Doosan HM 500 Operating instructions

Machine Tools
ATC Troubleshooting
(HM 500/630/800)

1
HM 500/630/800 HM3digitATCE26
◈ ATC Troubleshooting (HM 500/630/800)
If the changer arm is stopped for any reason while changing the tools (M06), you must return the
changer arm to the home position manually.
However, the countermeasures may differ according to the cause of trouble. So please find out the
exact cause before restoring or repairing the machine.
(1) If the changer arm is stuck while trying to pull out a tool from the spindle (in the state of
Tool Unclamp)
In most cases, this happens when the changer arm is stuck in the spindle while trying to pull out
a tool after tool unclamping is performed
, causing to trigger the " 2023 M06 Command Over
Time” alarm.
(2) If the changer arm is stuck in the spindle after changing a tool (in the state of Tool Clamp)
In most cases, this happens when the changer arm gripper is stuck in a tool after the changer
arm changed the tool and performed the tool clamping
, causing to trigger the " 2023 M06
Command Overtime” alarm.
(3) If the changer arm has stopped operation irrelevantly to the spindle
This happens if the machine is emergency stopped or there occurs a power failure while
performing the tool changing.
▶ ATC Recovery
1) If this happens due to the emergency stop or power
failure, take an appropriate measure to solve the
problem and turn power back on before entering
Machine Ready.
2) Select the “JOG” mode on the main OP.
3) Turn the mode selection switch in the ATC manual
OP to
“MANUAL” .
960
970
980
5710
5720
5730
5740
5750
5760
5770
930
940
950
730
740
750
760

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HM 500/630/800 HM3digitATCE26
4) Depending on a specific situation, turn the mode
selection switch in the ATC manual OP to
“TOOL
CHANGE STEP REVERSE” (4-1), (4-3)
or
“TOOL CHANGE STEP FORWARD” (4-2) .
4-1)
If the changer arm is stuck while trying to pull out a tool from the spindle
Turn the mode selection switch on the ATC manual OP to “ TOOL CHANGE STEP
REVERSE”
.
☞ If the machine is in the state of tool unclamping, manually perform the tool clamping
before proceeding.
▪How to confirm the state of tool unclamping: Check if the spindle emits the collet air
(in MDI or Auto mode), or check if the button indicator of Tool Unclamp on the
manual OP turns on.
4-2)
If the changer arm is stuck in the spindle after changing a tool
Turn the mode selection switch on the ATC manual OP to “TOOL CHANGE STEP
FORWARD”
.
4-3)
If the changer arm has stopped operation irrelevantly to the spindle
Turn the mode selection switch on the ATC manual OP to “ TOOL CHANGE STEP
REVERSE”
.
5) Repeat pressing briefly the “START” button on the
ATC manual OP until the main changer arm moves
to the home position where it doesn't move further.
▪In case 4-1) above, the changer arm is stuck in
the spindle for a reason while changing a tool.
Return the changer arm to the home position and
find the cause by performing the tool unclamping
manually.
☞
If the manual tool unclamping does not work at all, gently impact on the tool to remove it
with the hammer. Then, check the tool kick distance, the state of the unclamp cylinder,
collet, and the tapering side of the spindle or tool to find out the cause of trouble and take
a necessary measure.
▪In case 4-2) above, this happens when the gripper of the changer arm is stuck in the tool.
▪In case 4-3) above, this kind of trouble shooting will be made manually while the tools are
inserted in the changer arm. Just in case of a fall of the tool, prepare a shock absorber such
as wood palette under the machine, so that it can protect the machine from a possible fall.
If
the problem persists after following the steps below, use a rubber hammer to impact on the
end of the changer arm so that the gripper can be removed. Then, pull out the changer arm
and return it to the home position. Find out the cause of trouble and take a necessary action.
(check the tool and check also if ATC is aligned properly)

3
HM 500/630/800 HM3digitATCE26
① If the spindle is in the process of tool clamping,
manually perform the tool unclamping.
☞ How to confirm the state of tool
unclamping: Check if the spindle emits the
collet air (in MDI or Auto mode), or check if
the
button indicator of Tool Unclamp on the
manual OP turns on.
② Repeat briefly pressing the “START” button
until the tool in the changer arm inserts to the
spindle completely.
☞ An excessive pressing may get the
changer arm off of the spindle, causing a
fall of the tool. So you must stop pressing
the button when the tool is inserted nearly
to the end of the spindle.
③ Press the Tool Clamp button to manually
perform the tool clamping on the spindle.
☞ Ensure that the Unclamp button should be
turned off.
④ Repeat briefly pressing the “START” button until the changer arm reaches the home
position and wouldn't move further.
☞ If the main changer arm doesn't move further even by your pressing the
“START”
button, this indicates that the main changer arm reaches its home position.
Then, the
“2067 Must Be ATC M-Changer Man. 1 Cycle” alarm will be displayed on
the NC screen.
6) Turn the mode selection switch on the ATC manual
OP to
“TOOL CHANGE 1 CYCLE” , and press the
“START” button to perform the tool changing
automatically. Then, the alarm 2067 will be
released and the ATC home position will be
recovered.
☞ If the Tool Change 1 Cycle operation is not
performed, check the “Conditions of Manual
Tool Change 1 Cycle ” below:

4
HM 500/630/800 HM3digitATCE26
※
Conditions of Manual Tool Change 1 Cycle
① ATC Door Open
② Both Y and Z axes have completed changing the ATC positions (Y-axis and Z-axis 2nd
reference points) as well as the spindle orientation.
☞ This will be ignored if alarm AL2067 has occurred.
③ Switch the mode selection switch on the ATC manual OP to “MA NUAL”.
④ Waiting Pot Spindle Side (X10.0)
⑤ ATC Main Changer Home Position (X10.3)
7) Turn the switch to “DOOR CLOSE” and press the
START button to close the door.
8) Select SYSTEM > PMC > PMC DATA > G.DATA, and check the tool number (D450) in the
spindle as well as the tool number (D452) in the waiting pot. Make correction if necessary.
D450 : Tool number in the spindle
D452 : Tool number in the waiting pot
9) When each axis returns to their respective home position, ATC troubleshooting will be
completed.

5
HM 500/630/800 HM3digitATCE26
(Reference)
1) Tool Search OperatiOn
Tool Search Start (T__;)
Go To “A”
ATC Sub Changer
O.P Auto Mode ? No
★ AL 2078 “ATC OP Manual Mode”
occurs
▪
Select Auto at Auto/Manual selection Switch which is on
APC manual operation panel.
▪comfirm : X14.7(TSMD.M) –SA71 ATC Manual Mode On
Yes
No
Yes
Searched Tool No
= Spindle Tool No ?
No
Yes
Searched Tool No
= Waiting Tool No ?
★Tool Search
Complete
(complete)
Yes
Double Tool
Search ? ★1st Tool Magazine
And 2nd Tool In Valid
No
TMG & ATC Initial
Position?
★ AL 2036 “T
-Code Command Illegal Pos.” occurs
No
Yes
▪confirm : X10.1(WPMS.M) –SL52 Wait. Pot Spd. Side
X10.0(WPSS.M) –SL51 Wait. Pot Mag. Side
X8.5 (SCHP.M) –SX41 Sub Chan. Home Pos.
X9.6 (SCAI.M) –SL44 Sub Changer Arm In
X9.7 (SCAO.M) –SL45 Sub Changer Arm Out
X8.0(MTOI.M) –SL33 Tool Pot Tool Out Int.
On
Off
On
On
On
Off
TMG Stopper Out Command
1
▪Output : Y4.4(TMSO.V) –YV35 TMG Stopper Out
▪Complete : X7.4(TMSO.M) –SL32 TMG Stopper Out
On
On
TMG Stopper Out
O.K?
Yes
No
★ AL 2061 “TMG Stopper I n/ Out Alarm”
occur
▪confirm : X7.4(TMSO.M) –SL32 TMG Stopper Out
X7.3(TMSI.M) –SL31 TMG Stopper In On
Off

6
HM 500/630/800 HM3digitATCE26
TMG RotatiOn Command
2
▪Output(1) : Y4.1(MCW.V) –YV32 TMG CW or
(2) : Y4.2(MCCW.V) –YV33 TMG CCW
▪Output : Y4.3(TMRP.V) –YV34 TMG Rapid
On
On
“A”
TMG Slow Down Command
3
On
▪Output(1) : Y4.1(MCW.V) –YV32 TMG CW or
(2) : Y4.2(MCCW.V) –YV33 TMG CCW
▪Output : Y4.3(TMRP.V) –YV34 TMG Rapid
On
On
Off
TMG Slow Down
O.K?
Yes
No
TMG Stopper In Command
4
▪Output : Y4.4(TMSO.V) –YV35 TMG Stopper Out
▪complete : X7.3(TMSI.M) -SL31 TMG Stopper In Off
On
TMG Stopper In
O.K?
Yes
No
★ AL 2061 “TMG Stopper I n/ Out Alarm”
occur
comfirm : X7.4(TMSO.M) –SL32 TMG Stopper Out
X7.3(TMSI.M) –SL31 TMG Stopper In Off
On
Sub Changer Magazine Pot Pos.
5
Sub Changer Pot
Position O.K ?
Yes
No
Go To “B”
Sub Changer Arm Out
6
ATC Wait. Pot Tool
Detect Off OK ? No
★ AL 2057 “Wait. & MAG. Pot Tool Detect”
occur
comfirm : X10.2(WPDT.M) –SX5A Wait. Pot Tool Detect
Off
Yes ▪Output : Y5.0(SCP1.V) –YV41 Sub Changer Posi.1
Y5.1(SCP2.V) –YV42 Sub Changer Posi.2
Y5.2(SCP3.V) –YV43 Sub Changer Posi.3
Y5.3(SCP4.V) –YV44 Sub Changer Posi.4
▪complete : X8.6(SCPP.M) –SX42 Sub Changer Pot Pos
Off
Off
On
On
On
★ AL 2062 “ATC Sub Changer Position Alarm”
occur
comfirm : X8.6(SCPP.M) –SX42 Sub Changer Pot Pos
On
▪Output : Y5.4(SCAO.V) –YV45 Sub Changer Arm Out
▪complete : X9.7(SCAO.M) –SL45 Sub Changer Arm Out
On
On
Sub Changer Arm
Out O.K ?
Yes
No
★ AL 2063 “ATC Sub Changer Arm I n/ Out Alarm”
occur
comfirm : X9.7(SCAO.M) –SL45 Sub Changer Arm Out
On

7
HM 500/630/800 HM3digitATCE26
Tool Search Finish
“B”
Sub Changer Waiting Pot
7
Sub Changer Waiting
Position O.K ?
Yes
No
★ AL 2062 “ATC Sub Changer Position Alarm”
occur
comfirm : X8.7(SCWP.M) –SX43 Sub Chan. Wait. Pos
On
▪Output : Y5.0(SCP1.V) –YV41 Sub Changer Posi.1
Y5.1(SCP2.V) –YV42 Sub Changer Posi.2
Y5.2(SCP3.V) –YV43 Sub Changer Posi.3
Y5.3(SCP4.V) –YV44 Sub Changer Posi.4
▪complete : X8.7(SCWP.M) –SX43 Sub Chan. Wait. Pos
On
Off
On
Off
On
Sub Changer Arm In
8
▪Output : Y5.4(SCAO.V) –YV45 Sub Changer Arm Out
▪complete : X9.6(SCAI.M) –SL44 Sub Changer Arm In Off
On
Sub Changer Arm
Out O.K ?
Yes
No
★ AL 2063 “ATC Sub Changer Arm I n/ Out Alarm”
occur
On
Sub Changer Home Position
9
Sub Changer Waiting
Position O.K ?
Yes
No
★ AL 2062 “ATC Sub Changer Position Alarm”
occur
comfirm : X8.5(SCHP.M) –SX41 Sub Chan. Home Pos
On
▪Output : Y5.0(SCP1.V) –YV41 Sub Changer Posi.1
Y5.1(SCP2.V) –YV42 Sub Changer Posi.2
Y5.2(SCP3.V) –YV43 Sub Changer Posi.3
Y5.3(SCP4.V) –YV44 Sub Changer Posi.4
▪complete : X8.5(SCHP.M) –SX41 Sub Chan. Home Pos
Off
On
Off
On
On
Waiting Pot Spindle Side
10
▪Output : Y4.6 (WPSS.V) –YV5A Wait Pot 90 ˚ CCW
▪complete : X10.0(WPSS.M) –SL51 Wait Pot Spd. Side On
On
Waiting Pot
Spindle Side O.K ?
No
★ AL 2064 “Wait. Tool Pot Spd./ Mag. Side Alarm”
occur
comfirm : X10.0(WPSS.M) –SL51 Wait Pot Spindle Side
X10.1(WPMS.M) –SL52 Wait Pot Mag. Side On
Off

8
HM 500/630/800 HM3digitATCE26
2) Tool Change Operation
Tool Search O.K ?
Yes
No
★ AL 2037 “M06 Command I llegal Position”
occur
▪
Tool Search
Program : T__ ;
Tool Change Start (M06)
ATC Change Position & M19
1 ▪Y, Z-axis return to 2
nd
Ref.point & Spindle OrientatiOn
▪Program : G91 G30 Y0 Z0 M19 ;
Spindle
OrientatiOn ? No
Yes
No
Yes
ATC Change
Position ?
No
M06 Command
Initial Pos. O.K ?
★ AL 2037 “M06 Command I llegal Position”
occur
No
Yes
comfirm : X10.1(WPMS.M) –SL52 Wait. Pot SPD. Side
X10.0(WPSS.M) –SL51 Wait. Pot MAG. Side
X8.5 (SCHP.M) –SX41 Sub Chan. Home Pos.
X9.6 (SCAI.M) –SL44 Sub Changer Arm In
X8.0(MTOI.M) –SL33 Tool Pot Tool Out Int.
X10.3(CAHP.M) –SX51 M-Changer Home Pos
X10.4(ULMD.M) –SX52 M-Chan. Tool UNCL COMM
X10.5(CLMD.M) –SX53 M-Chan. Tool Clamp Com
On
On
On
On
Off
On
ATC Door Open Command
2
▪Output : Y6.4(ATDO.V) –YV5B ATC Door Open
▪complete : X11.0(ATDO.M) –SL56 ATC Door Open On
On
ATC Door Open
O.K ? No
★ AL 2068 “ATC Door Open / Close Alarm”
occur
comfirm : X11.0(ATDO.M) –SL56 ATC Door Open
X11.1(ATDC.M) –SL57 ATC Door Close On
Off
Off
Off
Go To “C”

9
HM 500/630/800 HM3digitATCE26
“C”
ATC Changer RotatiOn Motor Run
3 ▪
Output: Y6.0(CMFW.R) –KM81F ATC Motor Forward
On
Tool Unclamp
Com. Switch On ?
comfirm : X10.4(ULMD.M) –SX52 Tool Unclamp Comm.
On
Tool Unclamp Sol. On Command
4
▪ Output: Y3.0(STUN.V) –YV11 Spindle Tool Unclamp
On
Tool Clamp Comm.
Switch On ?
comfirm : X10.4(ULMD.M) –SX52 Tool Unclamp Comm.
On
Yes
Yes
Tool Unclamp Sol. Off Command
5 ▪
Output: Y3.0(STUN.V) –YV11 Spindle Tool Unclamp
Off
ATC Changer Arm
Home Position ?
Yes
★ AL 2023 “M06 Command Overtime Alarm”
occur
comfirm : X10.3(CAHP.M) –SX51 M-Ch Arm Home Pos
On
No
ATC Changer RotatiOn Motor Stop
6
▪ Output: Y6.0(CMFW.R) –KM81F ATC Motor Forward
Off
ATC Door Close Command
7 ▪
Output : Y6.5(ATDI.V) –YV5C ATC Door Close
▪ complete : X11.1(ATDC.M) –SL57 ATC Door Close
On
On
ATC Door Close
O.K ? No
★ AL 2068 “ATC Door Open / Close Alarm”
occur
comfirm : X11.0(ATDO.M) –SL56 ATC Door Open
X11.1(ATDC.M) –SL57 ATC Door Close
Off
On
Yes
ATC(M06) M-Function End

10
HM 500/630/800 HM3digitATCE26
3) Re-ChargeATC Step Operation
“D”
Sub Changer Waiting Pot
2
Sub Changer Waiting
Position O.K ?
Yes
No
▪ Output : Y5.0(SCP1.V) –YV41 Sub Changer Posi.1
Y5.1(SCP2.V) –YV42 Sub Changer Posi.2
Y5.2(SCP3.V) –YV43 Sub Changer Posi.3
Y5.3(SCP4.V) –YV44 Sub Changer Posi.4
▪complete : X8.7(SCWP.M) –SX43 Sub Chan. Wait. Pos
Off
On
Off
On
Waiting Pot Magazine Side
1
▪ Output : Y4.6 (WPSS.V) –YV5A Wait Pot 90 ˚ CCW
▪ complete : X10.1(WPMS.M) –SL52 Wait Pot Mag. Side
Off
On
Waiting Pot Magazine
Side O.K ?
No
O
★ AL 2064 “Wait. Tool Pot Spd./ Mag. Side Alarm”
occur
comfirm : X10.0(WPSS.M) –SL51 Wait Pot Spindle Side
X10.1(WPMS.M) –SL52 Wait Pot Mag. Side
Off
On
ATC(M06) M-Function End
Sub Changer Arm Out
3
▪ Output : Y5.4(SCAO.V) –YV45 Sub Changer Arm Out
▪ complete : X9.7(SCAO.M) –SL45 Sub Changer Arm Out
On
On
Sub Changer Arm
Out O.K ? No
★ AL
2062 “ATC Sub Changer Position Alarm” occur
comfirm : X8.7(SCWP.M) –SX43 Sub Chan. Wait. Pos
X8.6(SCPP.M) –SX42 Sub Changer Pot Pos
X8.5(SCHP.M) –SX41 Sub Chan. Home Pos
On
Off
Off
Yes
Sub Changer Magazine Pot Pos.
4
Sub Changer Pot
Position O.K ?
Yes
No
▪ Output : Y5.0(SCP1.V) –YV41 Sub Changer Posi.1
Y5.1(SCP2.V) –YV42 Sub Changer Posi.2
Y5.2(SCP3.V) –YV43 Sub Changer Posi.3
Y5.3(SCP4.V) –YV44 Sub Changer Posi.4
▪complete : X8.6(SCPP.M) –SX42 Sub Changer Pot Pos
Off
Off
On
On
On
★ AL 2062 “ATCSub Changer Position Alarm”
occur
comfirm : X8.7(SCWP.M) –SX43 Sub Chan. Wait. Pos
X8.6(SCPP.M) –SX42 Sub Changer Pot Pos
X8.5(SCHP.M) –SX41 Sub Chan. Home Pos
Off
On
Off
Sub Changer Arm In
5
▪ Output : Y5.4(SCAO.V) –YV45 Sub Changer Arm Out
▪ complete : X9.6(SCAI.M) –SL44 Sub Changer Arm In
Off
On
Sub Changer Arm
Out O.K ? No
★ AL 2063 “ATC Sub Changer Arm I n/ Out Alarm”
occur
comfirm : X9.7(SCAO.M) –SL45 Sub Changer Arm Out
X9.6(SCAI.M) –SL44 Sub Changer Arm In
On
Off
★ AL 2063 “ATC Sub Changer Arm I n/ Out Alarm”
occur
comfirm : X9.7(SCAO.M) –SL45 Sub Changer Arm Out
X9.6(SCAI.M) –SL44 Sub Changer Arm In
Off
On

11
HM 500/630/800 HM3digitATCE26
“D”
Sub Changer Home Position
6
Sub Changer Waiting
Position O.K ?
No
▪Output : Y5.0(SCP1.V) –YV41 Sub Changer Posi.1
Y5.1(SCP2.V) –YV42 Sub Changer Posi.2
Y5.2(SCP3.V) –YV43 Sub Changer Posi.3
Y5.3(SCP4.V) –YV44 Sub Changer Posi.4
▪complete : X8.5(SCHP.M) –SX41 Sub Chan. Home Pos
Off
On
Off
On
On
★ AL 2062 “ATC Sub Changer Position Alarm”
occur
comfirm : X8.7(SCWP.M) –SX43 Sub Chan. Wait. Pos
X8.6(SCPP.M) –SX42 Sub Changer Pot Pos
X8.5(SCHP.M) –SX41 Sub Chan. Home Pos
Off
Off
On
ATC Re-Charge End

12
HM 500/630/800 HM3digitATCE26
ATC Troubleshooting HM 500/630/800
Revision History
Version Year/Month Revision history Created by
01 2012. 06 Created a draft (HM3digitATCE26) Jung, Sam Young
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