Doosan HP5100 User manual

Machine Tools
ATC Troubleshooting
(HP 5100)

1
HP 5100 HP51ATCE26
◈ ATC Troubleshooting (HP 5100)
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.
☞ This kind of troubleshooting 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) When the spindle performs the Tool Clamp operation, the changer arm is just
stopped.
In this case, the changer arm passes its home position and stops within the spindle range.
(2) When the spindle performs the Tool Unclamp operation, the changer arm is just
stopped.
In this case, the changer arm is pulled out of the spindle and starts rotation by 180˚ before
stopping within the tool changing position.
(3) The changer arm is stuck right after the Clamp/Unclamp operation.
In this case, the changer arm is stuck in the spindle and consequently stops rotation.
(4) When the “Changer Arm Position Check Alarm” (Alarm #2065) occurs even after you
returned the changer arm to the home position
In this case, the changer arm has returned to its home position. However, the home
position of the servo does not match the machine home position of ATC (installed in the
cam assembly) for any reasons.
(1) Recovery sequence in case the changer arm is stopped while the spindle is performing
the tool clamping.
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 in the main OP.

2
HP 5100 HP51ATCE26
3) From the NC function key panel, press the “CUSTOM”
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
“ATC-ON” to select ATC.
The ATC Manual mode will switch from
“DISABLE” to
“ON” .
6) Move the cursor to select “ATC ARM REVERESE
STEP”
. From the main OP, repeat pressing briefly the
Cycle Start button to return the changer arm to the
home position.

3
HP 5100 HP51ATCE26
7) Repeat pressing briefly the “Cycle Start” button in the
main OP until the changer arm returns to the home
position where it doesn't move further. (If the changer
arm won't move further, it has completed returning to
the home position)
※ If the changer arm is stuck in the spindle that is
performing the tool clamping after the arm changed
a tool, select
“ATC ARM FORWARD STEP” to
move the arm manually.
Checkpoints: From the PMC G.DATAscreen, D450
= D452
8) Move the cursor to select “ATC ARM 1 CYCLE”
. From
the main OP, press the Cycle Start button so that the
changer arm changes one tool and realigns with the
cam.
9) When done, press the “OFF” soft key.
The ATC Manual mode will switch from
“ON” to
“DISABLE”
10) 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
11) When each axis returns to their respective home position, ATC troubleshooting will be completed.

4
HP 5100 HP51ATCE26
(2) Recovery sequence in case the changer arm is stopped while the spindle is
performing the tool clamping.
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 in the main OP.
3) From the NC function key panel, press the “CUSTOM”
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
“ATC-ON” to select ATC.
The ATC Manual mode will switch from
“DISABLE” to
“ON” .

5
HP 5100 HP51ATCE26
6) Move the cursor to select “ATC ARM REVERESE STEP” . From the main OP, repeat pressing
briefly the Cycle Start button to return the changer arm to the home position.
☞ When the changer arm is pulled out of the spindle with a tool inserted, press hard on the locking
pin to remove the tool, and move the changer arm to its home position so that it won't move
further. (If the changer arm won't move further, it has completed returning to the home position)
7) Move the cursor to select “ATC ARM 1 CYCLE” , and
press the Cycle Start button in the main OP to perform
it.
☞ The changer arm changes a tool once and realigns
with the internal cam.
※
Repeat the ATC Arm 1 Cycle operation until you find
out the cause of trouble.
8) When done, press the “OFF” soft key.
☞ The ATC Manual mode will switch from “ON” to
“DISABLE” .
9) 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
10) When each axis returns to their respective home position, ATC troubleshooting will be completed.
Locking
Pin
Locking
Pin

6
HP 5100 HP51ATCE26
(3) Recovery sequence in case the changer arm is stuck while performing the tool
clamping/unclamping.
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 in the main OP.
3) From the NC function key panel, press the “CUSTOM”
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
“ATC-ON” to select ATC.
The ATC Manual mode will switch from
“DISABLE” to
“ON” .

7
HP 5100 HP51ATCE26
6) If you encounter any of the followings, move the cursor up or down to select “ATC ARM
REVERESE STEP”
or “ATC ARM FORWARD STEP” , and repeat pressing briefly the “Cycle
Start” button in the main OP until the changer arm returns to the home position where it doesn't
move further. (If the changer arm won't move further, it has completed returning to the home
position)
6-1) When tool unclamping is done, you couldn't pull out the tool (D450 ≠ D452)
Move the cursor to select “ATC ARM REVERESE STEP” . From the main OP, repeat
pressing the Cycle Start button to return the changer arm to the home position.
※ 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 the tool to find out the cause of trouble and
take a necessary measure.
6-
2) When tool clamping is done, the changer arm is stuck in the tool so that it couldn't rotate at all.
(D450 = D452)
Move the cursor to select “ATC ARM FORWARD STEP” . From the main OP, repeat
pressing the Cycle Start button to return the changer arm to the home position.
If, for example, the changer arm is stuck with the Overload alarm (2009) tripped, turn off
the power and turn it back on. Then, use the plain screwdriver to press down the changer
arm roller while performing the Forward operation. Find out the reason the gripper of the
changer arm is stuck. (It happens mostly while realigning ATC)
Changer Arm
Roller

8
HP 5100 HP51ATCE26
※ (D450 ≠ D452)
와
(D450 = D452)
의
ATC
상태
7) Move the cursor to select “ATC ARM 1 CYCLE” . From
the main OP, press the
Cycle Start button so that the
changer arm changes one tool and realigns with the
cam.
8) When done, press the “OFF” soft key.
☞ The ATC Manual mode will switch from “ON”
to
“DISABLE” .
9) 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
10) When each axis returns to their respective home position, ATC troubleshooting will be completed.
(D450≠D452)
C. The home position
dog of the arm is located
under the proximity switch.
▶Reverse operation
(D450=D452)
C. The home position
dog of the arm is located
over the proximity switch.
▶Forward operation