39.2 APUP.R APC Changer Up

APC 180CW/

180CCW Check

249

HP5100 HP51MTE87

Waiting Pot Clamp Alarm

The ATC Waiting Pot Clamp command was not completed within 5

seconds, the Waiting Pot Clamp and Unclamp signals were detected

simultaneously, or both were not detected for over five seconds.

Faulty adjustment of the detection Reed Switch ①

Problemswith the detection Switch,acti② vation Solenoid Valve,


Faulty adjustment of the Switch①

Check the functioning of the Reed Switch attached to the Tool

Magazine Waiting Pot Clamp Air Cylinder. In the case of a problem

with adjustment, loosen the Switch Bracket security Bolt and move

them along the cylindrical length direction, adjusting the switch while

reading the Red Lamp.

② Problems with the detection Reed Switch, activity Solenoid Valve,


Differentiate and check the Reed Switch, cables from the Switch to

the electrical cabinet, and the Input Module. Make any necessary

repairs or replacements. Also differentiate and check the Air Solenoid

Valve, cables from the Valve to the electrical cabinet, and the Output

Module. Make any necessary repairs or replacements.

Solution

Cause

Status

Waiting Pot

Unclamp Check

Waiting Pot

Clamp Check

Pot Clamp ATC Door Close

ATC Arm Pin

Locking

2154

250

HP5100 HP51MTE87

Signal Address Tool

Symbol I/O

Connector (Pin)

Numbering Tube

Waiting Pot Clamp Check

X7.2 SD32.M

-SD32 Input Module Slot

08 XJ412 (44) SD32

Waiting PoUnclamp Check

X7.3 SD32.M

-SD33 Input Module Slot

08 XJ412 (11) SD33

Waiting Pot Clamp Y3.0

WPCL.R -YV37

Output Module Slot 02

T/Block(12) YV37


A19.1 2154 Waiting Pot Clamp Alarm

F0.6 SA Servo Ready



R435.4 TMB61 Waiting Pot Clamp Check Time


R4005.1 TMB61A Waiting Pot Clamp Check Time

X7.2 WPCL.M Waiting Pot Clamp Check

X7.3 WPUL.M Waiting Pot Unclamp Check

Y3.0 WPCL.R Waiting Pot Clamp

Waiting Pot

Clamp Alarm

Waiting Pot

Clamp Check Time

251

HP5100 HP51MTE87

Tool Magazine Pot Detect Switch Alarm

The given command cannot be completed in the current ATC Waiting Pot

location.

When the Pot is at the Magazine Side: the Waiting Pot Magazine Side ①

command was given.

When the Pot is at the Spindle Side: the Waiting Pot Spindle Side ②

command was given.

Wrong command①

Faulty Adjustment of the detecti② on Switch

Problems with the detection Switch, connection cables or related parts③

Check the Waiting Pot position(Tool Search presence) and give the ①

appropriate command.

Faulty adjustment of the Switch②

Check the location of the proximity switch and dog attached to the

Tool Magazine. In the case of a problem with adjustment, loosen the

proximity switch security Bolt and adjust the Switch.

Adjusted distance: 2 2.5mm☞ ∼

Problems with the detection Switch, connection cables ③ or related parts


the electrical cabinet, and the Input Model. Make any necessary

repairs or replacements.


Switch, Proximity /

PNP ESWPX0268F -

BES M18MI-PSC50B-

S05G Balluff

Cable, Proximity

Switch ECBLS0171F -SX36 BKS B20-1-05 Balluff


(Pin) Numbering

Tube

Tool Magazine

Pocket Detect

X7.7

TPDT.M -SX36 Input Module Slot 08 XJ412 (42) SX36

Tmg.2 Servo On Y9.0

(SV02.R) -A41

Output Module Slot

03 XJ400 (03) SV02

Tmg Servo On

Table

Y11.5

SVON.R -A41

Output Module Slot

10 XJ401 (43) SVON

Solution

Cause

Status

2155

252

HP5100 HP51MTE87


A19.2 2155 Tool Mag. Pot Detect SW Alarm

K6.0 KMTRX Matrix Tool Magazine Is Used


K10.1 KWPDTC Waiting Pot Detect Keep

R438.3 TMB84 Alarm 2155 Aux.

R627.3 TMB36 T-Code Command Delay Time


R703.0 RAYCS1 Re-Chan.ATC Step1(Pot Unclamp)

Tool Magazine Pot

Detect SW Alarm

Alarm 2155 Aux.

Waiting Pot

Magazine Side

Tool Magazine

Pocket Detect

253

HP5100 HP51MTE87


R704.6 ATCS7 Do.7(Changer Home Check

R713.3 TP.X=Y Tool Pot X=Y


R724.2 MWPSS Man Waiting Pot Spindle Side

R724.3 MWPMX Man Waiting Pot Mag. Side

X7.7 TPDT.M Tool Magazine Pocket Detect

Y9.0 SVO2.R TMG.2 Servo On


254

HP5100 HP51MTE87

Waiting Pot Spindle/Magazine Side Command Alarm

Waiting Pot Location Detection Switch or the Waiting Tool Pot Presence

Detection Switch has spent over five seconds in a different status from

the command signal.


Problems with the cables or ② parts


Check the location of the proximity switch and dog attached to the

APC. In the case of a problem with adjustment, loosen the proximity

switch security Bolt and adjust the Switch.

P② roblems with the detection Switch, motion Solenoid Valve, connection



the TMG terminal box, from the terminal box to the electrical cabinet,

and the Input Module. Make any necessary repairs or replacements.


Switch, Proximity /

PNP ESWPX0268F -SX5A/5B

BES M18MI-PSC50B-

S05G Balluff

Cable, Proximity

Switch ECBLS0171F - BKS B20-1-05 Balluff

Symbol Address Symbol I/O Connector

(Pin)

Numbering

Tube

Waiting Pot Spindle

Side

X7.0


Waiting Pot

Magazine Side

X7.1


Tool Magazine

Pocket Detect

X7.7

TPDT.M -SX36 Input Module Slot 08 XJ412 (42) SX36

Solution

Cause

Status

2158

255

HP5100 HP51MTE87

Waiting

Pot

Spindle

Waiting Pot

Magazine

Side

Tool

Magazine

Pocket

256

HP5100 HP51MTE87

APC Pallet Check Switch Alarm

More than 15 seconds have passed with both the APC Pallet No.1 and 2

Detection switches on or off.


② Problems with the detection Switch, Motion Solenoid Valve, connection



Check the location of the APC Pallet No. Check use proximity Switch

and Dog. In the case of a problem with adjustment, loosen the proximity

switch security Bolt and adjust the Switch. (Adjusted distance :

2 2.5mm)∼

Problems with the detection Switch, connection cables or related parts②


the electrical cabinet, and the Input Module. Make any necessary repairs

or replacements.

Product Product # Symbol Model Maker

Switch, Proximity /

PNP ESWPX0268F -

BES M18MI-PSC50B-

S05G Balluff

Cable, Proximity

Switch ECBLS0171F -SX75/76 BKS B20-1-05 Balluff


(Pin)

Numbering

Tube

Pallet No.1

Detection

(On/Off)

X11.1

PN01.M -SX75 Input Module Slot 09 XJ413 (28) SX75

Pallet No.2

Detection

(Off/On)

X11.2

PN02.M -SX76 Input Module Slot 09 XJ413 (44) SX76

Solution

Cause

Status

2160

257

HP5100 HP51MTE87


A15.6 2127 Pallet Changer CW/CCW Alarm

A19.7 2160 APC Pallet Check Switch Alarm


K25.0 KAPSET ATC Rotation Keep

R436.0 TMB65 APC Pallet No. Check Time



X11.1 PNO1.M Pallet No.1 Detection

X11.2 PNO2.M Pallet No.2 Detection

APC Pallet Check

Switch Alarm

APC Down Check

Pallet No.1

Check APC UP Check

Pallet No.2

Check

APC Pallet No.

Check Time

258

HP5100 HP51MTE87

ATC Door Open/Close Alarm

The ATC Door Open/Close command was not completed within 5

seconds, the Door Open and Close signals were detected simultaneously,

or five seconds passed without either signal being detected.

Faulty adjustment of the ATC Door Close Check Reed Switch①

Problems with the ATC Door Close detection Switch or related parts②

Loosen the Reed① Switch Holder security Screw and move it towards

the Shaft to secure the place where the Sensor LED lights up.

Check the Reed Switch, Connection cables, and I/O board② in order.



(Pin) Numbering

Tube

ATC Door Open X8.0

ATDO.M -SD51 Input Module Slot 08 XJ412 (07) SD51

ATC Door Close X8.1

ATDC.M -SD52 Input Module Slot 08 XJ412 (24) SD52

Solution

Cause

Status

2163

ATC Door

Close Check

Reed

Switch

Holder ATC Door

Open Check

Reed

Switch

Holder

259

HP5100 HP51MTE87


A20.2 2163 ATC Door Open/Close Alarm

F0.6 SA Servo Ready


R627.5 TMB38 ATC Door Open/Close Check Time


X8.0 ATDO.M ATC Door Open

X8.1 ATDC.M ATC Door Close

Y4.4 ATDO.R ATC Door Open

Y4.5 ATDC.R ATC Door Close

ATC Door

Open/Close Alarm

ATC Door

OP/CL Check Time

260

HP5100 HP51MTE87

T-code Or M06 Commanded Status

Manual Operation was activated during a ATC Tool Change Cycle.

Manual operation was attempted before the ATC Tool Change Cycle was

completed.

Cancel the alarm using the alarm reset button, and proceed with manual

operation after the ATC Tool Change Cycle is complete.


(Pin) Numbering

Tube

ATC Manual Start X15.4

TSST.M -SB81

Input Module Slot

10 XJ414 (27) SB81

ATC Manual Mode

Select

X15.6

TSMD.M -SA81

Input Module Slot

10 XJ414 (10) SA81


A24.7 2200 T-code Or M06 Commanded Status


R702.3 TPSCMD Tool Pot Search Command


R719.6 ATCMMD ATC Main Op Manual Mode




R4010.4 RTCMDF Re-change T-code Command Flag

Solution

Cause

Status

T-code Or M06 Commanded

Status

2200

261

HP5100 HP51MTE87

VPF Off Of Tool Magazine

After the Magazine rotation command, the Magazine Pot location signal

was not confirmed.

① The magazine did not rotate after the command.

② Problems with the magazine stop position signal(VPF)

① Check the Magazine command number and the actual number.

② Check the VPF signal.

During the magazine rotation, it turns on/off at every port, and ☞

turns on if it stops at the correct position.

If there is no VPF signal, check the connection of the cables from the ③

servo amp to the Input Module.


(Pin) Numbering

Tube

TMG Servo Verify X6.7

VPF.M -A41 Input Module Slot 08 XJ412 (46) VPF

Tmg Servo On Table

Y11.5 SVON.R

-A41 Output Module Slot 10 XJ401 (43) SVON

Mag.2 Servo Verify

X100.7 VPF2.M

-A41 Input Module Slot 06 XJ410 (46) VPF2

Tmg. Servo Start Y10.7

SVST.R -A85 Output Module Slot 04 XJ401 (46) ST

Tmg Servo on Table

Y11.5 SVON.R

-A41 Output Module Slot 10 XJ401 (43) SVON

Solution

Cause

Status

VPF Off Of Tool Magazine

2215

262

HP5100 HP51MTE87


A26.6 2215 VPF Off Of Tool Magazine

F0.6 SA Servo Ready



R443.6 TMB127 VPF Check Time


R836.2 VPF1C Check Vpf1




X6.7 VPF.M TMG Servo Verify

Y10.7 SVST.R TMG. Servo Start


F0.6 SA Servo Ready




R443.6 TMB127 VPF Check Time

R701.3 KDMAG Dual Mag.(100,120tools) Keep

R836.1 VPF2C Check VPF2

R836.2 VPF1C Check VPF1

X100.7 VPF2.M Mag.2 Servo Verify

Y13.7 ST2.R TMG. 2 Servo Motor Start

Y9.0 SVO2.R TMG. 2 Servo On

Check VPF1

VPF Check Time

Check VPF2

263

HP5100 HP51MTE87

Appendix 1) X-Y Signal Address


(Pin)

Numbering

Tube

Hydraulic Motor

Overload

X2.1

HOL.M

QM31~

-QM36

Input Module Slot

07 XJ411 (32) HOL

Coolant & Lub.

Motor Overload

X2.2

MOL.M

-QM10~

-QM185

Input Module Slot

07 XJ410 (48) MOL

Screw Conveyor

Overload

X2.4

SCOL.M

-QM63~

-QM62

Input Module Slot

07 XJ411 (37) SCOL

Oil Cooling Alarm X2.5

OCFT.M -OCFT

Input Module Slot

07 XJ411 (47) OCFT

Hyd. Pressure

Check (Main)

X3.0

HPRS.M -SP01

Input Module Slot

07 XJ411 (12) SP01

Air Pressure Check X3.1

EPRS.M -SP12

Input Module Slot

07 XJ410 (28) SP12

TSC Filter Or

Pressure Check

X3.3

CPOC.M -SP16

Input Module Slot

07 XJ411 (11) M222

Chip Conveyor

Alarm

X3.6

CCFT.M -M61

Input Module Slot

07 XJ411 (10) M241

Oil Cooling

Alarm(Special)

X4.0

SOCF.M -M73

Input Module Slot

07 XJ411 (07) OCFT1

Lub. Level Low X5.0

LUB.M -SV51

Input Module Slot

07 XJ411 (03) SV51

Lub. Pressure

Check

X5.1

LPRS.M -SP51

Input Module Slot

07 XJ411 (20) SP51

Lub. Manual Start X5.2

LMS.M -M51

Input Module Slot

07 XJ411 (35) SB51

Operator’s Safety

Door Interlock

X5.3

OSDI.M -KA02

Input Module Slot

07 XJ411 (02) S13

Set Up Door

Interlock

X5.4

SUIT.M S91

Input Module Slot

07 XJ411 (19) S91


TCL.M -SX11

Input Module Slot

08 XJ412 (31) SX11

Spindle Tool

Unclamp

X6.5

TUCL.M -SX12

Input Module Slot

08 XJ411 (47) SX12

TMG Servo Verify X6.7

VPF.M -A41

Input Module Slot

08 XJ412 (46) VPF

Waiting Pot Spindle

Side

X7.0

WPSS.M -SX5A

Input Module Slot

08 XJ412 (12) SX5A

Waiting Pot

Magazine Side

X7.1

WPMS.M -SX5B

Input Module Slot

08 XJ412 (28) SX5B

264

HP5100 HP51MTE87


(Pin)

Numbering

Tube

Waiting Pot Clamp

Check

X7.2

SD32.M -SD32

Input Module Slot

08 XJ412 (44) SD32

Waiting Pot

Unclamp Check

X7.3

SD32.M -SD33

Input Module Slot

08 XJ412 (11) SD33

ATC Servo Home

Position

X7.6

MCAH.M -A81

Input Module Slot

08 XJ412 (10) THOMEI

Tool Magazine

Pocket Detect

X7.7

TPDT.M -SX36

Input Module Slot

08 XJ412 (42) SX36

ATC Door Open X8.0

ATDO.M -SD51

Input Module Slot

08 XJ412 (07) SD51

ATC Door Close X8.1

ATDC.M -SD52

Input Module Slot

08 XJ412 (24) SD52

Tool Magazine Door

Interlock

X8.2

MDIT.M -S85

Input Module Slot

08 XJ412 (39) S85

Tool Clamp

Command

X8.5

CLMD.M SX51

Input Module Slot

08 XJ412 (38) SX51

Tool Unclamp

Command

X8.6

ULMD.M -SX52

Input Module Slot

08 XJ410 (22) SX52

ATC Home Position

Check

X8.7

CAHP.M -SX53

Input Module Slot

08 XJ412 (37) SX53

ATC Home Position

Check

X8.7

CAHP.M -SX53

Input Module Slot

08 XJ412 (37) SX53

ATC Servo Or

Inverter Alarm

X9.6

TALM.M

QM31~

-QM36

Input Module Slot

08 XJ412 (01) TALM

Pallet Clamp

(Index/Rotary)

(On)

X10.0

PCL.M -SP61

Input Module Slot

09 XJ413 (16) SP61

Table Clamp

(Index/Rotary)

(On)

X10.1

TACL.M -SL62

Input Module Slot

09 XJ413 (32) SL62

Pallet

Unclamp(Rotary)

X10.2

PUCL.M -SP63

Input Module Slot

09 XJ413 (48) SP63

Table Unclamp

(Index/Rotary)

(Off)

X10.3

TAUL.M -SL64

Input Module Slot

09 XJ413 (15) SP64

Table Unclamp X10.3

TAUL.M -SL64

Input Module Slot

09 XJ413 (15) SP64

Tool Magazine Door

Interlock

X10.6

MDI2.M -S85A

Input Module Slot

09 XJ413 (30) S85A

265

HP5100 HP51MTE87


(Pin)

Numbering

Tube

Pallet Rot. Lock

(Setup S-D.O.)

X11.0

PLOC.M

(SSDC.M)

-SX89 Input Module Slot

09 XJ413 (12) SX89

Pallet No.1

Detection

(On/Off)

X11.1

PN01.M -SX75

Input Module Slot

09 XJ413 (28) SX75

Pallet No.2

Detection

(Off/On)

X11.2

PN02.M SX76

Input Module Slot

09 XJ413 (44) SX76

APC Up Check

(Off)

X11.6

APUP.M -SX81

Input Module Slot

09 XJ413 (10) SX81

APC Down Check

(On)

X11.7

APDP.M -SX82

Input Module Slot

09 XJ413 (42) SX82

ATC Arm Pin

Locking

X15.3

ATAL.M -SD55

Input Module Slot

06 XJ414 (11) SD55

ATC Manual Start X15.4

TSST.M -SB81

Input Module Slot

10 XJ414 (27) SB81

ATC Arm Pin

Release

X15.5

ATAR.M -SD56

Input Module Slot

06 XJ414 (43) XJ414 (43)

ATC Manual Mode

Select

X15.6

TSMD.M -SA81

Input Module Slot

10 XJ414 (10) SA81

Set Up(APC) X16.6

SETU.M -SB93

Input Module Slot

10 XJ414 (22) SB93

APC Manual Mode

Selection

X16.7

PMMD.M -SA91

Input Module Slot

10 XJ414 (37) SA91

Tool Length Sensor

Up

X17.0

TLUP.M -SD61

Input Module Slot

10 XJ414 (03) SD61

Tool Length Sensor

Down

X17.1

TLDN.M -SD62

Input Module Slot

10 XJ414 (20) SD62

Set Up Door

Interlock 2

X17.5

SUIT.M -S91A

Input Module Slot

10 XJ414 (34) S91A

Machine Ready X32.4

MRD.M -SB11

Distributed I/O

Module A

XC56A

(A04) SB11

Cycle Start X32.5

ST.M -SB12

Distributed I/O

Module A

XC56A

(B04) SB12

Mag.2 Servo Verify X100.7

VPF2.M -A41

Input Module Slot

06 XJ410 (46) VPF2

ATC Door Open Y0.0

ATDO.R -YV51

Output Module Slot

01

T/Block

(02) YV51

266

HP5100 HP51MTE87


(Pin)

Numbering

Tube

ATC Door Close Y0.1

ATDC.R -YV52

Output Module Slot

01

T/Block

(03) YV52

ATC Arm Pin

Locking

Y0.2

ATAL.R -YV55

Output Module Slot

01

T/Block

(04) YV55

Pallet Air For Table Y1.5

PAIR.R -YV63

Output Module Slot

01

T/Block

(18) YV63

Tool Length Sensor

Up

Y1.7

TLUP.R -YV67

Output Module Slot

01

T/Block

(20) YV67

Lubrication For

Guide Way

Y2.4

LUBM.R -QM51

Output Module Slot

02 T/Block(07) KM51A

Waiting Pot Clamp Y3.0

WPCL.R -YV37

Output Module Slot

02 T/Block(12) YV37

Pallet Unclamp Y7.2

PUCL.R

-KAR62

-YV62

Output Module Slot

03

Mini Relay

(DC 24V)

XJ400 (44)

KAR62(11)

KAR62

YV62

Tmg.2 Servo On Y9.0

(SV02.R) -A41

Output Module Slot

03 XJ400 (03) SV02

Tmg.2 Servo Motor

Break Release

Y9.7

TMB2.R -KA185

Output Module Slot

03 XJ400 (33) KA185

Tmg. Servo Start Y10.7

SVST.R -A85

Output Module Slot

04 XJ401 (46) ST

Tool Mag. S-Motor

Brake Rel.

Y11.0

TMBK.R -KA85

Output Module Slot

04 XJ401 (12) KA85

ATC Servo Start Y12.6

TST.R -A81

Output Module Slot

04 XJ401 (22) TST

Tmg Servo On

Table

Y11.5

SVON.R -A41

Output Module Slot

10 XJ401 (43) SVON

Tmg.2 Servo Motor

Star

Y13.7

ST2.R -A41

Output Module Slot

04 XJ401 (33) ST2

X-Axis Ref. Point

Return

Y33.0

XZL.L -HL21

Distributed I/O

Module A

XC56A

(A20) HL21

Y-Axis Ref. Point

Return

Y33.1

YZL.L -HL22

Distributed I/O

Module A

XC56A

(A20) HL22

Z-Axis Ref. Point

Return

Y33.2

ZZL.L -HL23

Distributed I/O

Module A

XC56A

(A20) HL23

Hydraulic 1,2,3

Motor Run

Y38.4

HYDM.R -KA31

Distributed I/O

Module B

XCE57B

(A18) KA31

Pallet Changer Y39.0 -KAR73 Distributed I/O XCE57B KAR73

267

HP5100 HP51MTE87


(Pin)

Numbering

Tube

CW. Rotation PCW.R -YV73 Module B

Mini Relay

(DC 24V)

(A20)

KAR73(09)

YV73

Pallet Changer

CCW. Rotation

Y39.1

PCCW.R

-KAR74

-YV74

Distributed I/O

Module B

Mini Relay

(DC 24V)

XCE57B

(B20)

KAR74(10)

KAR74

YV74


APUP.R

-KAR75

-YV75

Distributed I/O

Module B

Mini Relay

(DC 24V)

XCE57B

(A21)

KAR75(11)

KAR75

YV75

APC Changer Down Y39.3

APDN.R

-KAR76

-YV76

Distributed I/O

Module B

Mini Relay

(DC 24V)

XCE57B

(B21)

KAR76(11)

KAR76

YV76

Waiting Pot Spindle

Side

Y39.4

WPSS.R

-KAR53

-YV53

Distributed I/O

Module B

Mini Relay

(DC 24V)

XCE57B

(A22)

KAR53(09)

KAR53

YV53

Waiting Pot

Magazine Side

Y39.5

WPMS.R

-KAR54

-YV54

Distributed I/O

Module B

Mini Relay

(DC 24V)

XCE57B

(B22)

KAR54(10)

KAR54

YV54

Spindle Tool

Unclamp

Y39.6

STUN.R

-KAR11

-YV11

Distributed I/O

Module B

Mini Relay

(DC 24V)

XCE57B

(A23)

KAR11(11)

KAR11

YV11

Table Unclamp Y39.7

TUCL.R

-KAR61

-YV61

Distributed I/O

Module B

Mini Relay

(DC 24V)

XCE57B

(B23)

KAR11(11)

KAR11

YV11

268

HP5100 HP51MTE87

Appendix 2) M-CODE LIST

M-CODE DESCRIPTION M-CODE DESCRIPTION

M00 PROGRAM STOP M25 CHIP CONVEYOR STOP

M01 OPTIONAL STOP M27 ATC SPEED LOW

(WHEN USE INVERTER)

M02 PROGRAM END M28 ATC SPEED HIGH

(WHEN USE INVERTER)

M03 SPINDLE FORWARD (CW)

ROTATION M29 RIGID TAPPING MODE ON

M04 SPINDLE REVERSE(CCW)

ROTATION M30

PROGRAM END (RESET &

REWIND)

M05 SPINDLE ROTATION

STOP

M06 ATC MACRO CALL

M07 THROUGH THE SPINDLE

COOLANT ON M33

TOOL DATA

COMPARE(TN=STN) ON

M08 FLOOD COOLANT ON M34 TOOL DATA

COMPARE(TN=STN) OFF

M09 COOLANT OFF

M10 4TH-AXIS CLAMP M36 RESERVED FOR “MACHINE

LOCK EFFECTIVE”

M11 4TH-AXIS UNCLAMP M37 RESERVED FOR “MACHINE

LOCK INEFFECTIVE”

M12 SHOWER COOLANT ON M38 5TH-AXIS CLAMP

M13 INTERMITTENT COOLANT

ON M39 5TH-AXIS UNCLAMP

M14 COLLET AIR BLOW ON M40 6TH-AXIS CLAMP

M15 COLLET AIR BLOW OFF M41 6TH-AXIS UNCLAMP

M16 TOOL MEASURE AIR BLOW

ON

M17 AIR GUN ON

M18 TOOL MEASURE AIR BLOW

OFF M44

THROUGH THE SPINDLE

AIR BLOWER ON

M19 SPINDLE ORIENTATION M45 THROUGH THE SPINDLE

AIR BLOWER OFF

M20 RESERVED FOR “LADDER & M46 MACHINE FLUSHING

269

HP5100 HP51MTE87


ROBOT” COOLANT ON

M21

RESERVED FOR

“OPTIONAL BLOCK SKIP

VALID”

M22

RESERVED FOR

“OPTIONAL BLOCK SKIP

CANCEL”

M48 OVERRIDE INVALID

M49 OVERRIDE VALID

M24 CHIP CONVEYOR START

M50 APC/SPLASH GUARD

DOOR OPEN 2 M78 PALLET CLAMP


DOOR CLOSE 2 M79 PALLET UNCLAMP


DOOR OPEN M80 MIRROR IMAGE OFF


DOOR CLOSE M81 MIRROR IMAGE X-AXIS

M54 PART COUNT M82 MIRROR IMAGE Y-AXIS

M55 REPEAT PROGRAM AFTER

M02/M30 M83 MIRROR IMAGE Z-AXIS

M84 AXIS MOVING VALID

WHEN SPDL STOP

M85 AXIS MOVING INVALID

WHEN SPDL STOP

M86 TOOL PRECHECK ON

M87 TOOL PRECHECK OFF

M60 PALLET CHANGE M88 PALLET RETRACT

FUNCTION ON

M61 APC 1 LOAD MACRO CALL M89 PALLET RETRACT

FUNCTION OFF

M62 APC 2 LOAD MACRO CALL

M63 PALLET UNLOAD MACRO

CALL M91 EXTERNAL M-CODE M91

M64 PALLET LOAD MACRO CALL M92 EXTERNAL M-CODE M92

M65 AUTO POWER OFF ENABLE M93 EXTERNAL M-CODE M93

270

HP5100 HP51MTE87


M66 ATC & APC CHANGE

SIMULTANEOUSLY M94 EXTERNAL M-CODE M94

M68 SPINDLE TOOL CLAMP M96 CUSTOM MACRO

INTERRUPTION ENABLE

M69 SPINDLE TOOL UNCLAMP M97 CUSTOM MACRO

INTERRUPTION DISABLE

M70 PALLET MAGAZINE INDEX

MACRO CALL M98 SUB PROGRAM CALL

M71 APC 1 UNLOAD CALL/PMG

INDEX 2 M99 SUB PROGRAM END

M72 APC 2 UNLOAD CALL/PMG

INDEX 3 M100 WARMING UP STOP

M73

WORK/TOOL

MEASUREMENT SENSOR

OFF

M101 WARMING UP

START(UNDER 7 DAYS)

M74 WORK MEASUREMENT

SENSOR ON M102

WARMING UP START(OVER

7 DAYS)

M75 WORK MEASUREMENT

SENSOR OFF

M76 TOOL MEASUREMENT

SENSOR ON

M77 TOOL MEASUREMENT

SENSOR OFF

M106 TOOL FROM PALLET ON M146 PALLET DATA INPUT

ENABLE 2

M107 TOOL FROM PALLET OFF M147 PALLET DATA INPUT

DISABLE 2

M148 PALLET DATA INPUT

ENABLE 3


DISABLE 3

M110 BASE COOLANT ON

M111 BASE COOLANT OFF

M155 EXTERNAL M-CODE M155

271

HP5100 HP51MTE87





M117 TOOL LIFE COUNT RESET M159 ATC START FLAG ON

(DUAL ROTARY TABLE)

M118 TOOL SKIP IN TOOL LIFE

MANAGEMENT M160

ATC START FLAG OFF

(DUAL ROTARY TABLE)

M119 SPINDLE MULTI

ORIENTATION

M170 TOOL BREAKAGE DETECT

MACRO CALL

M132 OIL MIST COLLECT ON

M133 OIL MIST COLLECT OFF M176 FIXTURE CLAMP

M134 OIL MIST CLEAR ON M177 FIXTURE UNCLAMP

M135 OIL MIST CLEAR OFF M178 FIXTURE 2 CLAMP

M136 COOLANT CHIP AIR BLOW

ON M179 FIXTURE 2 UNCLAMP

M137 COOLANT CHIP AIR BLOW

OFF M180 FIXTURE 3 CLAMP

M138 APC PAN COOLANT

RECOVERY ON M181 FIXTURE 3 UNCLAMP

M139 APC PAN COOLANT

RECOVERY OFF M182 FIXTURE 4 CLAMP

M183 FIXTURE 4 UNCLAMP

M184 MIRROR IMAGE 4TH AXIS

M185 MIRROR IMAGE 5TH AXIS


ENABLE 1 M186 MIRROR IMAGE 6TH AXIS


DISABLE 1

M188 W-AXIS CLAMP M224 TABLE LOCATE

M189 W-AXIS UNCLAMP M225 TABLE UNLOCATE

272

HP5100 HP51MTE87


M226 PALLET LOCATE

M191 POWER MATE-E REF.

RETURN M227 PALLET UNLOCATE

M192 TOOL BREAKAGE SENSOR

CHECK M228 Y-AXIS CLMAP

M193 TOOL BREAKAGE CHECK

START M229 Y-AXIS UNCLAMP

M194 TOOL BREAKAGE CHECK

(POWER MATE-E)

M231 ATC CHANGE START FLAG

MODE

M196 IN-POSITION CHECK ON M232 ATC WAIT POT UP/MAG.

HOME POS

M197 IN-POSITION CHECK OFF M233 ATC WAIT POT

DOWN/MAG. CHANG POS

M234 ATC ARM PIN LOCKING

M235 ATC ARM PIN RELEASE

M200 TOOL LOAD MONITOR OFF M236 ATC NEXT TOOL INDEX

M201 TOOL LOAD MONITOR ON M237 ATC MOTOR BRAKE

RELEASE ON

M238 ATC MOTOR BRAKE

RELEASE OFF

M239 ATC/APC MAINTENANCE

MODE ON

M240 ATC/APC MAINTENANCE

MODE OFF

M210 APC UP M241 ATC ARM 1 CYCLE MODE

ON

M211 APC DOWN M242 ATC ＋ STEP MODE ON

M212 APC ROTATION (CW) M243 ATC － STEP MODE ON

M213 APC ROTATION (CCW) M244 ATC ＋/－ STEP MODE ON

M214 APC MANUAL UP/DOWN

MODE ON M245

ATC WAITING POT

MAG/SPINDLE SIDE

M215 APC MANUAL CW/CCW

MODE ON M246 ATC WAITING POT CLAMP

273

HP5100 HP51MTE87


M247 ATC WAITING POT

UNCLAMP

M248 ATC WAITING POT

SPINDLE SIDE

M219 PRE-SPINDLE

ORIENTATION M249

ATC WAITING POT

MAGAZINE SIDE

M250 MACHINE SERVICE MODE

ON

M251 MACHINE SERVICE MODE

OFF

M222 ATC DOOR OPEN

M223 ATC DOOR CLOSE

M253 KEEP MAGAZINE ROTATE

BY T－CODE

M254 RELEASE MAGAZINE

ROTATE BY T－CODE

M255 SPINDLE TOOL NUMBER

SET

M256 NEXT TOOL NUMBER SET

M257 KEEP RELAY SET FOR

ATC/APC

M260 REMOVE ATTACHMENT

SPINDLE ORIGINAL

M261 MAX SPINDLE SPEED 1






274

HP5100 HP51MTE87

Appendix 3) Maintenance method of Spindle Amp Alarms

ALARM NO. DESCRIPTION REMEDY

Check And Correct The Peripheral

Temperature And Load Status. 01 Motor Overheated

If The Cooling Fan Stops, Replace It.

Check And Correct The Cutting Conditions To

Decrease The Load.

02 Speed Deviation Excessive Correct Parameter No.4082

N4082(Spindle Motor Speed Moderation)

Verification

Replace The SPM Unit.

Replace the Spindle Amp

Check The Motor Insulation Status. 03 Fuse Blow Of DC Link

Replace The Interface Cable.

04 Power Phase Missing Check The State Of The Input Power Supply

To The PSM.

Check And Correct The Parameter. 07 Excessive Speed

Replace The Feedback Cable.

Improve The Heat Sink Cooling Capacity.

09 Main Circuit Overload If The Cooling Fan Stops, Replace The SPM

Unit.

Check The Selected PSM.

11 Excess Voltage In DC Link

Check The Input Power Voltage And Change

In Power During Motor Deceleration.

If The Voltage Exceeds 253 VAC (For The 200-

V System)Or 530 VAC (For The 400-V

System), check the Power Supply Impedance.

Check The Motor Insulation Status.

Check The Spindle Parameters. 12 Excess Current In DC Link

Replace The SPM Unit.

Check to see if the PMC alarm has been

activated, and recheck the input/output status

through the ladder. 15 Problems with main axis

conversion/output

conversion Replace The Switching MC Magnet

(KM20/KM21)

16 Ram Error Replace The SPM Control Printed Circuit Board.

18 Rom Sum Check Error Replace The SPM Control Printer Circuit Board.

19 Excessive U Phase Current

Offset Replace The SPM Unit.

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HP5100 HP51MTE87


20 Excessive V Phase Current

Offset Replace The SPM Unit.

21 Position Sensor Polarity

Setting Error

Check And Correct The Parameters.

(PRM N4000#0,N4001#4)

Place The CNC-To-Spindle Cable Away From

The Power Cable.

(Problems caused by noise)

Separate the spindle signal cables from other

power cables, or attach protective equipment

such as a ferrite core.

24 Abnormal Serial Data

Transmission

Replace The Cable.

Replace The Cable.

27

Position Coder Signal

Disconnection

Readjust the abnormal BZ sensor and sensor

interval

29 Short Time Overload Check And Correct The Load Status.

30 Excess Input Circuit

Current

Check the power supply to the power supply

module

Check And Correct The Load Status.

31 Disconnection of the

speed detection signal and

motor binding status

Replace The Motor Sensor Cable(JY2 Or JY5)

Problems with the spindle motor feedback

cable

32

SLC Sli Internal Ram

Abnormal

Abnormal serial data

transfer use LSI internal

RAM

Replace The SPM Control Printer Circuit Board.

Check And Correct The Power Supply Voltage.

Insufficient DC Link capacity

(Problem with the power supply unit) 33

Insufficient DC Link

Charging

Replace The PSM Unit.

34 Abnormal Parameter

Setting

Correct A Parameter Value According To The

Manual.

If The Parameter Number Is Unknown,

Connect The Spindle Check Board,

And Check The Indicated Parameter.

35 Excessive Gear Ratio Data Check The Value According To The Parameter

Manual.

36 Error Counter Overflow

Check Whether The Position Gain Value Is Too

Large, And Correct The Value.

37 Speed Detecting Unit Correct The Value According To The Parameter

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HP5100 HP51MTE87


Error Setting Manual.

Check And Correct The Parameter

Replace The Cable.

Abnormal position coder cable 41

Erroneous Detection Of

The Position Coder

One Revolution Signal

Re-Adjust The BZ Sensor Signal.

Abnormal BZ Sensor signal or sensor interval

Replace The Cable.

Abnormal position coder cable 42

Nondetection Of

The Position Coder

One Revolution Signal Re-Adjust The BZ Sensor Signal.

abnormal BZ Sensor signal or sensor interval

43 Differential Speed Position

Coder Disconnection

Replace The Cable.

Abnormal position coder cable

Check And Correct The Parameter.

Replace The Cable.

Abnormal position coder cable 46 Erroneous Detection Of

One Revolution Signal

On Threading Re-Adjust The BZ Sensor Signal.

Abnormal BZ Sensor Signal or sensor interval

Replace The Cable.

Abnormal position coder cable

Re-Adjust The BZ Sensor Signal.

Abnormal BZ Sensor Signal or sensor interval 47 Abnormal Position Coder

Signal Correct The Cable Layout (Vicinity Of The

Power Line). Make sure that the cables do not

cross, and add protective equipment such as

ferrite cores.

49 Excessive Differential

Speed

Conversion Value

Check Whether The Calculated Differential

Speed Value Exceeds The Maximum Motor

Speed.

N3772 (setting maximum speed-G96)

50

Excessive Speed

Command

Value During Spindle

Synchronization

Check Whether The Calculated Speed Value

Exceeds The Maximum Motor Speed.

Check and Correct The Power Supply Voltage.

51 DC Link Under Voltage Replace The MC.

MC (KM20/KM21) Magnet connection status

Replace The SPM Control Printed Circuited

Board. 52 ITP Signal Error

Replace The Spindle Interface Printed Circuit

Board In The CNC. (JA41)

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HP5100 HP51MTE87



Board. 53 ITP Signal Error

Replace The Spindle Interface Printed Circuit

Board In The CNC. (JA41)

54 Overload Current Review The Load Status.

Replace The Magnetic Contactor.

55 Power Line State Signal

Error Check And Correct The Sequence and

abnormal Magnet Connection Status

(KM20/KM21)

56 Internal Cooling Fan

Stopped Replace The SPM Unit.

Decrease The Acceleration/Deceleration Duty.

Check the belt tension (belt method). Lower

the deceleration setting. (N4082)

Check the Peripheral Temperature and the

condition of all cooling equipment.

If The Cooling Fan Stops, Replace The Cooling

Fan.

57 Excessive Deceleration of

Power

If The Resistance Is Abnormal, Replace The

Resistor.

Check The PSM Cooling Status. 58

Convert Main Circuit

Overload Replace The SPM Unit.

59 Converter Cooling Fan

Stopped Replace The SPM Unit.

Replace The Cable.

66 Inter-Spindle-Amplifier

Communication Error Check And Correct The Connection of the

signal cable.

Check And Correct The Connection of the

feedback cable.

Check The Shield Processing.

Check And Correct The Connection.

73 Motor Sensor

Disconnection

Adjust The motor Sensor location and interval.

74 CPU Test Alarm Replace The SPM Control Printed Circuited

Board.

75 CRC Test Alarm Replace The SPM Control Printed Circuited

Board.

79 Initial Test Alarm Replace The SPM Control Printed Circuited

Board.

81 Motor Sensor One-Check And Correct The Parameter. N4016#6 /

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HP5100 HP51MTE87


N4017#2


feedback cable.

Rotation

Signal Detection Error

Adjust The motor Sensor location and interval.


feedback cable. 82 Motor Sensor One-

Rotation

Signal Undetected Adjust The motor Sensor location and interval.


83 Motor Sensor Signal Error Check the location and intervals of the motor

sensor


Check The Shield Processing.


feedback cable.

Check And Correct The spindle-related

Parameter.

84 Spindle Sensor

Disconnection

Adjust The motor Sensor (position coder)

location and interval.

Check And Correct The Parameter.

Replace The Feedback Cable. 85 Spindle Sensor

One-Rotation

Signal Detection Error Adjust The Sensor.


Check the connection status of the feedback

cable. 86

Spindle Sensor

One-Rotation

Signal Undetected Adjust The Sensor.

Adjusting the motor sensor (position coder)

location and interval

87 Spindle Sensor Signal

Error

The One-Rotation Signal Of The Spindle

Sensor

Is Not Generated. check the electric conection

and adjust the sensor locations and intervals.

88 Cooling Fan Stopped Replace The SPM External Cooling Fan.

A0 A1 A2

Program Rom Error

(The Control

Programming Is Not

Running)

If This Alarm Is Issued When The Spindle

Amplifier Power Is Switched On.

-.Wrong Software Specification.

-.Defective Printed Circuited Board.

Replace The SPM Or SPM Control Circuited

Board.

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HP5100 HP51MTE87


If The Alarm Is Issued When The Motor Is

Active.

Check The Grounding Wire.

If The Spindle Sensor Signal Wire Is Bundled

Together With Any Motor Power Line,

Separate

Them and add protective equipment such as

ferrite cores.

Replace The Communication Cable

Between Amplifier And Module.

Abnormal Spindle Amp or NC Board b0

Communication Error

Between Amplifier

Modules

Replace The SPM Or PSM Control Printed

Circuited Board.

b1 Low Converter Control

Power Supply Voltage

(PSM Alarm Indication:6)

Replace The PSM Control Printed Circuit Board.

Check The Regenerative Resistance.

Check The Motor Selection. b2 Excessive Converter

Regenerative Power

(PSM Alarm Indication:8) Replace The PSM.

b3 Stopped Cooling Fan Of

The Converter Radiator

(PSM Alarm Indication: A)

Replace The Cooling Fan.

Replace The Communication Cable

Between CNC And SPM. Abnormal spindle

amp or NC Board.


Board.

C0 C1 C2

Abnormal Data

Transmission

Replace The CPM Side Spindle Interface

Printed Circuit Board. Abnormal NC Unit

(JA41, unit where serial signals are input)

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HP5100 HP51MTE87

Appendix 4) ATC Main Changer Sequence Table

Spindle Tool Clamp

Output : Y39.6(STUN.R), KAR11-YV11,Distribute I/O B (A23)

Completion : X6.4(TCL.M), SX11, Input Module Slot8(Pin31)

X6.5(TUCL.M), SX12, Input Module Slot8(Pin47)

Initial Condition

① Arm & Servo Home Position

② 2nd Reference Point & M19

③ Pot Spindle Side

& Clamp

④ Arm Pin Release

X8.7 (SX53) CAHP.M

X7.0 (SX5A) WPSS.M

X7.2 (SD32) WPCL.M

X15.5 (SD56) ATAR.M


Output : Y39.6(STUN.R), KAR11-YV11,Distribute I/O B (A23)

Completion : X6.4(TCL.M), SX11, Input Module Slot8(Pin31)

X6.5(TUCL.M), SX12, Input Module Slot8(Pin47)

On

Off

On


Input Signal : X8.7(CAHP.M), SX53, Input Module Slot8(Pin37) On


Output : Y 0.2(ATAL.R), YV55,Output Module Slot01(Pin04)

Completion: X15.3(ATAL.M), SD55, Input Module Slot06(Pin11)


On

On

Off


Output : Y 0.2(ATAL.R), YV55,Output Module Slot01(Pin04)

Completion : X15.3(ATAL.M), SD55, Input Module Slot06(Pin11)


On

On

Off

Changer Arm Home

Gripping Tool


Tool Change

Spindle Tool Clamp

Changer Arm Home

Arm

Forward

Arm Out

&

Rotation

Arm In

Arm

Forward

Arm Pin Locking

Arm Pin Release

Off

On

Off

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HP5100 HP51MTE87

Appendix 5) Pallet Change Sequence Chart

START (M60 Command)

Y,Z-Axis 2nd Ref. Position

Y,Z-Axis 2nd Ref. POS.？

B-Axis Ref. Position

B-Axis Ref. Position.？

APC Initial Position？

Pushed Set-Up Button？

Pallet Unclamp

Pallet Unclamp

？

APC Up

APC Up O.K？

A

①

②

③

④

Yes

Yes

Yes

Yes

Yes

Yes

▶ Y,Z-Axis Return to the 2nd reference point Program : G00 G91 G30 Y0. Z0.;

▶ X,Y,Z-Axis Return to the 2nd reference point Program : G00 G91 G30 Y0. Z0.;

▶ B-Axis Return to the reference point Program : G00 G91 G28 B0.;

▶ B-Axis Return to the reference point Program : G00 G91 G28 B0.;

Output Signal: Y39.2 APUP.R -KAR75/-YV75 Completion Signal : X11.6 ACUP.M -SX81

★ 2042 M61/M62 Command Illegal POS. activated X10.0 PCL.M -SP61 X10.1 TACL.M -SL62 X11.1 PNO1.M -SX75, X11.2 PNO2.M -SX76

X11.6 APUP.M -SX81 X11.7 APDN.M -SX82

X12.1 ACUP.M -SX81

On

On

Off

On

Off

On/Off

Output Signal : Y7.2 PUCL.R -KAR62/-YV62 Completion Signal: X10.0 PCL.M -SP61

On

Off

★ 2085 APC Set-Up Location S/W Unpush Activated Confirm Signal : X16.6 SETU.M -SB93 On

Confirm Signal: X10.0 PCL.M -SP61

★ 2073 Table or Pallet CL/UNCL Switch Alarm Activated

Off

No

No

No

No

No

No Confirm Signal: X11.6 ACUP.M -SX81

★ 2126 APC Up/Down Alarm Activated

On

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HP5100 HP51MTE87

Pallet 1 Position？ GO TO

⑤

APC Arm 180 CW Rot. End？

⑥

APC Down O.K？

⑦

Pallet Clamp O.K？

Pallet 2 Position？

⑧

APC Arm 180 CCW Rot. End？

No

Yes

1

APC Arm 180 CW Rotation Output Signal : Y39.0 PCW.R -KAR73/-YV73 Completion Signal : X11.2 PNO2.M -SX76

No Checking Signal : X11.2 PNO2.M -SX76

★ 2127 APC Changer 180CW/180CCW Alarm Occurrence

Yes

APC Down Output Signal : Y39.3 APDN.R -KAR76/-YV76 Completion Signal : X11.7 APDN.M -SX82

No Checking Signal : X11.7 APDN.M -SX82

★ 2126 APC Up/Down Alarm Occurrence

Yes

Pallet Clamp Output Signal : Y7.2 PUCL.R -KAR62/-YV62 Completion Signal : X10.0 PCL.M -SP61

No Checking Signal : X10.0 PCL.M -SP61

★ 2073 Table or Pallet CL/UNCL Switch Alarm Occurrence

Yes

ON

End

A

2

1

Yes

APC Arm 180 CCW Rotation Output Signal : Y39.1 PCCW.R -KAR74/-YV74 Completion Signal : X11.1 PNO1.M -SX75

No Checking Signal : X11.1 PNO1.M -SX75

★ 2127 APC Changer 180CW/180CCW Alarm Occurrence

Checking Signal : 1 POS. X11.1 PNO1.M -SX75 2 POS. X11.2 PNO2.M -SX76 ON

OFF

Yes

2

ON

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HP5100 HP51MTE87

Appendix 6) Recovering ATC Breakage

If the Changer Arm stopped in the middle of Tool Change(M06), you must

manually return the Changer Arm to its home position. Because the necessary

measures differ with each situation, you must accurately find the cause of the

problem and take appropriate measures.

☞ Since this is done with tools attached to the Changer Arm, be careful not to drop the

tools. Just in case tools fall, set up a wooden pallet to protect tools or the machine cover

below the ATC.

(1) Changer Arm stop during Spindle Tool Clamp Status

The Changer Arm stopped between the Home Position and the Spindle.

(2) Changer Arm stop during Spindle Tool Unclamp Status

The Changer Arm stopped after falling out from the Spindle and rotating 180˚

before inserting the tool into the Spindle.

(3) Arm Jam during Unclamping or directly following Clamping

The Changer Arm stopped while stuck in the Spindle.

(4) Alarm 2065 (“Changer Arm Position Check Alarm”) activated despite

having returned the Changer Arm to Home Position

The Changer Arm has been returned to Home Position, but for some reason this

position does not match the Servo reference point or the ATC machine reference

point set in the Cam bundle.

(1) Recovery Process when the Changer Arm has stopped during

Spindle Tool Clamp Status

1) In Emergency Stop status, or in Power Off

status, remove the cause and turn the

machine on, press Machine Ready.

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HP5100 HP51MTE87

2) Select "JOG" mode from the main operation

panel.

3) Press the "CUSTOM" NC Function Key.

The“CUSTOM WINDOW”screen appears.

4) Press the "PMC-SW”soft key. The ATC, APC

Manual screen appears.

5) When the ATC, APC Manual screen appears,

press the “ATC-ON”soft key to select the ATC.

The ATC Manual Mode changes from

“DISABLE”to “ON”.

6) Move the cursor keys to choose "ATC ARM

REVERESE STEP,”and repeatedly press the main

operation panel's cycle start button repeatedly

to move the Changer Arm to Home Poistion.

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HP5100 HP51MTE87

7) Repeatedly press the main operation panel's

Cycle Start button to move the Changer Arm to

Home position, where it no longer moves. (If

the Changer Arm stops moving, it has been

returned to Home Position.)

※ If the Changer Arm jams after replacing

tools and Spindle Tool Clamping, select

"ATC ARM FORWARD STEP”to manually

send it to other sections.

Verification: D450 = D452 in PMC G.DATA

Mode

8) Move the cursor Key to select“ATC ARM 1

CYCLE,”and press the main operation panel's

Cycle Start button. The Changer Arm will

execute Tool Change once, and the inner Cam

and Changer Arm will be reordered.

9) At completion, press the “OFF”soft key. The

ATC Manual Mode will change from “ON” to

“DISABLE.”

10) Press (in order)“SYSTEM” => PMC => PMC DATA => G.DATA, confirm the tool

numbers of the Spindle and Standby Port from D450, D452, and reset.

D450 : Spindle tool number

D452 : Waiting pot tool number

11) When each axis is returned to its reference point, the ATC breakage recovery is

complete.

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HP5100 HP51MTE87

Appendix 7) Maintenance method of Servo driver Alarm

① UV (Under Voltage) Alarm : Voltage shortage Alarm in Main circuit direct

current voltage.

Dirve

LED

Contents Inside DC link voltage become below the designated value.

Measure

▪ Check input voltage whether it is within 200V ~ 220V. And reset it if it

has a problem.

▪ Check the connections of Motor power cable. Replace it if it has a

problem

▪ Change the drive if the same alarm occurs when the turret servo drive

was turned off and on even after the above measures were taken.

Note) Turret Servo Drive Alarm is aimed to protect Servo drive, motor, Turret Unit.

So if you power Off and then on to cancel the alarm, drive and motor itself

has no problem so it doesn’t have to be replaced.

Measure the voltage

between 2 terminals

among L1, L2, and L3

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HP5100 HP51MTE87

② OV (Over Voltage) Alarm : Overvoltage alarm in Main circuit direct current

voltage.

Drive LED

Contents Inside DC link voltage become below the designated value.

Measure

▪ Check input voltage whether it is within 200V ~ 220V. And reset it if it

has a problem.

▪ Disassemble the drive, detach connector connected in PAB, check

whether the regenerative resistance is 26Ω. And then replace it if it

has a problem.

▪ Check Motor power cable connections and then replace it if it has a

problem.

▪ Change the drive if the same alarm occurs when the turret servo drive

was turned off and on even after the above measures were taken.




.

Connector for regenerative

resistor

Power Board (PAB)

Regenerative resistor

Measure the voltage

between 2 terminals

among L1, L2, and L3

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HP5100 HP51MTE87

③ OH (Over Heat) Alarm : Overheat alarm.

Drive

LED

Contents IPM become overheat.

Method

▪ When the alarm shows, Power off the turret servo drive to cool down

the Servo drive.After power on,if the same alarm shows, then IPM is

defective. Replace the drive.

Enclosed) Turret Servo Drive Alarm is aimed to protect Servo drive, motor, Turret

Unit. So if you power Off and then on to cancel the alarm, the drive or motor

are not included in the replacement

④ OC (Over Current) Alarm : Over current alarm.

Drive

LED

Contents Over current flow in motor.

Measure

▪ Check whether acceleration and retardation parameter No. 29, No. 30

setting is low.

▪ After checking disconnections of motor power cable, replace the cable if

it has a problem




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HP5100 HP51MTE87

⑤ CA Alarm : Encoder-related alarm, the method will be different according to

11Bit old drive or 17Bit new drive

Drive

LED

11 Bit ▪ A,B,Z error among encoder signal.

Contents

17 Bit ▪ Power input into the Turret Servo drive before encoder

initialization.

11 bit

▪ Detach from Servo drive and reset it due to Encoder data

receiving cable connection error.

▪ Check the disconnection of encoder data receiving cable, and

replace it if it has a problem.

▪ See the Motor encoder connector Short and then replace the motor

if it has a problem.

Measure

17 bit

▪ After power off turret servo drive, 5 seconds later after motor

encoder initialization finished, turn on turret servo drive and

then the alarm will be released.

▪ Turret Servo drvie from DVSD-TT-14A to DVSD-TT-14A-04 will

be applied. After DVSD-TT-14A-05 version, CA alarm is

deleted

Encoder data receiving cable

Motor encoder connector

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HP5100 HP51MTE87

⑥ CO Alarm : Applied after 17Bit Turret servo drive DVSD-TT-14A-05 version.

Encoder signal abnormal related alarm.

Drive

LED

Alarm Encoder signal error.

Measure

▪ Detach from Servo drive and reset it due to Encoder data receiving

cable connection error.

▪ Check the disconnection of encoder data receiving cable, and replace it


▪ See the Motor encoder connector Short and then replace the motor if it has a

problem.




.



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HP5100 HP51MTE87

⑦ OS (Over Speed) Alarm : Overspeed alarm.

Drive

LED

Contents Motor speed exceed the maximum speed

Measure

▪ Detach from Servo drive and reset it due to Encoder data receiving

cable connection error.

▪ Check the disconnection of encoder data receiving cable, and replace it


▪ Check the disconnection of motor power cable, and replace it if it has a

problem.

▪ Check the Motor encoder connector Short and then replace the motor if it has

a problem.




.

Encoder data Receiving cable


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HP5100 HP51MTE87

⑧ OL (Over Load) Alarm : Overload alarm

Drive

LED

Contents

▪ Turret servo motor overload continue more than the regulated time.

▪ Overload detection time

250% ~ : 1sec, 220% ~ : 24sec, 200% ~ : 48sec

180% ~ : 96sec, 160% ~ : 192sec, 150% ~ : 384sec

140% ~ : 769sec, 130% ~ : 1536sec

Measure

▪ Set turret to Unclamp in Keep Relay, check whether the turret rotate

smoothly, Check the rotation while increasing parameter No.10, No.11

by 10.and do the proper action if it does not move well.

▪ Check the parameter setting.

(Enclosed) If after 11Bit AS Turret servo driveDASD-CT15SPXC-05 version

and after 17Bit new turret servo drive DVSD-TT-14A-04 version, No. 4

parameter value is 2048. And if you change the value, then the

overload alarm will show.

▪ It happens when the tool load is high for the turret or it has a mechanical

problem. So check the rotation of turret through adding 10 in parameter

No.10, No.11. Do proper action if problem found..

▪ Check Relay and do the proper action.

▪ Motor power cable or encoder data receiving cable could have a problem.

So pull them out of turret servo drive and assemble it again.

Motor power cable

Encoder data Receiving cable

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HP5100 HP51MTE87

▪ Check the disconnection of motor power cable or encoder receiving cable.

Replace it if it has a problem.

▪ Perform above, turn the turret servo drive ‘Off’ and then ‘On’. If alarm

continues, replace the drive.




⑨ SE Alarm : Double Interrut Alarm.

Drive

LED

Contents CPU calculation or turret servo drive inside MCB trouble.

Measure

▪ Initialize turret servo drive parameter and reset the parameter


continues, replace the drive.




⑩ PE (Parameter Error) Alarm : Parameter abnormal alarm.

Drive

LED

Contents Turret servo drive parameter saved value is not within the regulated

range.

Measure

▪ Initialize turret servo drive parameter and position compensation value

and reset the parameter and reference point


continues, replace the drive..




.

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HP5100 HP51MTE87

⑪ RP (Residue Pulse) Alarm(ALP-rP) : Position deviation excess alarm.

Drive

LED

Contents Rest pulse exceed the regulated value fixed in the parameter no.19

Measure

▪ Check whether parameter No.19 setting is low.

▪ Encoder data receiving cable could be error, so detach from turret servo

drive and then re assemble it.

▪ Check the disconnection of motor encoder cable, and replace it if it has

a problem.

▪ Check the disconnection of motor encoder connector, and replace it if it

has a problem.




.



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HP5100 HP51MTE87

⑫ EN (Battery) Alarm : Encoder backup battery abnormal alarm.

▪ If Turret servo drive and motor are united when machine power has not been

provided, use battery’s power.

▪ Battery life(The largest consumption current 150㎂)

In 25℃, 1.44 year ~ 1.5 year

In 75℃, 0.89 year ~ 0.96 year

Drive

LED

Contents Encoder backup battery discharged or pulled out.

Measure

▪ Replace the encoder backup battery inside the turret servo drive.

▪ Disassemble Turret servo drive and check the connector’s status.

Replace it if it has a problem




Encoder backup battery

Encoder backup Battery connector

Main Control Board (MCB)

HMC 고장진단 및 처치 HP51MTK87

127

Revision Record

HMC Maintenance HP5100 (HP51MTK87)

Version Date Contents Writer

01 2008.05 1st edition Mr.Jeong Sam

Young

02 2008. 07 1st revised Mr.Lee Dae

Seop

03

04

05

06

07

08

09

10

Documents

HMC Maintenance - CNCzone