Doosan HM 5000 User manual

Machine Tools
ATC Troubleshooting
(HM 5000/6300/8000)

1
HM 5000/6300/8000 HM4digitATCE26
◈ ATC Troubleshooting (HM 8000)
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 " 2062 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 " 2062 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) Turn the mode switch in the main OP to “JOG” .
3) Press the CUSTOM1 button from the button bar of the
main OP.
☞
The “PMC Switch” screen appears.
960
970
980
5710
5720
5730
5740
5750
5760
5770
930
940
950
730
740
750
760

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HM 5000/6300/8000 HM4digitATCE26
4) Press the MANUAL soft key from the bottom soft key
bar.
☞ The “ATC APC Manual Switch” screen appears.
5) Press the ATC-ON soft key from the bottom soft key
bar.
☞ From the “ATC APC Manual Switch” screen, you
will notice that the “ATC Manual Mode” is turned
on.
6) Depending on the operation that you want to perform, select “TOOL CHANGE STEP REVERSE”
(6-1), (6-3) or
“TOOL CHANGE STEP FORWARD” (6-2).
6-1) If the changer arm is stuck while trying to pull out a tool from the spindle
Turn the mode selection switch in 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.
6-2) If the changer arm is stuck in the spindle after changing a tool
Turn the mode selection switch in theATC manual OP to “TOOL CHANGE STEP FORWARD” .
6-3) If the changer arm has stopped operation irrelevantly to the spindle (in the state of
Spindle Unclamp)
Turn the mode selection switch in the ATC manual OP to “
TOOL CHANGE STEP REVERSE”
.

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HM 5000/6300/8000 HM4digitATCE26
7) Repeat pressing briefly the “START” button in the ATC
manual OP until the main changer arm moves to the
home position where it doesn't move further.
For 6-1 above:
In this case, 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.
For 6-2 above:
This happens when the gripper of the changer arm is stuck in the tool. 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)
For 6-3 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 the possible fall.
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.

4
HM 5000/6300/8000 HM4digitATCE26
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
“2243 Must Be ATC M-Changer Man. 1 Cycle” alarm will be displayed on the
NC screen.
8) Turn the mode selection switch in theATC 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 restored.
☞ If the Tool Change 1 Cycle operation is not
performed, check the
“Conditions of Manual Tool
Change 1 Cycle”
below:
※
Conditions of Manual Tool Change 1 Cycle
① ATC Door Open (X12.1), or If there is no door at all: K10.3 (ATC Door Not Used)
② Both Y and Z axes have completed changing theATC positions (Y-axis and Z-axis 2
nd
reference
points) This will be ignored if alarm AL2243 has occurred.
③ Switch the mode selection switch on theATC manual OP to “MA NUAL”.
④ M06 Initial Position :
▪Waiting Pot Spindle Side(X7.6), ▪ Sub Changer Home Position(X10.3),
▪Sub Changer Arm In (X10.1), ▪ ATC Main Changer Home Position (X8.5)
⑤
Servo Ready
9) Turn the switch to “DOOR CLOSE” and press the
START button to close the door.

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HM 5000/6300/8000 HM4digitATCE26
10) From the PMC DATA screen, check the tool number (D450) in the spindle as well as the tool
number (D452) in the waiting pot, and make correction if necessary. When each axis returns to
their respective home position, ATC troubleshooting is completed.
D450 : Tool number in the spindle
D452 : Tool number in the waiting pot

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HM 5000/6300/8000 HM4digitATCE26
(Reference) How to correct the data
(1) Set the mode switch in the main OP to "MDI".
(2) Press the “OFS/SET” key in the right side of the main
OP monitor.
▪The following options will be displayed in the bottom
soft key bar.
(3) Press the [SETTING] soft key.
▪The Setting menu appears where the cursor will be
positioned to “PARAMETER WRITE” on the top.
※ If the screen is not displayed as shown in the right
picture, move to the first page of the Setting
Parameter menu (“0”

“NO.SRH”) and press
the Page Up button three times. Then, you will
see the right screen properly.
(4) Enter the number of "1" and keep pressing the INPUT
and EXEC keys.
★ The “SW0100 Parameter Enable Switch ON”
alarm will occur.

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HM 5000/6300/8000 HM4digitATCE26
(5) Press the “SYSTEM” key in the right side of the main
OP monitor.
▪The following options will be displayed in the bottom
soft key bar.
(6) Move to the Keep Relay screen.
① Press the soft keys one after another to move to the Keep Relay screen.
② Press the Vertical Soft Key in the right corner and press the [DATA] key.
7) Use the
“Page↑” or “Page↓”
key to turn
over the page until you find the right data
page. Enter a new value in the Data field
and press “Input” .
(8) When done, move back to
“SETTING”
and turn off “PARAMETER WRITE” (“1”
‘0”). Then, press the
“RESET” key to
release the alarm.
Activate the
Vertical Soft Key
1
2

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HM 5000/6300/8000 HM4digitATCE26
◈ Tool Search Sequence Chart
Tool Search Start (T _ _;)
ATC Sub Changer
O.P Auto Mode?
No
Yes
▪ Switch to Auto (Auto/Manual) in the manual OP.
★AL 2250 “ATC OP Manual Mode”
occurs
Searched tool No
=Spd. Tool No?
No
Searched tool No
=Wait. Tool No?
No
Double Tool
Search?
No
TMG & ATC Initial
Position?
Yes
Yes
Yes
Yes
No
★Tool Search Complete
★1st Tool to Tool Magazine, And 2
nd
Tool In Valid
★AL 2059 “T-Code Command Illegal Position” occurs
▪ Check: X7.7(WPMS.M) –SL37 Wait. Pot Mag. Side
X7.6(WPSS.M) –SL51 Wait. Pot Spd. Side
X10.3(SCHP.M) –SX41 Sub Chan. Home Pos.
X10.1(SCAI.M) –SL44 Sub Changer Arm In
X10.2(SCAO.M) –SL32 Sub Changer Arm Out
On
On
On
Off
Off
1
Sub Changer Mag. Pot Position
▪ Completed: X10.4(SCPP.M) –SX34 Sub Chan. Mag. Pos.
On
▪ Output: Y12.2(SCS1.R) –YV33 Sub Changer Pos. 1
Y12.3(SCS2.R) –YV34 Sub Changer Pos. 2
Y12.4(SCS3.R) –YV35 Sub Changer Pos. 3
Y12.5(SCS4.R) –YV36 Sub Changer Pos. 4
On
On
Off
Off
Sub Changer Pot
Position?
No
★AL 2272 “ATC Sub Changer Pos. Check Alarm” occurs
Yes
▪ Check: X10.4(SCPP.M) –SX34 Sub Chan. Mag. Pos.
On
2
Sub Changer Arm Out
▪ Output: Y12.1(SCAT.R) –YV32 Sub Changer Arm Out
On
▪ Completed: X10.2(SCAO.M) –
SL32 Sub Changer Arm
Out
On

9
HM 5000/6300/8000 HM4digitATCE26
Sub Changer Arm
Out O.K?
No
★AL 2273 “ATC Sub Tool In/Out Alarm” occurs
▪ Check: X10.2(SCAO.M) –SL32 Sub Changer Arm Out
X10.1(SCAO.M) –SL31 Sub Changer Arm In
On
Yes
3
Sub Changer Wait. Pot Position
▪ Output: Y12.2(SCS1.R) –YV33 Sub Changer Pos. 1
Y12.3(SCS2.R) –YV34 Sub Changer Pos. 2
Y12.4(SCS3.R) –YV35 Sub Changer Pos. 3
Y12.5(SCS4.R) –YV36 Sub Changer Pos. 4
▪ Completed: X10.5(SCWP.M) –
SX35 Sub Chan. Wait.
Pos.
On
On
Off
Sub Changer
Waiting Pot Pos.?
No
★AL 2272 “ATC Sub Changer Pos. Check Alarm”
occurs
▪ Check: X10.5(CAWP.M)–SX35 Sub Chan.Wait. Pot Pos.
On
Yes
On
Off
4
Sub Changer Arm In
▪ Output: Y2.5(SBAI.R) –YV31 Sub Changer Arm In
On
▪ Completed: X10.1(SCAO.M) –SL31 Sub Changer Arm In
On
Sub Changer Arm
In O.K?
No
★AL 2273 “ATC Sub Tool In/Out Alarm”
occurs
▪ Check: X10.1(SCAO.M) –SL31 Sub Changer Arm In
X10.2(SCAO.M) –SL32 Sub Changer Arm Out
On
Yes
Off
Off
5
Sub Changer Home Position
▪ Output: Y12.2(SCS1.R) –YV33 Sub Changer Pos. 1
Y12.3(SCS2.R) –YV34 Sub Changer Pos. 2
Y12.4(SCS3.R) –YV35 Sub Changer Pos. 3
Y12.5(SCS4.R) –YV36 Sub Changer Pos. 4
▪ Completed: X10.3(SCHP.M) –
SX33 Sub Chan. Home
Pos.
On
On
Off
Sub Changer
Home Position?
No
★AL 2272 “ATC Sub Changer Pos. Check Alarm” occurs
▪ Check: X10.3(SCHP.M) –SX33 Sub Chan. Home Pos.
On
Yes
Off
On
6
Waiting Pot Spindle Side
▪ Output: Y12.0(WPSS.R) –YV40 Waiting Pot Spd. Side
On
▪ Completed: X7.6(WPSS.M) –
SL36 Waiting Pot Spindle
Side
On
Waiting Pot
Spindle Side?
No
★AL 2291 “Waiting Pot Spd/Mag. Side Alarm” occurs
▪ Check: X7.6(WPSS.M) –SL36 Waiting Pot Spindle Side
X7.7(WPMS.M) –SL32 Waiting Pot Mag. Side
On
Off
Yes
Tool Search END

10
HM 5000/6300/8000 HM4digitATCE26
◈ Tool Change (M06) Sequence Chart
1
ATC Change Position & M19
Spindle
Orientation?
No
Yes
ATC Change
Position?
No
Yes
2
ATC Door Open Command
Tool Change Start (M06)
ATC Door Open
O.K?
No
Yes
M06 Command
Initial Position?
No
Yes
▪ Return Y, Z to 2nd reference point & Spindle Orientation
▪ Program : G91 G30 Y0 Z0 M19 ;
▪ Completed: X12.1(ATDO.M) –SL51 ATC Door Open
▪ Check: X12.1(ATDO.M) –SL51 ATC Door Open
X12.2(ATDC.M) –SL52 ATC Door Close
On
Off
On
▪ Check: X7.7(WPMS.M) –SL37 Wait. Pot Mag. Side
X7.6(WPSS.M) –SL51 Wait. Pot Spd. Side
X10.3(SCHP.M) –SX41 Sub Chan. Home Pos.
X10.1(SCAI.M) –SL44 Sub Changer Arm In
X10.4(SCMP.M) –SX41 Sub Chan. Pot Pos.
X10.5(SCWP.M) –SX41 Sub Chan. Wait Pos.
X10.0(TPOT.M) –SL33 Tool Pot Tool Out Int.
X8.5 (CAHP.M) -SX41 M-Chen. Arm Home Pos.
★AL 2060 “M06 Command Illegal Position” occurs
Tool Search
O.K?
No
Yes
★AL 2245“ATC Door Open /Close Alarm” occurs
★AL 2060 “M06 Command Illegal Position” occurs
▪ Check: Perform the tool search.
Program : T _ _;
3
ATC Changer Motor Rotation Run
Tool Unclamp
Comm. SW On?
Yes
On
Off
On
On
On
Off
Off
On
▪ Output: Y3.4(CMFW.R) –KM81F ATC Motor Forward
On
▪
Check: X8.6(MLMD.M) –SX42 Tool Unclamp Comm.
On
▪ Output: Y3.0(ATDO.R) –YV37 ATC Door Open
On

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HM 5000/6300/8000 HM4digitATCE26
4
Tool Unclamp Sol. On Command
▪ Output: Y14.0(STCP.R) –YV11 Spindle Tool Unclamp
On
Tool Clamp
Comm. SW On?
▪ Check: X8.7(CLMD.M) –SX43 Spindle Clamp Comm.
Yes
On
5
Tool Unclamp Sol. Off Command
▪ Output: Y14.0(STCP.R) –YV11 Spindle Tool Unclamp
Off
Changer Arm
Home Position?
▪ Check: X8.5(CAHP.M) –SX41 Changer Arm Home Pos.
On
Yes
6
ATC Changer Rotation Motor Stop
▪
Output: Y3.4(CMFW.R) –KM81F ATC Motor Forward
Off
7
ATC Door Close Command
▪ Output: Y3.1(ATDC.R) –YV38 ATC Door Close
On
▪ Completed: X13.2(CAHP.M) –SL52 ATC Door Close
On
No
ATC Door Close
O.K?
No
Yes
★AL 2245“ATC Door Open /Close Alarm” occurs
★AL 2062“M06 Command Overtime” occurs
▪ Check: X12.1(ATDO.M) –SL51 ATC Door Open
X12.2 (ATDC.M) –SL52 ATC Door Close
On
Off
M06 completed

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HM 5000/6300/8000 HM4digitATCE26
◈ Tool Re-Charge Step Sequence Chart
M06 End
4
Sub Changer Mag. Pot Position
▪ Completed: X10.4(SCPP.M) –SX34 Sub Chan. Mag. Pos.
On
▪ Output: Y12.2(SCS1.R) –YV33 Sub Changer Pos. 1
Y12.3(SCS2.R) –YV34 Sub Changer Pos. 2
Y12.4(SCS3.R) –YV35 Sub Changer Pos. 3
Y12.5(SCS4.R) –YV36 Sub Changer Pos. 4
On
On
Off
Off
Sub Changer Pot
Position?
No
★AL 2272 “ATC Sub Changer Pos. Check Alarm” occurs
▪ Check: X10.3(SCHP.M) –SX33 Sub Chan. Home Pos.
X10.4(SCPP.M) –SX34 Sub Chan. Pot Pos.
X10.5(SCWP.M) –SX35 Sub Chan. Wait. Pos.
On
1
Waiting Pot Magazine Side
▪ Output: Y2.7(WPMS.R) –YV30 Waiting Pot Mag. Side
On
▪ Completed: X7.7(WPMS.M) –SL32 Waiting Pot Mag. Side
On
Waiting Pot
Spindle Side?
No
★AL 2291 “Waiting Pot Spd/Mag. Side Alarm” occurs
▪ Check: X7.6(WPSS.M) –SL36 Waiting Pot Spindle Side
X7.7(WPMS.M) –SL32 Waiting Pot Mag. Side
On
Off
Yes
2
Sub Changer Wait. Pot Position
▪ Output: Y12.2(SCS1.R) –YV33 Sub Changer Pos. 1
Y12.3(SCS2.R) –YV34 Sub Changer Pos. 2
Y12.4(SCS3.R) –YV35 Sub Changer Pos. 3
Y12.5(SCS4.R) –YV36 Sub Changer Pos. 4
On
Off
▪ Completed: X10.5(SCWP.M) –
SX35 Sub Chan. Wait.
Pos.
On
On
Off
Sub Changer
Waiting Pot Pos.?
No
★AL 2272 “ATC Sub Changer Pos. Check Alarm”
occurs
▪ Check: X10.3(SCHP.M) –SX33 Sub Chan. Home Pos.
X10.4(SCPP.M) –SX34 Sub Chan. Pot Pos.
X10.5(SCWP.M) –SX35 Sub Chan. Wait. Pos.
On
Yes
3
Sub Changer Arm Out
▪ Output: Y12.1(SCAT.R) –YV32 Sub Changer Arm Out
On
▪ Completed: X10.2(SCAO.M) –
SL32 Sub Changer Arm
Out
On
Sub Changer Arm
Out O.K?
No
★AL 2273 “ATC Sub Tool In/Out Alarm”
occurs
▪ Check: X10.2(SCAO.M) –SL32 Sub Changer Arm Out
X10.1(SCAO.M) –SL31 Sub Changer Arm In
On
Off
Yes
Yes
Go to “A”
Off
Off
Off
Off

13
HM 5000/6300/8000 HM4digitATCE26
Yes
6
Sub Changer Home Position
▪ Output: Y12.2(SCS1.R) –YV33 Sub Changer Pos. 1
Y12.3(SCS2.R) –YV34 Sub Changer Pos. 2
Y12.4(SCS3.R) –YV35 Sub Changer Pos. 3
Y12.5(SCS4.R) –YV36 Sub Changer Pos. 4
▪ Completed: X10.3(SCHP.M) –
SX33 Sub Chan. Home
Pos.
On
On
Off
Sub Changer
Home Position?
No
★AL 2272 “ATC Sub Changer Pos. Check Alarm”
occurs
▪ Check: X10.3(SCHP.M) –SX33 Sub Chan. Home Pos.
X10.4(SCPP.M) –SX34 Sub Chan. Pot Pos.
X10.5(SCWP.M) –SX35 Sub Chan. Wait. Pos.
On
Off
On
Yes
5
Sub Changer Arm In
▪ Output: Y2.5(SBAI.R) –YV31 Sub Changer Arm In
On
▪ Completed: X10.1(SCAO.M) –SL31 Sub Changer Arm In
On
Sub Changer Arm
In O.K?
No
★AL 2273 “ATC Sub Tool In/Out Alarm” occurs
▪ Check: X10.1(SCAO.M) –SL31 Sub Changer Arm In
X10.2(SCAO.M) –SL32 Sub Changer Arm Out
On
Off
Yes
A
Off
Off
ATC Re-Charge End

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HM 5000/6300/8000 HM4digitATCE26
Revision History
ATC Troubleshooting HM 5000/6300/8000
Version Year/Month Revision history Created by
01 2012. 06 Created a draft (HM4digitATCE26) Jung, Sam Young
02
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05
06
07
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