HMC Maintenance Manual (Alarm) - CNCzone

Machine Tools

HMC Maintenance Manual (Alarm) (HM 8000/F30i Series)

1

HM 8000(F30i Series) HM8000ALE2A ㅇ

Table of Contents 1. Emergency Alarm .............................................................................................................................. 4

1.1 2001 Emg. Button or Axes Emergency ....................................................................................... 4

1.2 2002 Main Spindle Servo Alarm .................................................................................................. 6

1.4 2004 Hyd. Pump Motor Overload .............................................................................................. 16

1.5 2005 Hyd. Pressure Down Alarm ................................................................................................. 18

1.6 2006 Spindle Gear Shift Check Switch Alarm .......................................................................... 21

1.7 2007 Main Power Phase & ATC SW Error ................................................................................ 26

1.8 2008 PSM Power Run Alarm ..................................................................................................... 28

1.9 2011 Hyd. Pump Motor Not Run ................................................................................................ 31

1.10 2013 Spindle Stop Signal Alarm .............................................................................................. 32

1.11 2014 Invert Fault Alarm ............................................................................................................ 33

1.12 2015 Spindle Tool Unclamp Alarm........................................................................................... 37

1.13 2017 Spindle Head Oil Overflow ............................................................................................. 39

1.14 2019 Machine Model Select Keep Relay Not Set .................................................................. 41

2. Cycle Alarm........................................................................................................................................ 42

2.1 2031 Must Be Returned To Ref. Point ....................................................................................... 42

2.2 2032 External Feed Hold (OP Push Button Switch) ................................................................. 43

2.3 2033 Air Pressure down Alarm .................................................................................................. 44

2.4 2034 Coolant & Lub. Pump Overload ....................................................................................... 46

2.5 2035 External Coolant Unit Alarm ............................................................................................. 49

2.6 2036 Coolant Level Switch Low................................................................................................. 52

2.7 2037 Power Back Up Module Error ........................................................................................ 53

2.8 2040 Operator’s Door Open Alarm ............................................................................................ 55

2.9 2049 Spindle Speed Arrival Alarm ............................................................................................. 56

2.10 2050 Spindle Rotation Malfunction .......................................................................................... 63

2.11 2051 Spindle Orientation Overtime ......................................................................................... 66

2.12 2055 Spindle Tool Clamp/Unclamp Overtime Alarm .............................................................. 69

2.13 2056 Gear Shifting Overtime ................................................................................................... 72

2.14 2058 Tool No. Select Keep Relay Not Set .............................................................................. 75

2.15 2059 T-Code Command Illegal Position ................................................................................. 79

2.16 2060 M06 Command Illegal Position ...................................................................................... 88

2.17 2061 T-Code Command Over Alarm ....................................................................................... 95

2.18 2062 M06 Command Overtime Alarm ..................................................................................... 96

2

HM 8000(F30i Series) HM8000ALE2A

2.19 2063 ATC Servo Unit Alarm .................................................................................................... 111

2.20 2064 ATC Door Open ............................................................................................................. 121

2.21 2066 Splash Guard (APC) Door Open (PMG) ...................................................................... 123

2.23 2068 Pallet Change Illegal Position ....................................................................................... 131

2.24 2086 Main Changer Overtime Alarm ..................................................................................... 135

2.25 2091 B-Axis Command Error(Inc. Dec. Point) ...................................................................... 141

2.26 2093 X-Axis APC Changer Position Switch Alarm ............................................................... 143

2.27 2094 Pallet Number Command Error .................................................................................... 145

2.28 2142 Please Turn Off And On NC Power .............................................................................. 146

3. Single Block Alarm ........................................................................................................................ 147

3.1 2160 Lub. Level Low ................................................................................................................. 147

3.2 2161 Lub. Pressure Alarm ........................................................................................................ 149

3.3 2162 Parts Count End Alarm .................................................................................................... 151

3.4 2164 Oil Cooling Unit Alarm ..................................................................................................... 152

3.5 2166 Filter Changer of TSC. Alarm.......................................................................................... 162

3.6 2167 High TSC Flow Down Alarm ........................................................................................... 164

3.7 2168 Coolant Pressure Down Alarm ....................................................................................... 166

3.8 2170 Tool Life Count End Alarm .............................................................................................. 167

3.9 2171 RST Command Alarm On STL ....................................................................................... 169

3.10 2172 Tool Length Sensor Up Status ...................................................................................... 170

3.11 2173 Wait. & Mag. Pot Tool Detect ........................................................................................ 172

3.12 2175 Hyd. Unit Oil Temperature Alarm .................................................................................. 175

4. Massage Alarm ............................................................................................................................... 176

4.1 2191 Coolant Chiller Unit Alarm ............................................................................................... 176

4.2 2193 Safety Switch Locking Alarm .......................................................................................... 177

4.3 2194 Man Axis Moving Interlock .............................................................................................. 179

4.4 2195 OP- Door Close, Must Be D-Open ................................................................................. 194

4.5 2196 Screw Conveyor Overload .............................................................................................. 196

4.6 2197 Chip Conveyor Alarm or Off Mode Alarm ....................................................................... 198

4.7 2198 Auto Power Off Ready .................................................................................................... 199

4.8 2202 Machine Lock ................................................................................................................... 200

4.9 2203 Screw Conveyor CCW Manual Mode ............................................................................ 202

4.10 2204 Feedrate Override 0% ................................................................................................... 204

4.11 2205 Measurement Device Low Battery ............................................................................... 206

4.12 2206 Measurement Device Alarm ......................................................................................... 207

4.13 2207 Machine Interference Zone Error ................................................................................. 208

4.14 2208 Machine In Service Mode ............................................................................................. 213

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4.15 2215 Tool Length Sensor Up/Down Alarm ............................................................................ 214

4.16 2218 First, There Must Be Z-Ref. Return .............................................................................. 216

4.17 2221 5-Th Clamp/Unclamp Alarm ......................................................................................... 217

4.18 2222 Program Start Check Alarm .......................................................................................... 219

4.19 2223 B-Axis Moving Interlock Alarm...................................................................................... 221

4.20 2234 Gear Shift Lost............................................................................................................... 222

4.21 2240 ATC Not Use (K7.6 Set) ................................................................................................ 226

4.22 2241 Wait. Pot or Spindle Tool data Zero ............................................................................. 227

4.23 2243 Must Be ATC M-Changer Man. 1 Cycle ....................................................................... 229

4.24 2245 ATC Door Open Close Alarm ....................................................................................... 230

4.25 2247 T-Code or M06 Commanded States ............................................................................ 233

4.26 2250 ATC OP Manual Mode .................................................................................................. 234

4.27 2251 ATC Overtime Alarm ..................................................................................................... 235

4.28 2259 Wait Pot No. = Spindle Pot No. .................................................................................... 241

4.29 2260 Tool Mag. Rotation Over Time ...................................................................................... 243

4.30 2262 ATC Magazine Guard Door Open ................................................................................ 245

4.31 2264 Tool Magazine Servo Battery Alarm ............................................................................. 249

4.32 2265 VPF Off of Tool Magazine Alarm .................................................................................. 260

4.33 2266 Servo Mag. Tool Number Error..................................................................................... 262

4.34 2270 ATC Mag. Pot Tool Out SW. Alarm............................................................................... 263

4.35 2272 ATC Sub Changer Position Check Alarm .................................................................... 265

4.36 2273 ATC Sub Tool Arm In/Out Alarm ................................................................................... 268

4.37 2321 APC Initial Position Alarm ............................................................................................. 270

4.38 2322 APC Set-Up Station Door Open ................................................................................... 273

4.39 2323 4-Th Clamp/Unclamp Alarm ......................................................................................... 277

4.40 2324 Table or Pallet Clamp Alarm ......................................................................................... 282

4.41 2325 APC Set-Up Switch Unpush ......................................................................................... 287

4.42 2326 APC OP Manual Mode .................................................................................................. 290

4.43 2333 APC Not Use (K7.7 Set) ............................................................................................... 292

4.44 2335 APC Changer Open/Close Alarm ................................................................................. 293

4.45 2336 APC Changer Up/Down Alarm ..................................................................................... 295

4.46 2337 APC Changer 180CW/CCW Alarm .............................................................................. 297

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1. Emergency Alarm

1.1 2001 Emg. Button or Axes Emergency 1) Description

The Emergency Stop push-button switch on the operation panel is pressed down, or at least one Emergency Stop limit switch for the axes is tripped.

2) Cause of problem

① The Emergency Stop push-button switch on the operation panel, ATC manual OP, APC manual OP or the chip conveyor is pressed down.

② The Emergency Stop limit switch for each axis (X, Y or Z) is pressed down. ③ An error in the Emergency Stop switch on the OP, or the Emergency Stop limit switch for

each axis, or other related parts. ④ Disconnection of the wiring.

3) Action

① Check if the red mushroom push-button switch on the OP (Main OP, ATC OP, Chip Conveyor OP) is pressed down, and if so, turn the switch counter clockwise to release it.

② If the Limit switch for any axis (X, Y, or Z) is tripped, press both the Machine Ready switch and the Emergency Release switch simultaneously to enter the Machine Ready state. (If you want to return to the emergency stop state, simply release the switch.) Then, move the problem-making axis in jog or handle mode so as to remove it from the emergency stop limit switch.

③ Check the Emergency Stop push-button switch on the main OP, the Emergency Stop limit switch on the axis, and other related parts for any problem. Repair or replace the defective part if necessary.

④ Disconnection of the wiring Refer to the circuit diagram and use the electric tester to check each terminal block. If you find an error, repair or replace the defective part.

Part Name Part No. Symbol Spec. Maker

Switch, Emergency P/B ESWPB0439 SB1,5,7,8,61 KH-3046ER-RED KACON

Switch, Limit ESWLM0111 SL1.1,2.1,3.1,5.1 D4C-4332 OMRON

Signal Address Device Symbol I/O Connector

(Pin) Numbering

Emergency Stop X8.4

(ESP.M) -SB1,5,7,8,61 I/O Module Slot 8 XJ412 (23) ESP

5


Adress Symbol Coil Comment

X8.4 ESP.M Emergency Stop

A0.0 2001 OP Emergency PB or LS Off

X33.6 MRD.M Machine Ready

R650.2 APONI Auto Power On Initial Flag

R652.7 ARST Alarm Reset

Emergency Button or

Axes Emergency

6


1.2 2002 Main Spindle Servo Alarm 1) Description

There occurred an alarm from the main spindle drive unit. 2) Cause of problem

① An error found in the main spindle drive unit ② An error found in the spindle motor, power cable or signal cables

3) Action

① Check the alarm number that is displayed on the main spindle drive unit of the electric cabinet. Take a necessary measure according to the alarm number. ☞ Refer to "Troubleshooting by the spindle amplifier alarm" in the appendix.

② Check the spindle motor for the 3-phase power source and the feedback cable if there is a problem.

Address Symbol Coil Comment

F45.0 ALMA Spindle Alarm

Y9.2 MRY.R Machine Ready

A0.1 2002 Main Spindle Servo Alarm


Main Spindle Servo

Alarm

Alarm Display

7


8


◈ Reference) Troubleshooting for each of the spindle amplifier alarms

Alarm No. Description Remedy

01 Motor overheated

Check the ambient temperature and the load conditions.

If the cooling fan stops operating, replace it with a new one.

02 Excessive speed deviations

Check the load conditions and correct them if excessive.

Check and correct parameter No.4082 (correction of the acceleration/deceleration of the spindle motor)

03 Fuse blown in the DC LINK area

Replace the spindle amplifier (SPM).

Check the insulation status of the spindle motor.

Check and replace the interface cable.

04 The main power has a phase missing.

Check the state of the input power supply to the PSM.

07 Excessive speed Check and correct the spindle-related parameter.

Replace the feedback cable.

09 The main circuit is overloaded.

Check and replace the cooling fan motor and the heat sink if necessary.

If the cooling fan stops operation, replace the SPM unit.

11 Excessive voltage on the DC LINK area

Check and replace the selected power supply unit if necessary.

Check the input power voltage as well as the voltage changes during motor deceleration. If the voltage exceeds 253 VAC (for the 200V system) or 530 VAC (for the 400V system), improve the power supply impedance.

12 Excessive current on the DC LINK area

Check the insulation status of the spindle motor.

Check and correct the spindle-related parameter.


15 An error in the spindle switch or the output switch

Check if there occurred the PMC alarm, and use the ladder to check the I/O status again.

Replace the MC magnet (usually KM20/KM21)

16 RAM error Replace the SPM control printed circuit board.

18 Rom Sum Check Error Replace the SPM control printed circuit board.

19 Excessive offset of the U-phase current


20 Excessive offset of the V-phase current


9



21 A polarity settings error in the position sensor

Check the parameter settings by referring to the manual. (PRM N4000N0,N4001N4)

24 An error in transmission of the serial data

(An error occurred due to the noise) Separate the CNC-To-Spindle cable from the power cable, or apply a protective device such as ferrite core.

Replace the cable.

27

Disconnection of the position coder signal

Replace the position coder cable

An error in BZ sensor or a problem with the sensor interval

29 Overload in a short time Check and correct the load status.

30 Excessive current in the input circuit

Check the state of the input power supply to the PSM.

31 Motor binding

Check and correct the load status.

Replace the feedback cable (JY2 or JY5) of the spindle motor.

32 An error in the LSI internal RAM for serial data transmission

Replace the SPM control printed circuit board.

33 Charging the DC Link is insufficient.

Insufficient capacity of the DC Link (Check and replace the power supply unit if necessary)

Replace the PSM unit.

34 A parameter settings error. Correct the parameter value according to the manual. If the parameter number is unknown, connect the spindle check board to identify the parameter.

35 Excessive gear ratio data Check the parameter settings by referring to the manual.

36 Excessive position deviations Check if the position gain value is too large, and correct the value if necessary.

37 A parameter settings error of the speed detection unit

Check the parameter settings by referring to the manual.

41

The signal for one rotation of the position coder has an error.


An error in the position coder cable

An error in BZ sensor or a problem with the sensor interval

42 The one rotation signal of the Check and replace the position coder cable if necessary.

10



position coder is not found

An error in the BZ sensor signal or a problem with the sensor interval. Readjust the BZ sensor signal or the sensor interval as appropriate.

43 Differential speed position coder disconnected

Check and replace the position coder cable if necessary.

46

The one rotation signal of the position coder on threading is not found



An error in the BZ sensor signal or a problem with the sensor interval. Readjust the BZ sensor signal or the sensor interval as appropriate.

47 Abnormal Position Coder Signal


An error in the BZ sensor signal or a problem with the sensor interval.

Ensure that the position coder is properly connected to the power source line. (Be careful not to entangle the line, and apply the ferrite core to the line if possible)

49 Excessive differential speed conversion value

Ensure that the calculated differential speed value (programmed S code) does not exceed the maximum motor speed. N3772 (Maximum speed - G96)

50

Excessive speed command during spindle synchronization

Ensure that the calculated speed value (programmed S code) does not exceed the maximum motor speed.

51 DC Link Under Voltage

Check the input voltage of the power supply unit.

Check the contact state of the magnet and replace MC(KM20/KM21) if necessary.

52 ITP signal error

Replace the SPM control printed circuited board.

Replace the spindle interface printed circuit board (JA41) of the CNC machine.

53 ITP signal error


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Replace the spindle interface printed circuit board (JA41) of the CNC machine.

54 Overload Current Check and correct the overload conditions.

55 Power Line State Signal Error

Replace the magnetic contactor. Check and replace the magnetic contactor (KM10) if necessary.

Check and correct the ladder sequence. Check and replace the magnetic contactor. (KM20/KM21)

56 Internal cooling fan stopped


57 Excessively decelerated speed

Decrease the acceleration/deceleration duty. Measure the tension of the belt. (belt type) Check and correct the acceleration / deceleration duty. (N4082)

Check the cooling condition (ambient temperature) Check the internal temperature of the electric cabinet, and check also the (cooling) fan motor if working normally.

If the cooling fan has stopped operation, replace it as it is defective.

If the regenerative resistance value is abnormal, replace the resistor.

58 The main circuit of the converter is overloaded

Check the performance of the PSM cooling fan.


59 The cooling fan of the converter stopped


66

Communication error between spindle and converter

Replace the signal cable.

Check and correct the wiring of the signal cable.

73 Motor Sensor Disconnection


Check the shielding of the feedback cable.

Check and correct the wiring of the feedback cable.

Adjust the position and distance of the sensor.

74 CPU Test Alarm Replace the SPM control printed circuited board.

12



75 CRC Test Alarm Replace the SPM control printed circuited board.

79 Initial Test Alarm Replace the SPM control printed circuited board.

81 An error in the one-rotation signal of the motor sensor

Check and correct the parameters: N4016N6 / N4017N2


Adjust the position and distance of the motor sensor.

82 An error in detecting the one-rotation signal of the motor sensor



83 Motor sensor signal error



84 Spindle sensor disconnected


Check the shielding of the feedback cable.



Adjust the position and distance of the motor sensor (position coder).

85 An error in detecting the one-rotation signal of the spindle sensor




86 Spindle Sensor One-Rotation Signal Undetected



87 Spindle sensor signal error

The one-rotation signal of the spindle sensor is not detected. Check the wiring and adjust the position and distance of the sensor.

88 Cooling fan stopped

Replace the motor of the cooling fan that is installed in the spindle unit.

A0 A1 A2

Program Rom Error (The Control Programming Is Not Running)

If the alarm is tripped at the moment the spindle amplifier gets applied with power, this is caused by:

-. Wrong software specification.

13



-. Defective printed circuited board. Replace The SPM or SPM Control Circuited Board.

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.

b0 Communication Error Between Amplifier Modules

Replace the communication cable between amplifier and module.

Replace the SPM or PSM control printed circuited board.

b1

Low Converter Control Power Supply Voltage (PSM Alarm:6)

Replace the PSM control printed circuit board.

b2

Excessive converter regenerative voltage (PSM alarm: 8)

Check the regenerative resistor.

The spindle motor is defective.

Check and replace the selected power supply unit if necessary.

b3

The cooling fan of the converter radiator stopped working (PSM Alarm Indication: A)

If the cooling fan stops operating, replace it with a new one.

C0 C1 C2

Communication data alarm

Replace the communication cable between CNC and SPM.


Replace the CPM side spindle interface printed circuit board (JA41).

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1.3 2003 Circuit Protect Trip

1) Description The circuit protector that is installed in the electric cabinet is tripped.

2) Cause of problem

① The circuit protector is triggered. (Abnormal signal is detected) ② An error in power control ③ The circuit protector has an error itself.

3) Action

① Find out the cause that the circuit protector is tripped. ☞ (ex) If QF22 is tripped, check the secondary circuit (L+) of QF22 if it's short-circuited,

and take a necessary measure before turning the circuit protector back on. ② If the alarm occurs but no circuit protector is tripped, measure the resistance of each

contact point, and find out the defective circuit protector, and replace it with a new one. ☞ If you measure the resistance on the contact point of the circuit protector that is turned

on, you will get "0" ohm if it's normal. ③ If you have found nothing wrong in steps ① and ② above, that is thought to be caused by

the I/O circuit board. Check the I/O board and repair or replace it if necessary.


Breaker, Auxiliary ENFBX0290K QF22,23,25,28,91 C60. 26924. Of Contact Schneider

Protector, Circuit ENFBX0266K QF22, 26 C60. 24427. 3A. 1P Schneider

Protector, Circuit ENFBX0267K QF23 C60. 24428. 4A. 1P Schneider




(Pin) Numbering

Circuit Protector Trip X2.3

(TRIP.M) -QF Input Module Slot : 7 XJ411 (15) TRIP

Circuit Protect Trip

15



X2.3 TRIP.M Circuit Protector Trip

A0.2 2003 Circuit Protector Trip


M

-XJ411:

1L+

X2.3

15

TRIP A5

TRIP

a1

a2 TRIPA

a1

a2 TRIPC

a1

a2 TRIPD

a1

a2 TRIPE

a1

a2

TRIPA a1

a2

TRIPC

a2

TRIPD a1

a2

TRIPE

a1

a2

-QF14

-QF15

-QF22

-QF23

-QF81

-QF26

-QF27

-QF28

-QF51

Input Module (AID32E) : Slot 7

Transformer Power Source

Transformer Power Source

Y Axis/Mag. Motor Brake

ATC Motor Brake

APC Motor Brake

DC Sol. Power Source

Lub. Motor AC110V Control Circuit

C20A: 40, 41 49, 50

Circuit Protector Trip

16


1.4 2004 Hyd. Pump Motor Overload 1) Description

An excessive electric current is detected in the hydraulic pump motor. 2) Cause of problem

① Burn in the hydraulic pump motor or the power cable. ② The circuit breaker that detects the excessive current is overloaded or defective itself.

3) Action

① Check and replace the pump motor or the power cable if necessary. ② Check the circuit breaker for the load settings and make correction if necessary. If the

circuit breaker itself has an error, replace it with a new one.

▪ Overload settings

QM31 : 2.2 Kw : 9.6 A QM32 : 7.5 Kw : 29 A QM36 : 3.7 Kw : 17A, 2.2Kw : 10A


Breaker, Auxiliary ENFBX0290M QM31,32,36 TESYS. GVAE20. 2A Schneider

Breaker, Circuit ENFBX0285M QM31,32,36 TESYS. GV2ME16. 9-14A Schneider

Breaker, Circuit ENFBX0260M QM36 TESYS. GV2ME21. 13-18A Schneider


(Pin) Numbering

Hydraulic Motor Overload

X2.1 (HOL.M)

-QM Input Module : Slot 7 XJ411 (32) HOL

17



X2.1 HOVL.M Hydraulic Pump Motor Overload

A0.3 2004 Hydraulic Pump Motor Overload


Hyd. Pump Motor

Overload

M -XJ411:

X2.1

32

HOL


C20A: 40, 41 49, 50

a3

a4 HOLA

a3

a4 HOLB

a3

a4

-QM31

-QM32

-QM36

Hydraulic Pump Motor (Main)

Hydraulic Pump Motor (PMG)

HOL

A4

Hydraulic Pump Motor Overload

Hydraulic Pump Motor (Fixture)

18


1.5 2005 Hyd. Pressure Down Alarm 1) Description

Hyd. The pressure of the power unit falls below the setting value of the Hyd. pressure switch, causing the Hyd. pressure switch to be tripped.

2) Cause of problem

① The hydraulic power unit has an error or its pressure falls below 20kg/㎠. ② Check if the hydraulic pressure switch or if any of its parts is defective.

3) Action

① Turn the pressure valve of the hydraulic power unit clockwise to adjust the pressure to 50kg/㎠.

② Check if the hydraulic power unit pressure switch has an error, or the wiring or related component parts are defective. Hyd. Check the hydraulic power unit, the pressure switch, and the wiring from the switch to the electric cabinet as well as the I/O board, and make repair or replacement if you find a problem.


Cable, Pressure Switch ECBLS0167F -WK11 BKS B19-1-05 BALUFF

Switch Pressure R37983 -SP01 EDS810-060-0-024 HYDACS


(Pin) Numbering

Hyd. Pressure Check X8.3

HDPS.M -SP31 Input Module Slot 7 XJ413(6) SP31

Hydraulic Motor Run Y2.0

HYDM.R -KA31A

Output Module Slot 2

(02) KA31A

Pressure Gauge

Pressure Control Valve

19


Hydraulic Pressure Down

Aux. Hyd. Pressure

O.K Flag

Hyd. Pressure O.K

Hyd. Pressure Check Time(Main)

20



R841.0 APOKF Aux. Pressure OK Flag

R625.3 TMB20 Hyd. Pump On Check Time

F0.6 SA Servo Ready

R630.3 HPOK Hyd. Pressure OK

A0.4 2005 Hyd. Pressure Down Alarm


A0.0 2001 OP Emergency PB or LS Off

A0.1 2002 Main Spindle servo Alarm

A0.2 2003 Circuit Protect Trip

A0.3 2004 Hyd. Pump Motor Overload

A0.5 2006 Gear Shift Check SW. Alarm

A0.6 2007 Main Power Phase & ATC SW. Error

A0.7 2008 PSM Power Run Alarm

A1.2 2011 Hyd. Pump Motor Not Run

A1.4 2013 Spindle Stop Signal Alarm

A1.5 2014 Invert Unit Fault

A1.6 2015 Spindle Tool Unclamp Alarm

A2.0 2017 Spindle Head Oil Overflow

A2.2 2019 M/C Model Select Keep/R Not Set

R647.0 APOFF Auto Power Off

F1.0 AL NC Alarm

Y0.0 HYDM.R Hydraulic Motor Run

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

K11.7 KFXHYD When Motor of Hyd. Fixture Used

K7.6 KATC ATC Not Used

R440.4 TMB101 Hyd. Pressure Check Time(PMG)

R1420.7 PMGSEL PMG Operation Selected

R629.2 TMB51 Hyd. Pressure Check Time(Main)

R441.2 TMB107 Hyd. Pressure D-Time Initial

K5.0 KHPRS Hydraulic Pressure SW. Not Used

X2.0 HPRS.M Main Hydraulic Pressure

X8.3 PHYP.M PMG Hyd. Pressure

R630.0 MRYA Machine Ready Aux.

21


1.6 2006 Spindle Gear Shift Check Switch Alarm 1) Description

2 or more of 3 check switches (Low, Middle, and High) on the spindle head gear range were tripped, or none of them was tripped.

2) Cause of problem

The check switch for the main spindle gear range has short-circuited or any of its component parts is defective.

3) Action

Check the gear box switch of the main spindle if it works properly on the DGN screen, and take a necessary measure.

Note 1) Spindle Gear Shifting I/O Settings


(Pin) Numbering

Spindle Gear Low X6.1

(SGL.M) -SL12

Input Module : Slot 08

XJ412 (32) SL12

Spindle Gear Middle X6.2

(GSM.M) -SL13


XJ412 (48) SL13

Spindle Gear High X6.3

(GSH.M) -SL14


XJ412 (15) SL14

Spindle Gear Middle Y6.3

(GRM.R) -KAR52

Output Module : Slot 2

XJ401 (6) YV14

Spindle Gear High Y6.4

(GRH.R) -KAR53


XJ401 (23) YV15

Spindle Gear Low Y6.5

(GRL.R) -KAR54


XJ401 (38) YV16

22


* Hydraulic Flow Diagram of Spindle Head

Spindle Gear Shift Check Switch Alarm

Gear Shift End Flag

YV14 YV15 YV16 Cylinder Piston

SL12 SL13 SL14

P T

Tool Unclamp

P T

A B

P T

A B

P T

A B Unclamp Middle High Low

Tool Clamp

Gear Shifter L M H

Φ1.0 Φ1.2 Φ1.0 C D E

C D E

23



R841.1 GSTEND Gear Shift End Flag

R658.6 GOK Gear Shift O.K

X6.1 GSL.M Spindle Gear Low

X6.2 GSM.M Spindle Gear Middle

X6.3 GSH.M Spindle Gear High

R658.2 GSHON Gear Shift On

A0.5 2006 Gear Shift Check Switch Alarm


F0.6 SA Servo Ready

R624.2 TMB11 Gear Shift OK Check Time

Gear Shift O.K

Gear Shift Range Low

Gear Shift Range Middle

Gear Shift Range High

Gear Shift O.K Check Time

24


R657.4 SGRL Spindle Gear Range Low

R657.5 SGRM Spindle Gear Range Middle

R657.6 SGRH Spindle Gear Range High

R659.5 GRL Gear Shift Low

Y6.3 SRM.R Spindle Gear Middle

K0.6 KHM1000 If HM1000, Set To 1

Y6.4 GRH.R Spindle Gear High

Y14.4 SGRL Spindle Gear Range Low

Note 3) How to move to DGN (Diagnostic)

(1) Press the “SYSTEM” button in the right side of the main OP monitor. ▪ The following soft key bar will be displayed at the bottom.

(2) Move to the DGN screen. ① Press the soft keys one after another to move to the DGN screen. ② Press any soft key in the right corner to activate the vertical soft key bar, and press the

[STATUS] key.

Activate the vertical soft key

1 2

25


(3) Enter a desired DGN address and press [SEARCH] to display the DGN screen of your choice.

Note 4) How to read DGN (Diagnostic)

ex) X 0007 0 0 1 1 0 0 1 0 Bit 1, 4 and 5 in Address X7 turn ON while Bit 0, 2, 3, 6 and 7 turn OFF.

Symbol 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

26


1.7 2007 Main Power Phase & ATC SW Error 1) Description

Two of three phases of the main power are reversely connected. An error was found in the power phase error detector that checks the phases of 3-phase power source. (K0.5 was set to 1)

2) Cause of problem

① Two of the three phases are reversely connected.(The tool clamp command signal is detected in advance of the tool unclamp command signal during the ATC tool change)

② An error in the Power Phase Error Detector (-E11) or any related part 3) Action

Turn off the machine, and switch the connection of those reversed two phases. ☞ When the power phase error detector (-E11) is properly supplied with power, then the

circuit of the internal contact "a" will be turned on.


(Pin) Numbering

Power Phase Error Detection

X4.5 PHAL.M

-E11 Input Module : Slot 07 XJ411(38) E11A

Spindle Tool Clamp Command

X8.7 CLMD.M

-SX43 Input Module : Slot 08 XJ412(37) SX43

SX41 Home

Position (SX41)

Unclamp Command

(SX42)

Clamp Command

(SX43)

SX42

SX43

27



X4.5 PHAL.M Power Phase Error Detection

K0.5 KPHASE Power Phase Error Detection Used

R5323.7 TCFLT Tool Clamp Command Fault



A0.6 2007 Main Power Phase & ATC SW Error


X8.7 CLMD.M Spindle Tool Command_HM4D

R5323.6 TUCCFG ATC Unclamp Command Flag

R5323.7 TCFLT Tool Clamp Command Fault

R455.0 M06CDF M06 Command Flag

R652.6 ERST External Reset

F0.6 SA Servo Ready

Main Power Phase & ATC SW Error

Tool Clamp Command Fault

28


1.8 2008 PSM Power Run Alarm 1) Description

The power supply module has a problem while in operation. 2) Cause of problem

There was a problem with the interoperation between KM11 and the auxiliary contact point A. 3) Action

① Check the main contactor of KM11 magnetic contactor if it operates properly and the auxiliary contact point A turns on or off according to your command of ON/OFF. ☞ KM11 magnetic contactor is supposed to turn on/off according to the signal of Machine

Ready ON/OFF. ☞ If you set "K2.0=(1)" to take the command of Servo Power ON/OFF, KM11 magnetic

contactor turns off if the door is open, and turns on if the door is close. ② Check the wiring from the auxiliary contact point to the distributed I/O module B.


(Pin) Numbering

Power Supply(PSM) Magnetic Contact On

X4.0 (PMON.M)

-KM11 -KM12


XJ411 (7) PMON

Front Door Interlock X4.3

(OSDI.M) -S11 -S12


XJ411(6) OSDI

KM11 (magnet) Auxiliary contact "a"

29



X4.0

7

M XJ412:

21,36 40,41 C20C:

Power Supply (PSM) Magnetic Contactor On

-KM11

-KM12 * Shorts, iF PSM2 (KM12) Not Used

13

14

XT411

PMON

B2

13

14

30



R629.3 TMB52 Power Module Alarm Check Time

A0.7 2008 PSM Power Run Alarm


G8.4 B.ESP Emergency Stop

X4.3 OSDI.M Operator Side Door Interlock

R438.1 TMB82 Connect Delay Time Again

X4.0 PMON.M Power Supply(PSM) Magnet On State

K2.0 KMPOFF Use Motor Power On/Off Function

F0.6 SA Servo Ready

PSM Power Run Error

Power Module Alarm Check Time

31


1.9 2011 Hyd. Pump Motor Not Run 1) Description

An error in the magnetic relay that drives the hydraulic pump 2) Cause of problem

There was a problem with the interoperation between KA23 and the auxiliary contact point A. 3) Action

① Check if KA23 magnetic relay turns on/off normally, and check also if the auxiliary contact point A actually turns on/off according to a given signal.

② Check the wiring from the auxiliary contact point to the distributed I/O module B.



Y0.0 HYDM.R Hydraulic Motor Run

A1.2 2011 Hyd. Pump Motor Not Run


Y9.2 TMB20 Hyd. Pump On Check Time

Hydraulic Motor Not Run

Hyd. Pump Check Time

32


1.10 2013 Spindle Stop Signal Alarm 1) Description

The main spindle drive unit causes an error in the stop signal of the spindle. 2) Cause of problem

① An error found in the main spindle drive unit ② An error found in the spindle motor, power cable or signal cables

3) Action

① Check the alarm number that is displayed on the main spindle drive unit of the electric cabinet. Take a necessary measure according to the alarm number. ☞ Refer to "Troubleshooting by the spindle amplifier alarm" in the appendix.

② Check the spindle motor for the 3-phase power source and the feedback cable if there is a problem.


R625.4 TMB21 Spindle Stop Signal Fault Check Time A1.4 2013 Spindle Stop Signal Alarm

R625.7 ARST Alarm Reset G70.5 SFRA Spindle Forward G70.4 SRVA Spindle Reverse G70.6 ORCMA Orientation Command F45.1 SSTA Spindle Stop Confirm F45.2 SDTA Spindle Speed Detection

Spindle Stop Signal Alarm

Spindle Stop Signal Fault Check Time

33


1.11 2014 Invert Fault Alarm 1) Description

The ATC driving motor was over-currented. (Motor Overload Trip) 2) Cause of problem

① The ATC motor was overloaded. ② The ATC motor or the power cable is defective. ③ The circuit breaker that detects the excessive current is overloaded or defective itself.

3) Action

① Check if ATC is mechanically stuck. If so, find the cause of problem and solve it. ② Check and replace the ATC motor or the power cable if necessary. ② Check the circuit breaker for the load settings and make correction if necessary. If the circuit

breaker itself has an error, replace it with a new one.

Breaker Application Load

Specification QM81 ATC Control Motor(0.75KW) 3.3A

Signal Address I/O Connector (Pin) Numbering

Inverter Overload X18.7

INVF4.M Input Module : Slot 6 XJ410(46) INVF


X15.7 INVF.M Invert Overload


X18.7 INVF4.M Invert Overload_HM4D

A1.5 2014 Invert Unit Fault

R652.6 ARST Alarm Reset F0.6 SA Servo Ready

Invert Unit Fault

34


(Reference) Inverter Alarm Details

Display Protection Function Description

Over Current

Protection

The inverter cuts off its output when the output current of the inverter flows more than 200% of the inverter rated current. The inverter will cut off its output current if the output current exceeds 200% of the rated current of the inverter.

Over Voltage

Protection

The inverter cuts off its output if the DC voltage of the main circuit increases higher than the rated value when the motor decelerates or when regenerative energy flows back to the Inverter due to a regenerative load. This fault can also occur due to a surge voltage generated at the power supply system. The inverter will cut off its output current if the direct voltage of the main circuit exceeds the rated level in a decelerated motor speed or due to a regenerative load. This protection function may be activated due to a voltage surge in the power line.

Current Limit Protection (Overload Protection)

The inverter cuts off its output if the output current of the inverter flows at 180% of the inverter rated current for more than the current limit time (S/W). The inverter will cut off its output if the output current of the inverter exceeds 180% of the specified current limit for more than the current limit time (S/W).

Heat Sink Overheat

The inverter cuts off its output if the heat sink over heats due to a damaged cooling fan or an alien substance in the cooling fan by detecting the temperature of the heat sink. The inverter will cut off its output if the cooling fan fails to operate or the heat sink is overheat from impurities inside the cooling fan.

Electronic Thermal

The internal electronic thermal of the inverter determines the overheating of the motor if the motor is overloaded and the inverter cuts off the output. The inverter cannot protect the motor when driving a multi-pole motor or when driving multiple motors, so consider thermal relays or other thermal protective devices for each motor. Overload capacity : 150% for 1 min The built-in electronic thermal sensor detects an overload of the motor, and cuts off the output of the inverter. However, this protection does not apply to a multi-polar motor or a multi-motor inverter so it is advisable to install a thermal relay or thermal protector for each motor. ☞ Overload Withstand: 1 minute at 150% of the rated current of the motor

Low Voltage Protection

The inverter cuts off It’s output of the DC voltage is below the detection level because insufficient torque or over heating of

35



the motor can occurs when the input voltage of the inverter drops. As a reduced power voltage of the inverter causes an insufficient torque or an overheat of the motor, this protector will cut off the output DC voltage of the inverter if the detected current of the motor falls below the specified.

Input Phase Open

The inverter cuts off the output when One or more of the input(R, S, T) phase is open and the output load is over 50% of the inverter rated current for more than 1 minute. The inverter checks whether the phase is open by detecting the DC voltage of the main circuit. If there occurs an open input phase (R, S, T), the inverter still continues to operate to the extend of 50% of the rated current of the inverter. However, the inverter will cut off its output voltage if the output current stays at over 50% for more than 10 seconds. The inverter detects the direct voltage of the main circuit and check if there is any phase lost.

Output Phase Open

The inverter cuts off Its output when the One or more of the output (U, V, W) phase is open. The inverter detects the output current to check the phase open of the output. The inverter cuts off its output voltage if one or more of the output (U, V, W) phases are open. This function detects the output current of the inverter to check if there is any open phase.

BX Protection

(Instant Cut Off)

Use for the emergency stop of the inverter. The inverter instantly cuts off the output when the BX terminal is turned On, and returns to regular operation when the BX terminal is turned Off. Take caution when using this Function. Used for the emergency stop of the inverter. The inverter instantly cuts off its output voltage if the BX terminal is turned On, and resumes normal operation as soon as the BX terminal is turned Off. Care must be taken when using this function.

Inverter Overload

The inverter cuts off it’s output when the output current of the inverter flows more than the rated level (150% for 1 minute, 200% for 0.5 seconds). The inverter cuts off its output voltage if the output current of the inverter exceeds the rated level. (150% for 1 minute, 200% for 0.5 second)

External Fault A

Use this Function if the user needs to cut off the output by an external fault signal. (Normal open contact) Use this function if you need to cut off the output of the

36



inverter because of an external error signal. (Normal open contact A)

External Fault B

Use this Function if the user needs to cut off the output by an external fault signal. (Normal close contact) Use this function if you need to cut off the output of the inverter because of an external error signal. (Normal open contact B)

Operating Method when the

Frequency Reference Is Lost Operation mode in case the frequency

reference is lost

There are 3 nodes, continue operation, decelerate and stop, and free run, according to the I/O-48 [Operating method when the frequency reference is lost] setting. There are 3 operation modes (I/O-48) available if the frequency reference is lost: continuous operation, deceleration and stop, and free run.

EEPROM Error 1

The EEPROM of keypad has a fault causing parameter read/write error. This error occurs if the keypad has a mechanical error and there is an error in reading or writing parameters.

EEPROM Error 2

The ROM version of inverter and keypad is different. This alarm is tripped to prevent a copy of parameters from the keypad to the main unit when the keypad has a different software version from that of the main unit.

Inverter H/W

Fault

A fault signal is outputted when an error occurs to the control circuitry of the inverter. There are the Wdog error, The EEP error, and the ADC offset for this fault. This alarm is tripped if there is a mechanical error in the inverter. Details include: CPU errors, EEP errors, FAN errors, GF and NTC connection errors.

CPU Error

The CPU has a fault. This is a hardware error signal that is displayed from a CPU error.

EEP Error

The EEPROM On inverter main board has a fault. This is an EEPROM error signal that is displayed from a main unit control board error.

Wiring Error

The Input/Output wiring of inverter is Wrong. Check the I/O wiring of the inverter and take a necessary action.

Fan Error

The cooling fan does not locate. This is an error signal that is displayed if the cooling fan of the inverter has a rotation error.

37


1.12 2015 Spindle Tool Unclamp Alarm 1) Description

With the spindle tool clamped (the signal of unclamping the spindle tool is turned off), the signal sensor switch (clamping the spindle tool) is turned off. Or, the signal sensor switch that detects the unclamping of the spindle tool is turned on.

2) Cause of problem

① An error in adjusting the Spindle Tool Clamp switch or the Spindle Tool Unclamp sensor switch

② An error in the switch itself, the wiring, or any of its component parts 3) Action

① Adjust the switch correctly ② Check the proximity switch, the wiring, and the I/O module in this sequence. Make repair

or replacement if necessary.


Cable, Proximity S/W ECBLS0170F -WK111/116 BKS B20-1-03 Balluff Switch, Proximity/PNP ESWPX0265F -SX11/15 BES516-325-E5-C-S4 Balluff


(Pin) Numbering

Spindle Tool Clamp X6.0

(STCP.M) -SX11

Input Module Slot 08

XJ412 (16) SX11

Spindle Tool Unclamp X6.5

(TUCL.M) -SX15

Input Module Slot 08

XJ412 (47) SX15

Spindle Tool Unclamp Y6.0

(STUN.R) -YV11

Output Module Slot 2

XJ401 (7) YV11

Spindle Tool Clamp (SX11)

Spindle Tool Unclamp (SX12)

0.8~1.2mm

Proximity Switch Dog

38



R841.2 SPTCLF Spindle Tool Clamp Flag

K15.1 K#A SP. Max RPM Group A (6K,8K,20K)

X6.0 STCP.M Spindle Tool Clamp

X6.5 TUCL.M Spindle Tool Unclamp



Y14.0 STUC.R Spindle Tool Unclamp

Y6.0 STUN.R Spindle Tool Unclamp

R5325.3 4SPTCLP Spindle Tool Clamp Command

R5325.4 4SPTUNC Spindle Tool Unclamp Command

R729.1 SPTCLP Spindle Tool Clamp Command

R729.2 SPTUNC Spindle Tool Unclamp Command

F0.6 SA Servo Ready

Spindle Tool Unclamp Alarm

Spindle Tool Clamp Flag

39


1.13 2017 Spindle Head Oil Overflow 1) Description

The oil level switch in the spindle head was tripped. 2) Cause of problem

① The lubricant level in the spindle head is excessive due to an error in the oil level switch. ② The oil level switch has an error or the wiring has a problem. ③ The recovery pump motor has an error.

3) Action

① Check the spindle oil drain pump. Check the drain line filter. ② Check the oil level switch, wiring cables and I/O module, and make repair or replacement

if necessary. ③ Check if the recovery pump motor synchronizes with Machine Ready properly.


Switch Float R37112 -SV11 W-105-A(300MM) A-RYUNG


(Pin) Numbering

Spindle Head Oil Overflow

X6.4 (SVOF.M)

-SV11 Input Module Slot :

08 XJ412 (31) SV11

Recovery Pump Motor

Y0.6 (REVM.R)

-QM73 Output Module : Slot

1 XJ400 (A8) KM73A

Spindle Head Oil Drain Pump

Oil Level Switch (SV11)

40



R442.6 TMB119 Spindle Head Oil Overflow Check

A2.0 2017 Spindle Head Oil Overflow


X6.4 SVOF.M Spindle Head Oil Overflow

Spindle Head Oil Overflow

Spindle Head Oil Overflow Check

41


1.14 2019 Machine Model Select Keep Relay Not Set 1) Description

The operator did not configure the Keep Relay (K0.0: HM-630, K0.1: HM-800, K0.2: HM-500) settings, or configured more than one setting.

2) Action

Check the Keep Relay settings and select a value appropriate to the machine.

Keep Relay K 0.0 K 0.1 K 0.2 K0.6

Machine HM-6300 HM-8000 HM-5000 HM1000



K0.0 KHM63 ACE-HM630 Machine



A2.2 2019 Machine Model Select Keep/R Not Set

Machine Model Select K/R Not Set

42


2. Cycle Alarm

2.1 2031 Must Be Returned To Ref. Point 1) Description

While not restoring the reference point manually, the operator just performed the cycle start in any of the MDI, AUTO, or TAPE mode.

2) Cause of problem

The reference point was not restored after the machine turned on. 3) Action

Restore the reference point manually. (X, Y, Z axis)


R841.4 HOMIAL Ref. Point Return ITLK Alarm

R644.4 MLKBMV B-Axis Moving At Machine Lock

R644.2 MLKF Machine Lock On Flag

A3.6 2031 Must Be Returned To Ref. Point

X33.7 ST.M Cycle Start

R635.7 AUT Auto Mode


Must Be Returned To Ref. Point

Ref. Point Return ITLK Alarm

43


2.2 2032 External Feed Hold (OP Push Button Switch) 1) Description

An error in the signal of the feed hold switch while the program is running (in AUTO mode) 2) Cause of problem

① The feed hold switch on the main OP is tripped. ② A short-circuit or defective part in the feed hold switch

3) Action

① If you have pressed the feed hold switch by necessity, release the switch to set off the alarm. Then, you can press the Cycle Start switch to resume running the program.

② Turn the feed hold switch on/off manually and check if it works properly. If not, take a necessary action.


X29.6 SP.M Cycle Stop


F0.5 STL Cycle Start

F0.4 SPL Feed Hold

R631.0 SPCLFH Spindle & Coolant At Feed Hold

R631.3 CYSTP Cycle Stop

A3.7 2032 External Feed Hold (OP Push Button SW)

Press the Feed Holder switch

Press the Cycle Start

switch

External Feed Hold (OP Push Button SW)

44


2.3 2033 Air Pressure down Alarm 1) Description

The air pressure switch is tripped because the air pressure falls below the specified value. 2) Cause of problem

① The factory-supplied air pressure falls below the standard (4kg). ② The air pressure switch or any of its parts is defective.

3) Action

① Increase the factory-supplied air pressure to more than 5kg/㎠. Check the air pressure measurement displayed on the gauge of the air service unit (located on the rear panel), and if it's below 4kg/㎠, turn the air pressure handle to the right. If the gauge is no further increased, this indicates the current air pressure is not appropriate. Check the factory-supplied air pressure.

② Check the air pressure switch, wiring and I/O module if there is no error. And make repair or replacement if necessary.


(Pin) Numbering

Air Pressure Check X3.1

(APRS.M) -SP12 Input Module Slot : 07 XJ411 (28) SP12

Pallet Air For Table Y7.4

(PAIR.R) -KAR65

Output Module Slot : 4

XJ401 (19) YV65

Air Pressure Switch (SP12)

Air Supply Unit

45



X3.1 APRS.M Main Air Pressure Check

R440.7 TMB104 Air Pressure Down Check D-Time

A4.0 2033 Air Pressure Down Alarm


K5.1 KAPRS Air Pressure Switch Not Used

F0.6 SA Servo Ready

Y7.4 PAIR.R Pallet Air Table

Y15.4 PAIT.R Pallet Air For Table

Air Pressure Down Alarm

Air Pressure Down Check D-Time

46


2.4 2034 Coolant & Lub. Pump Overload 1) Description

An excessive electric current is detected in the coolant or lubricant pump motor. 2) Cause of problem

① The coolant or lubricant pump motor, or the power cable is burnt out. ② The circuit breaker that detects the excessive current is overloaded or defective itself.

3) Action

① Check the coolant or lubricant pump motor, or the power cable, and repair or replace a defective one if found.

② Check the circuit breaker for the load settings and make correction if necessary. If the circuit breaker itself has an error, replace it with a new one.

Breaker Application Load Specification

QM10 Spindle & Y-Axis Servo Fan Motor 1.5A

QM41 Flood Coolant Pump Motor 8.0A

QM42 TSC Coolant Pump Motor 8.0A (1.5Kw), 17.0A (3.7Kw)

QM43 Shower Coolant Pump Motor 8.0A

QM44 Flushing Coolant Pump Motor 8.0A

QM45 Coolant Gun Pump Motor 2.5A

QM73 Spindle Oil Recovery Pump Motor 2.5A

QM76 Oil Mist Collector Motor 7.8A (10.2A)

QM81 ATC Motor Control With Invert 3.3A

QM85 Tool Magazine Servo Amp 10.1A

Part Name Part No. Symbol Spec.

Breaker, Motor Circuit ENFBX0255R QM10 3RV1011-1AA10(1.1-1.6A)

Breaker, Auxiliary ENFBX0290R QM10,41,42,43, QM44,45,76,81,85

3RV1901-1F(2NO)

Breaker, Motor Circuit ENFBX0259R QM41,42,76 3RV1011-1JA10 (7-10A)

Breaker, Motor Circuit ENFBX0256R QM44,73 3RV1011-1CA10 (1.8-2.5A)

Breaker, Motor Circuit ENFBX0261R QM42,45, 3RV1021-4BA10(14-20A)

Breaker, Motor Circuit ENFBX0258R QM42/43 3RV1011-1GA10(4.5-6.3A)


(Pin) Numbering

Motor Overload X2.2

(MOL.M) - Input Module : Slot 07 XJ411 (48) MOL

47



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

A4.1 2034 Coolant & Lub. Pump Overload


M -XJ411:

X2.2

48

MOL

A4


C20A: 40, 41 49, 50

MOL

MOLA

a1

a2 -QM10 Spd.& Y-Servo Fan

Motor

A3

A4

MOLC

-QM42 T-S-C Coolant Pump Motor

A3

A4

MOLF

-QM73 Spd. Oil Recovery Pump Motor

A3

A4

MOLI

-QM81 ATC Motor Control With Invert

A3

A4

MOLD

-QM43 Shower Coolant Pump Motor

A3

A4

MOLE

-QM44 Flushing Coolant Pump Motor

A3

A4

MOLG

-QM45 Coolant Gun Pump Motor

A3

A4

MOLH

-QM76 Oil Mist Collector Motor

A3

A4

MOLJ

-QM74 Hyd. Unit Heater

A3

A4

MOLK

-QM91 APC1 Control Motor (HM1000)

A3

A4

MOLL

-QM92 APC2 Control Motor (HM1000)

A3

A4

MOLM

-QMA1

A3

A4

-QM85 Tool Magazine Servo Amp

MOLB

A3

A4 -QM41 Flood Coolant Pump

Motor

Coolant & Lub. Motor Overload

48


49


2.5 2035 External Coolant Unit Alarm 1) Description

An error occurred in an external coolant unit. 2) Cause of problem

① The coolant pressure of the TSC unit has decreased, or the filter of the TSC filter unit is clogged.

② The pressure switch has an error or the wiring has a problem. 3) Action

① Take necessary measures to solve the problems of both the TSC unit and the filter. ② Check the pressure switch and the wiring, and repair or replace a defective one if

necessary.


(Pin) Numbering

Coolant Pressure X3.2

(TSCA.M) -SP15 Input Module Slot 07 XJ411 (44) SP15

T.S.C Filter Status X3.3

(FILT.R) -SP16 Input Module Slot 07 XJ411 (11) SP16

External Coolant Unit Alarm

High Press. Coolant Press. Check D-Time

50



X3.2 TSCA.M T.S.C Unit AL / Coolant Over Flow

F0.6 SA Servo Ready

K9.2 KHTC.M Tank Type High Press. TSC Used

Y0.2 CLTM.R Thru-The-Tool / Spindle Coolant

R628.5 TMB46 High Press. Check D-Time

A4.2 2035 External Coolant Unit Alarm


K12.7 KCO&MD Cool. Dual high TSC or Middle TSC

X3.3 FILT.M TSC Filter Check OK

R662.1 TFSCOF TSC Pressure S/W Checking Off

51


52


2.6 2036 Coolant Level Switch Low 1) Description

The separation chip conveyor or drum filter chip conveyor triggers the Coolant Level alarm. 2) Cause of problem

① The coolant tank runs out of coolant. ② The Level switch has an error or the wiring has a problem.

3) Action

① Refill the coolant tank with coolant. ② Check the level switch and the wiring, and repair or replace a defective one if necessary.


(Pin) Numbering

Coolant Level Alarm

X3.7 (COL.M)

M250 Input Module : Slot 07 XJ411 (42) M250


X3.7 COL.M Coolant Level Alarm

F0.6 SA Servo Ready

A4.3 2036 Coolant Level Switch Low


Coolant Level Switch Low

53


2.7 2037 Power Back Up Module Error 1) Description

A device featuring the optional power backup module has an error in the main power supply unit.

2) Cause of problem

① Power failure in the workshop ② An error in the power backup module

3) Action

① check the main power supply unit of the workshop. ② If the unit has no error but the problem persists, check the power backup module and

repair or replace it if necessary.


(Pin) Numbering

Power Back-Up Module On Check

X2.6 (PFM.M)

Input Module : Slot 4 -XCX16 (2) PFM


X2.6 PFM.M Power Failure Detection

F1.7 MA NC Ready

F0.6 SA Servo Ready

K2.1 KPFM Used Power Back-Up Module

A4.4 2037 Power Back-Up Power Failure Alarm

Power Back Up Module Error

54


55


2.8 2040 Operator’s Door Open Alarm 1) Description

The door in the main OP side is open. 2) Cause of problem

① The door in the operator's side is open. ② The door itself has an error or the wiring has a problem.

3) Action

① Close the door. ② Check the operator's side safety switch as well as the wiring, and repair or replace a

defective one if necessary.


(Pin) Numbering

Operator Side Door Interlock

X4.3 (OSDI.M)

-13A Input Module : Slot

07 XJ411 (6) SODI



A4.7 2040 Operator’s Door Open Alarm




A25.7 2208 Machine In Service Mode

Operator’s Door Open Alarm

56


2.9 2049 Spindle Speed Arrival Alarm 1) Description

After the spindle rotation command (M03, M04) was instructed, the spindle has failed to reach the instructed revolutions within 20 seconds.

2) Cause of problem

① An error found in parameter settings related to the spindle ② An error found in the signal from the main spindle drive unit ③ An error found in the signal from the position coder

3) Action

① Refer to the parameter sheet that comes with the product and check the spindle-related parameters (N3700∼N4175). Take a necessary measure if an error is found.

② Check the alarm number that is displayed on the main spindle drive unit of the electric cabinet, and take a necessary measure according to the alarm number. ☞ Refer to "Troubleshooting by the spindle amplifier alarm" in the appendix.

③ Set the parameter (N4001/N4002) to ignore the position coder settings (“1”“0”), and rotate the spindle to check if the position coder is set properly. If not, take an appropriate action.


R626.0 TMB25 Spindle Speed Arrival Check Time

A6.0 2049 Spindle Speed Arrival Alarm


A6.1 2050 Spindle Rotation Malfunction

G70.5 SFRA Spindle Forward

G70.4 SRVA Spindle Reverse

R668.0 SARINT Spindle Speed Arrival Interlock

R658.2 SGHON Gear Shift On

Spindle Speed Arrival Alarm

Spindle Speed Arrival Check Time

57


(Note) Spindle-related NC Parameter Table

(TEC:TECNOMACH DIA:U.S.A)

03623 X 1 04832 S1 0Y 1 04900 S1 00000000Z 1 04911 S1 0B 0 04912 S1 05 0 04913 S1 0

03624 X 35.0 04914 S1 0Y 50.0 04950 S1 00000000Z 50.0 04959 X 00000000B 0.0 Y 000000005 0.0 Z 00000000

? SPINDLE CONTROL [4.18] B 0000000003700 L1 00100000 5 0000000003702 L1 00000100 04960 S1 0

04961 S1 004962 S1 0

03705 L1 01001010 04963 S1 0.003708 L1 00010001 04964 S1 003716 S1 0000000103717 S1 1 04970 S1 003720 S1 4096 04971 S1 003729 S1 00000001 04972 S1 003730 S1 (#) 04973 S1 0

04974 S1 003731 S1 (#) 04976 S1 0

04977 S1 003736 L1 4095 04978 S1 003740 L1 200 04979 S1 0

05006 0000000103741 S1 50003742 S1 2000 ? CANNED CYCLES [4.20]03743 S1 6000 05101 L1 1000000103744 S1 6000 ? Canned Cycle for Drilling (1/2) [4.20.1]03751 L1 501 05114 L1 M0.1

05115 L1 M1.003752 L1 2001 ? RIGID TAPPING [4.21]

05200 L1 0000100003761 L1 271 05210 L1 29

05241 S1 27003762 L1 1151

05242 S1 115003771 L1 50

05243 S1 360003772 S1 600004800 00000000 05261 S1 150004801 S1 0000000004810 S1 0 05262 S1 1500

04811 S1 0 05263 S1 1500

04821 S1 0 05271 S1 1500

04826 S1 0 05272 S1 150004831 S1 0

EDITION DATE PAGEA01 09.02.25 8484848484848

Error pulse difference between the two spindles forturning on the spindle phase synchronizationcompletion signal

Time constant for acceleration/deceleration in rigidtapping for each gear (2nd gear) ? The Value dependson their SP. Spec.

Error pulse difference between the two spindles forissuing an alarm on spindle synchronization

Time constant for acceleration/deceleration in rigidtapping for each gear (3rd gear) ? The Value dependson their SP. Spec.

Master axis of each slave spindleunder simple synchronous spindle

Time constant for acceleration/deceleration in rigidtapping extraction (first) ? The Value depends on theirSP. Spec.Time constant for acceleration/deceleration in rigidtapping extraction (second) ? The Value depends ontheir SP. Spec.Master axis of each slave spindle

under spindle synchronous control

Spindle Motor Speed W hen Switching Fromgear 1 ToGear 2, ():Optionto Gear 2 During Tapping, ():Option

Return value of high-speed peck drilling cycle

Clearance value in a peck drilling cycle

Do. From Gear 2 To Gear 3, ():Optionto Gear 2 DuringTapping, ():Option():Option 3Bit(Sig) For Rigid Tapping Of Spindle Gear Shift

Time constant for acceleration/deceleration in rigidtapping for each gear(1st gear) ? The Value depends ontheir SP. Spec.

Drift compensation value (fourth stage)

If a T code is specified in a block where G50, G04, or G10isspecified:1: The alarm (PS0245) is issued.

#2 G83 and G87 1: Specify a peck drilling cycle

Maximum spindle speed for gear 4

Maximum spindle speed for gear 1Maximum spindle speed for gear 2Maximum spindle speed for gear 3

Time elapsed prior to checking thespindle speed arrival signal

Compensation value for the offsetvoltage of spindle speed analogSpindle Motor Maximum Clamp

Position gain multiplier (fourth stage)

Drift compensation value (first stage)

Drift compensation value (second stage)

Drift compensation value (third stage)

Number of position coder pulses Position gain multiplier (first stage)

Position gain multiplier (second stage)

Data used for adjusting the gain ofthe analog output of spindle speed

Position gain multiplier (third stage)

Number of M codes for specifying aspindle positioning angle

W hether the stop position external setting-type spindleorientation function is available(Bit 2: First spindle. Bit 3: Second spindle.)

M code specifying the spindle orientation

M code releasing the spindle positioning mode

M code for specifying a spindle positioning angle

Index / Rotary TableInterval between pitch errorcompensation positions for eachaxis

Index / Rotary TableMagnification for pitch errorcompensation for each axis

HM1000 (1 PATH) NC PARAMETER NC UNIT FS31iA

NO. DATA REMARKS NO. DATA REMARKS

Maximum spindle speed in rigid tapping (3rd gear) ?The Value depends on their SP. Spec.Maximum spindle speed

Spindle Speed W hen Switching From Gear 1To Gear 2During Tapping, ():Option():Option Maximum spindle speed in rigid tapping (1st gear) ?

The Value depends on their SP. Spec.

Motor number to each spindle Position gain

Rigid tapping mode specification M code

Do. From Gear 2 To Gear 3 DuringTapping,():Option Maximum spindle speed in rigid tapping (2nd gear) ?

The Value depends on their SP. Spec.Minimum spindle speed in constantsurface speed control mode (G96)

58



04042 S1 30 04076 S1 33

04043 S1 30 04077 S1 (#)04080 S1 80

04044 S1 3004081 S1 20

04045 S1 30 04082 S1 1004083 S1 30

04046 S1 30 04084 S1 3004085 S1 41

04047 S1 3004086 S1 100

04048 S1 10 04087 S1 11504088 S1 75

04049 S1 1004089 S1 200

04050 S1 1004051 S1 10 04090 S1 9004052 S1 90 04091 S1 100

04053 S1 90 04092 S1 100

04054 S1 50 04094 S1 0

04055 S1 50 04095 S1 004096 S1 0

04056 S1 1200 04097 S1 004057 S1 300 04098 S1 004058 S1 10004059 S1 100 04099 S1 30004060 S1 500 04100 S1 150004061 S1 500 04101 S1 9504062 S1 500 04102 S1 175204063 S1 800 04103 S1 004064 S1 100 04104 S1 450004065 S1 2500 04106 S1 4500

04108 S1 004066 S1 2500

04109 S1 2504067 S1 2500

04110 S1 92404068 S1 2515 04111 S1 252

04112 S1 20004069 S1 300004070 S1 3000 04113 S1 290

04114 S1 004071 S1 3000

04115 S1 10004072 S1 3000 04116 S1 556404073 S1 0 04117 S1 2953004074 S1 0

04118 S1 11004075 S1 10

PAGEA01 09.02.25 9848484848485

EDITION DATE

Position gain on Cs contouring control (Low) ⓐ Motor leakage constantGrid shift on servo mode ⓐ Regular-time voltage compensation coefficient for

high-speed zone/regular-time motor voltage coefficientReference position return speed onCs contouring control/servo mode ⓐ Acceleration-time voltage compensation coefficient

for high-speed zone/acceleration-time motor voltagecoefficientDetection level for orientation completion signal

Position gain on servo mode/spindlesynchronization control (Low)

ⓐ Secondary current coefficientⓐ Criterion level for saturation related to the voltagecommand/PW M command clamp valuePosition gain on Cs contouring control (High)

Position gain on Cs contouringcontrol (Medium High)

ⓐ Slip constantⓐ Slip compensation coefficient for a high-speedzone/slip compensation coefficient at decelerationPosition gain on Cs contouring

control (Medium Low) ⓐ PW M command clamp value at deceleration

Ordinary orientation: Rate of change ⓐ Current loop proportional gainPosition gain on servo mode/spindlesynchronization control (High)

ⓐ Current loop integral gainⓐ Velocity at which the current loopintegral gain is zeroPosition gain on servo mode/spindle

synchronization control (Medium ⓐ Filter time constant for processing saturation relatedto the voltage commandPosition gain on servo mode/spindle

synchronization control (Medium ⓐ Current conversion constant

Position gain on orientation (Medium High) ⓐ Output limit for motor output specifications

Position gain on orientation (Medium Low) ⓐ Excitation voltage saturation speed at no-load

Position gain on orientation (Low) ⓐ Base speed limit ratio

Gear ratio (Medium High) Maximum speed for positionfeedback signal detectionGear ratio (Medium Low)

Gear ratio (Low) Delay time for motor excitationPosition gain on orientation (High) ⓐ Base speed of motor output specifications

Velocity loop integral gain on Cscontouring control (High)

Disturbance torque compensationconstant (acceleration feedback

Velocity loop integral gain on Cscontouring control (Low)

Adjusted output voltage of speedometer

Adjusted output voltage of loadGear ratio (High) Feedback gain of spindle speed

Velocity loop integral gain on orientation (Low) Overload detection levelVelocity loop integral gain on servo mode/spindlesynchronization control (High)

Rate of change in position gain during referenceposition return on servo mode

Velocity loop integral gain on servo mode/spindlesynchronization control (Low)

Rate of change in position gain during referenceposition return on Cs contouring control

Velocity loop integral gain on velocitycontrol mode (High)

Overspeed levelLevel for detecting excess velocitydeviation when motor is restrainedⓐ Velocity loop integral gain on

velocity control mode (Low) Level for detecting excess velocitydeviation when motor rotatesVelocity loop integral gain on orientation (High)

Velocity loop proportional gain onservo mode (Low)

Setting of acceleration/deceleration time

ⓐ Motor voltage on velocity control mode

Velocity loop proportional gain on Cscontouring control (High)

Motor voltage on orientationMotor voltage on servomode/spindle synchronization

Velocity loop proportional gain on Cscontouring control (Low) Motor voltage on Cs contouring control

Velocity loop proportional gain onorientation (High)

Ordinary orientation: Motor speedlimit value on orientation

Velocity loop proportional gain onorientation (Low)

Orientation stop position shiftⓐ Regenerative power limit for high-speed zone/regenerative power limitVelocity loop proportional gain on

servo mode (High) Delay time until motor power is cut off



59



04119 S1 29 04330 S1 0

04120 S1 0 04334 S1 004336 S1 0

04121 S1 504340 S1 0

04122 S1 004123 S1 30 04341 S1 004127 S1 142 04344 S1 0

04345 S1 004128 S1 105 04346 S1 0

04351 S1 004129 S1 0 04352 S1 0000000004130 S1 25700 04353 S1 00000000

04355 S1 004131 S1 0 04356 S1 0

04133 S1 320 04357 S1 004134 S1 13004135 S1 0 04358 S1 0

04160 S1 0 04361 S1 004162 S1 0 04362 S1 0

04363 S1 004163 S1 0 04364 S1 0

04369 S1 004169 S1 004170 S1 0 04384 S1 004171 S1 0

04385 S1 004172 S1 0

04386 S1 004173 S1 0 04387 S1 0

04388 S1 004174 S1 0 04391 S1 0

04215 S1 0 04392 S1 0

04224 S1 0 04393 S1 004225 S1 0 04394 S1 0000000004248 S1 0 04395 S1 0000000004249 S1 0 04396 S1 0000000004250 S1 0 04397 S1 0000000004320 S1 0 04398 S1 0000000004321 S1 0 04399 S1 00000000

04400 S1 0000000004322 S1 0 04401 S1 00000000

04402 S1 0000000004323 S1 0 04403 S1 0000000004326 S1 0 04406 S1 0

04328 S1 0 04408 S1 004409 S1 0

PAGEA01 09.02.25 9848484848485

EDITION DATE

Motor acceleration at deceleration time (Low)

Acceleration limitation start speed atdeceleration time (High)

Acceleration/deceleration time constant at return to thereference position in Cs contouring control

Command multiplication for spindleorientation by position coder

Fine acceleration/deceleration time constant

Feed-forward timing adjustment coefficient

Motor acceleration at decelerationtime (Medium High)Motor acceleration at decelerationtime (Medium Low)

Spindle load monitor observer gain 1Spindle load monitor observer gain 2Motor acceleration at deceleration time (High)

Maximum amplitude in dual position feedback Resonance elimination filter 1 : damping

Dual position feedback zero w idthSpindle load monitor torque constant

Denominator of arbitrary gear ratiobetween motor sensor and spindle

Spindle EGB : synchronization ratio numerator

Spindle EGB : synchronization ratio denominator

Numerator of arbitrary gear ratiobetween motor sensor and spindle

Resonance elimination filter 1 :attenuation center frequency

Primary delay time constant in dualposition feedback

Resonance elimination filter 1 :attenuation bandwidth

Current overload alarm detection level Spindle EGB : Maximum acceleration/deceleration valuein automatic phase matchingDenominator of arbitrary gear ratio between motor

sensor and spindle (High) Spindle EGB : time constant for free-running phase matchingNumerator of arbitrary gear ratio

between motor sensor and spindle Spindle EGB : master side detector pulse count

Integral gain of velocity loop during cutting feed on Cscontouring control mode (High)

Load meter compensation 1Load meter compensation 2

Integral gain of velocity loop during cutting feed on Cscontouring control mode (Low)

Load meter compensation 3Spindle synchronization orientationdeceleration coefficientⓐ Temperature monitoring time constant

Motor model code Spindle sensor signal amplituderatio compensationⓐ Motor overheat detect level (2-word)

Grid shift during Cs contouringcontrol mode l (2-word)

Spindle sensor signal phasedifference compensation

Hysteresis of speed detection level Number of spindle sensor arbitrary teeth

ⓐ Secondary current coefficient for rigid tappingⓐ Current loop proportional gain speedcoefficient/current phase delay compensationcoefficient Motor sensor signal amplitude ratio compensation

Time constant for velocity detectingfilter (on Cs contouring control)

Motor sensor signal phasedifference compensation

Short-time overload detection time Unexpected disturbance torque detection level

ⓐ Value displayed on load meter atmaximum output

Advanced preview feed-forward coefficient

Spindle motor speed command detection levelⓐ Compensation coefficient between the specificationand TRUE base/maximum torque curve compensationcoefficient

Incomplete integration factorCurrent detection offset

ⓐ Deceleration-time excitation current change timeconstant/excitation current change time constant

Acceleration limitation start speed atdeceleration time (Low)

ⓐ Dead-band rectangular wavecomponent zero voltage/dead-band

Number of motor sensor arbitrary teeth

Switching point used for an acceleration/decelerationtime constant used for spindle synchronization controlTime constant for changing the

torque (TCMD filter time constant) Bell-shaped acceleration/deceleration time constantduring spindle synchronizationTime constant for velocity detecting filter



60



04410 S1 0

04411 S1 0

04412 S1 0

04413 S1 0

04414 S1 0

04415 S1 0

04416 S1 0

04417 S1 0

04418 S1 004419 S1 0

04420 S1 0

04421 S1 004422 S1 0

04423 S1 0

04424 S1 004498 S1 0

04499 S1 0

04500 S1 0

04501 S1 0

04502 S1 0

04503 S1 0

04508 S1 0

PAGEA01 09.02.25 9848484848485

EDITION DATE

Denominator of arbitrary gear ratio between spindlesensor and spindle (Low)

Numerator of arbitrary gear ratio between spindle sensorand spindle (Low)

Rate of change in acceleration at soft start/stop

Resonance elimination filter 3 :attenuation bandwidthResonance elimination filter 3 : damping

Spindle EGB master side : numerator of arbitrary gearratio between motor sensor and spindle

Denominator of arbitrary gear ratio between spindlesensor and spindle (High)

Numerator of arbitrary gear ratio between spindle sensorand spindle (High)

Resonance elimination filter 4 :attenuation center frequencyResonance elimination filter 4 :attenuation bandwidthResonance elimination filter 4 : damping

Spindle EGB master side : denominator of arbitrary gearratio between motor sensor and spindle

Disturbance input function :disturbance torque commandDisturbance input function : motorspeed command for measurementResonance elimination filter 2 :attenuation center frequencyResonance elimination filter 2 :attenuation bandwidthResonance elimination filter 2 : damping

Resonance elimination filter 3 :attenuation center frequency

Disturbance input function :measurement frequency intervalDisturbance input function : numberof measurements per frequency

Disturbance input function :measurement start frequencyDisturbance input function :measurement end frequency



61


(Note) To change the parameter settings

(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 soft key bar will be displayed at the bottom.

(3) Press the [SETTING] button. ▪ The Setting screen appears where the cursor is positioned

at the “PARAMETER WRITE” item 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.

62



(6) Press the 〔PARAMETER〕 key in the soft key bar.

▪ You will see the Parameter setting screen.

☞ About the soft key bar Find a desired parameter number.

Ex) If calling parameter #4175: Enter the number of "4175" and press the [NO.SRH］soft key in the key bar to move to the Parameter N4175 screen with the cursor positioned at the number.

Used to turn ON (1) the BIT-format parameter. Ex) Press this to turn ON (1) only the highlighted BIT-format parameters.

Used to turn OFF (0) the BIT-format parameter. Ex) Press this to turn OFF (0) only the highlighted BIT-format parameters.

Used to increase or decrease a word-format parameter by adding or subtracting data. Ex) If you want to add to or subtract from the existing data included in the

parameter, enter a data value to add or subtract (In subtraction, add "-" in front of the data value.) and press this button.

Used to enter a parameter value in the word format. Ex) Regardless of the existing data, enter a data value and press this button.

The data value will be entered immediately and properly. (7) Select a navigation button that is suitable to your needs, and use it to adjust the value as

necessary. (8) When done, move back to “SETTING” and turn off “PARAMETER WRITE”(“1” ‘0”).

Then, press the “RESET” key to release the alarm.

63


2.10 2050 Spindle Rotation Malfunction 1) Description

The spindle rotation command is instructed under the condition where the spindle is prohibited from rotating.

2) Cause of problem

After the machine starts initially, the rotation command is instructed with no revolution (S-code command) specified.

3) Action

Instruct the spindle rotation command after instructing S-Code.

Spindle Rotation Malfunction

Initial S-Function On

64



X35.6 SROT.M Manual Spindle Rotation

R654.2 SBY Spindle Stand-By

R649.6 DCL Operator Door Close Confirm

R654.1 SBYA Spindle Stand-By Aux

R635.6 MAN Manual Mode

F0.6 SA Servo Ready

R600.0 M03 Spindle Forward (CW) Rotation

R600.1 M04 Spindle Reverse (CCW) Rotation

R659.1 SFON Initial S-Function On

R626.1 TMB26 Spindle Rotation Overtime

R653.0 MEND M-Function End

R1649.2 S3601AL Command Error Over S3600

K16.7 KMTM150 Used Variable Orientation Func

Gear Shift On

Spindle Gear Range Low

Spindle Gear Range Middle

Spindle Gear Range High

65



R658.2 GSHON Gear Shift On

A6.1 2050 Spindle Rotation Malfunction


R603.2 M29 Rigid Tapping

F7.2 SF S Function Strobe

R1649.0 M150SF Multi M150 And SF Command

R1649.1 M150CD Multi Only M150 Command

R657.0 SGL Spindle Gear Low


R657.1 SGM Spindle Gear Middle


R657.2 SGH Spindle Gear High



Y6.3 GRM.R Spindle Gear Middle

K0.6 KHM1000 If HM1000, Set to 1

Y14.3 SGRM.R Spindle Gear Middle



Y14.4 SGRH.R Spindle Gear High


66


2.11 2051 Spindle Orientation Overtime 1) Description

Since the spindle orientation command was instructed in manual or auto mode, no completion signal is output within 15 seconds.

2) Cause of problem

① An error in parameter settings related to the spindle orientation ② An error in the position coder or defect in feedback cable

3) Action

① Check the parameters (N4042 ~ N4080) related to spindle orientation if they are set properly. If not, change the settings as appropriate.

② Check the safety switch, and wiring between sensor and spindle head terminal box, and between terminal box and spindle drive unit of the electric cabinet, and make repair or replacement if you encounter a problem.


R625.5 TMB22 Orientation Check Time

A6.2 2051 Spindle Orientation Overtime


R602.0 M19 Spindle Orientation

R618.2 M150 Spindle Multi Orientation

R653.0 MEND M-Function End

Spindle Orientation Overtime

Orientation Check Time

67



G70.6 ORCMA Orientation Command

X4.2 OSDO.M Machine Door Unlock By Key Switch

R727.2 MORC Man Spindle Orientation Command

F45.7 ORARA Spindle Orientation Complete

68



04042 S1 30 04076 S1 33

04043 S1 30 04077 S1 (#)04080 S1 80

04044 S1 3004081 S1 20

04045 S1 30 04082 S1 1004083 S1 30

04046 S1 30 04084 S1 3004085 S1 41

04047 S1 3004086 S1 100

04048 S1 10 04087 S1 11504088 S1 75

04049 S1 1004089 S1 200

04050 S1 1004051 S1 10 04090 S1 9004052 S1 90 04091 S1 100

04053 S1 90 04092 S1 100

04054 S1 50 04094 S1 0

04055 S1 50 04095 S1 004096 S1 0

04056 S1 1200 04097 S1 004057 S1 300 04098 S1 004058 S1 10004059 S1 100 04099 S1 30004060 S1 500 04100 S1 150004061 S1 500 04101 S1 9504062 S1 500 04102 S1 175204063 S1 800 04103 S1 004064 S1 100 04104 S1 450004065 S1 2500 04106 S1 4500

04108 S1 004066 S1 2500

04109 S1 2504067 S1 2500

04110 S1 92404068 S1 2515 04111 S1 252

04112 S1 20004069 S1 300004070 S1 3000 04113 S1 290

04114 S1 004071 S1 3000

04115 S1 10004072 S1 3000 04116 S1 556404073 S1 0 04117 S1 2953004074 S1 0

04118 S1 11004075 S1 10

PAGEA01 09.02.25 9848484848485

EDITION DATE

Position gain on Cs contouring control (Low) ⓐ Motor leakage constantGrid shift on servo mode ⓐ Regular-time voltage compensation coefficient for

high-speed zone/regular-time motor voltage coefficientReference position return speed onCs contouring control/servo mode ⓐ Acceleration-time voltage compensation coefficient

for high-speed zone/acceleration-time motor voltagecoefficientDetection level for orientation completion signal

Position gain on servo mode/spindlesynchronization control (Low)

ⓐ Secondary current coefficientⓐ Criterion level for saturation related to the voltagecommand/PW M command clamp valuePosition gain on Cs contouring control (High)

Position gain on Cs contouringcontrol (Medium High)

ⓐ Slip constantⓐ Slip compensation coefficient for a high-speedzone/slip compensation coefficient at decelerationPosition gain on Cs contouring

control (Medium Low) ⓐ PW M command clamp value at deceleration

Ordinary orientation: Rate of change ⓐ Current loop proportional gainPosition gain on servo mode/spindlesynchronization control (High)

ⓐ Current loop integral gainⓐ Velocity at which the current loopintegral gain is zeroPosition gain on servo mode/spindle

synchronization control (Medium ⓐ Filter time constant for processing saturation relatedto the voltage commandPosition gain on servo mode/spindle

synchronization control (Medium ⓐ Current conversion constant

Position gain on orientation (Medium High) ⓐ Output limit for motor output specifications

Position gain on orientation (Medium Low) ⓐ Excitation voltage saturation speed at no-load

Position gain on orientation (Low) ⓐ Base speed limit ratio

Gear ratio (Medium High) Maximum speed for positionfeedback signal detectionGear ratio (Medium Low)

Gear ratio (Low) Delay time for motor excitationPosition gain on orientation (High) ⓐ Base speed of motor output specifications

Velocity loop integral gain on Cscontouring control (High)

Disturbance torque compensationconstant (acceleration feedback

Velocity loop integral gain on Cscontouring control (Low)

Adjusted output voltage of speedometer

Adjusted output voltage of loadGear ratio (High) Feedback gain of spindle speed

Velocity loop integral gain on orientation (Low) Overload detection levelVelocity loop integral gain on servo mode/spindlesynchronization control (High)

Rate of change in position gain during referenceposition return on servo mode

Velocity loop integral gain on servo mode/spindlesynchronization control (Low)

Rate of change in position gain during referenceposition return on Cs contouring control

Velocity loop integral gain on velocitycontrol mode (High)

Overspeed levelLevel for detecting excess velocitydeviation when motor is restrainedⓐ Velocity loop integral gain on

velocity control mode (Low) Level for detecting excess velocitydeviation when motor rotatesVelocity loop integral gain on orientation (High)

Velocity loop proportional gain onservo mode (Low)

Setting of acceleration/deceleration time

ⓐ Motor voltage on velocity control mode

Velocity loop proportional gain on Cscontouring control (High)

Motor voltage on orientationMotor voltage on servomode/spindle synchronization

Velocity loop proportional gain on Cscontouring control (Low) Motor voltage on Cs contouring control

Velocity loop proportional gain onorientation (High)

Ordinary orientation: Motor speedlimit value on orientation

Velocity loop proportional gain onorientation (Low)

Orientation stop position shiftⓐ Regenerative power limit for high-speed zone/regenerative power limitVelocity loop proportional gain on

servo mode (High) Delay time until motor power is cut off



69


2.12 2055 Spindle Tool Clamp/Unclamp Overtime Alarm 1) Description

It has passed 10 seconds since the position sensor switch of the spindle tool unclamp cylinder did not match with the applicable instruction.

2) Cause of problem

① An error in adjusting the position sensor switch ② An error in the wiring or any of its component parts

3) Action

① An error in adjusting the position sensor switch Check the sensor indicator displayed on the proximity switch (located in the rear of the spindle tool unclamping cylinder) and correct it according to the indicator.

② An error in the wiring or any of its component parts Check the proximity switch, the wiring from the proximity switch to the electric cabinet as well as the I/O module if there is a problem. Repair or replace the defective part if necessary.


Cable, Proximity/Switch ECBLS0170T - WWAKRT4-2 Turck

Switch, Proximity/PNP ESWPX0265F -SX11/15 BES516-325-E5-C-S4 Balluff


(Pin) Numbering

Spindle Tool Clamp X6.0

(TCL.M) -SX11 Input Module : Slot 08 XJ412 (16) SX11

Spindle Tool Unclamp

X6.5 (TUCL.M)

-SX15 Input Module : Slot 08 XJ412 (47) SX15

Spindle Tool Unclamp

Y14.0 (STUC.R)

-YV11 Output Module : Slot 05 XA107 (10) YV11

70



R626.5 TMB30 Spindle Clamp / Unclamp Check Time

A6.6 2055 Spindle Tool CL / UNCL Overtime Alarm



Spindle Tool CL/UNC Overtime Alarm

Spindle Tool CL/UNC Overtime Alarm





71



Y14.0 STUC.R Spindle Tool Unclamp

Y6.0 STUN.R Spindle Tool Unclamp

X6.0 STCP.M Spindle Tool Clamp

K15.1 K#A Spindle Max. RPM Group A(6K,8K,20K)

X6.5 TUCL.M Spindle Tool Unclamp

F0.6 SA Servo Ready

72


2.13 2056 Gear Shifting Overtime 1) Description

The gear shifting is not complete within 40 seconds after the command was instructed. 2) Cause of problem

① An error found in the solenoid valve for shifting the main spindle gear, or short-circuit of or error in the gear-shift switch

② An error found in the hydraulic cylinder that shifts the gears, or the shift gear itself is defective.

3) Action

① Check the solenoid valve, limit switch, wiring cables and I/O module, and make repair or replacement if you encounter a problem.

② Turn off the machine and loosen the tube connector that is connected to the cylinder. Move the cylinder piston up or down to check if it works normally. If you feel it's clamped somewhere, repair it as necessary.

Part Name Part No. Symbol Spec.

Switch, Limit ESWLM0018A -SL12,13,14 WLD2

Solenoid Valve R30699A -YV14 K-DG4V-3-2A-M-U7-H-DI

Solenoid Valve R30691A -YV15,16 K-DG4V-3-6C-M-U7-H-DI


(Pin) Numbering


(GSL.M) -SL12

Input Module Slot : 08

XJ412 (32) SL12


(GSM.M) -SL13


XJ412 (48) SL13


(GSH.M) -SL14 Input Module Slot :08 XJ412 (15) SL14


(GRM.R) -YV16 Output Module Slot 2 XJ401 (38) KAR54


(GRM.R) -YV14 Output Module Slot 2 XJ401 (6) KAR52


(GRH.R) -YV15 Output Module Slot 2 XJ401 (23) KAR53

73



R625.7 TMB24 Gear Shift Overtime A6.7 2056 Gear Shift Overtime Alarm


R658.2 GSHON Gear Shift On R657.0 SGL Spindle Gear Low


Gear Shift O.K Check Time

Gear Shift Overtime

Gear Shift On

Spindle Gear Range Low

Spindle Gear Range Middle

Spindle Gear Range High

74



R657.1 SGM Spindle Gear Middle

R657.5 SGRM Spindle Gear Range Middle R657.2 SGH Spindle Gear High

R657.6 SGRH Spindle Gear Range High X6.1 GSL.M Spindle Gear Low








* Hydraulic Flow Diagram of Spindle Head

Cylinder

Piston

SL12 SL13 SL14

YV14

YV15 YV16

P T

Tool Unclamp

P T

A B

P T

A B

P T


Tool Clamp

Gear Shifter

L M H

Φ1.0 Φ1.2 Φ1.0

C D E

C D E

75


2.14 2058 Tool No. Select Keep Relay Not Set 1) Description

An error in the Keep Relay setting that specifies the maximum number of tool pots. 2) Cause of problem

The Keep Relay setting that enables you to select the maximum number of tool pots is not specified, or more than one setting is found.

3) Action

Check the Keep Relay settings and select a value appropriate to the machine.


R700.0 TOLSOK Tool No. Select Keep Relay Set O.K K6.3 K40TS Tool Magazine 40Tools Used K6.4 K60TS Tool Magazine 60Tools Used K6.2 K90TS Tool Magazine 90Tools Used K6.6 K120TS Tool Magazine 120Tools Used K6.0 KMATRX Matrix Tool Magazine Is Used K7.6 KATC ATC Not Used A7.1 2058 Tool No. Select Keep Relay Not Set

Tool No. Select Keep Relay Not Set

Tool No. Select Keep Relay Set O.K

76


(Note) To change the Keep Relay settings



(3) Press the [SETTING] button. ▪ The Setting screen appears where the cursor is positioned

at the “PARAMETER WRITE” item on the top. ※ If the screen is not displayed as shown in the right



★ The “SW0100 Parameter Enable Switch ON” alarm will occur.

77



(6) Move to the Keep Relay screen.

① Press the soft keys one after another to move to the Keep Relay screen. ② Press to activate the vertical soft key in the lower right corner and press the

[KEEP RELAY] key. Activate the

vertical soft key 1 2

78


(7) Enter a desired Keep Relay number and press [SEARCH], or move the cursor to the Keep

Relay item and enter 1 or 0. Then, press the INPUT button. (8) When done, move back to “SETTING” and turn off “PARAMETER WRITE”(“1” ‘0”).

Then, press the “RESET” key to release the alarm.

K-Relay K6.6 K6.5 K6.4 K6.3 K6.2 K6.1 K6.0

No. of Tools 120 Tools

60 Tools 40 Tools 90 Tools Matrix

79


2.15 2059 T-Code Command Illegal Position 1) Description

When the tool magazine or ATC waiting pot had not been initialized, a tool was called (T_:). 2) Cause of problem

① A positioning error in switches that check the home position of ATC or tool magazine ② Defective component part in the switch

3) Action

① Check if the switch works properly on the DGN screen, and adjust the distance from the dog as appropriate.

② Check the Limit Switch, wiring cables and I/O module, and make repair or replacement if you encounter a problem.


(Pin) Numbering

Mag. Tool Pot Int. Tool Out

X10.0 (TPOT.M)

-SL39 Input Module Slot 8, 9 XJ413 (16) SL39

ATC Sub Changer Home Position

X10.3 (SCHP.M)

-SX33 Input Module Slot 8, 9 XJ413 (15) SX33

ATC Sub Changer Arm In

X10.1 (SCAI.M)


ATC Sub Changer Arm Out

X10.2 (SCAO.M)


ATC Waiting Pot Spindle Side

X7.6 (WPSS.M)

-SL36 Input Module Slot 8,9 XJ412 (10) SL36

ATC Waiting Pot Mag. Side

X7.7 (WPMS.M)

-SL37 Input Module Slot 8,9 XJ412 (42) SL37

※ T-Code Initial Position

Address X07.6 X07.7 X10.0 X10.1 X10.2 X10.3

Status 1 0 0 1 0 1

T-Code Command Illegal Position

80


T-Code Initial Position

Alarm 2059 / 2060 Aux D-Time

2059B

2059A

HD40 T-Code Initial Position

Mag. Tool Pot Tool Out Interlock

81



R446.0 TMB145 Alarm 2059/2060 Aux D-Time

A7.2 2059 T-Code Command Illegal Position


A32.5 2262 ATC Magazine Guard Door Open

K7.6 KATC ATC Not Use

R730.5 2059B 2059B

R730.6 2060B 2060B

R732.5 2059A 2059A

F212.4 TMN-FM ATC Manual Mode From Matrix

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

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

K6.0 KMATRX Matrix Tool Magazine Is Used

R701.6 TFINP T-Code Initial Position

R460.0 TTF T-Code Strobe


R702.0 TCCMDA T-Code Command Aux

R2401.4 TCCMDF T-Code Command Flag

R702.2 RTCCMD Re-Charge T-Code Command

R708.2 STSECH Spindle Tool Search

R605.2 M45 Spindle Tool No. Set

R700.2 WPTNCM Same Tool Is Commanded With Wait. Pot

R718.4 TSMDM ATC Sub Changer Manual Mode

R842.1 ATCALM ATC Alarm

R701.5 TFNP2 T-Code Initial Position2 (M6)

R701.7 TFIN3 T-Code Initial Position (RTCCMD)

R701.2 TFNP1 T-Code Initial Position1 (TCMDF)

K0.6 KHM1000 If HM1000 Set To 1

R717.2 TFINPA HM4D T-Code Initial Position

X7.7 WPMS.M Waiting Pot Magazine Side

X7.6 WPSS.M Waiting Pot Spindle Side

X10.3 SCHP.M Sub Changer Home Position

X10.1 SCAI.M Cub Changer Arm In

82



X10.2 SCAO.M Cub Changer Arm Out

R5300.3 MTOI.M Magazine Tool Pot Tool Out Interlock

F216.2 WPDT-F Waiting Pot Tool Detect

F216.4 WPS-FM Waiting Pot Spindle Side S/w

F216.5 WPM-FM Waiting Pot Magazine Side S/w

F219.1 SCI-FM ATC Sub Changer Initial Position

X10.0 TPOT.M Magazine Tool Pot –Out Confirm

SL36 SL37 SL39

SX35

SX34

SX33 SL32 SL31

83


(Reference) How to move to DGN (Diagnostic)


(2) Move to the DGN screen.

① Press the soft keys one after another to move to the DGN screen. ② Press any soft key in the right corner to activate the vertical soft key bar, and press the

[STATUS] key.



1 2

84


◈Tool Search Sequence Chart

Tool Search Start (T _ _;)

No

★ AL 2250 “ATC OP Manual Mode” occurs ATC Sub Changer O.P Auto Mode?

▪ Turn the mode switch in the manual OP to Auto.

Yes

Searched tool No =Spd. Tool No? Yes

No

Searched tool No =Wait. Tool No? Yes

★ Tool Search Complete

No

Double Tool Search? Yes

★ 1st Tool to Tool Magazine, And 2nd Tool In Valid

No

TMG & ATC Initial Position? No

★ AL 2059 “T-Code Command Illegal Position” occurs

Confirmed : 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 Yes

1 Sub Changer Mag. 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 : X10.4(SCPP.M) –SX34 Sub Chan. Mag. Pos. On

On Off

Sub Changer Pot Position? No

★ AL 2272 “ATC Sub Changer Pos. Check Alarm” occurs

Confirmed : X10.4(SCPP.M) –SX34 Sub Chan. Mag. PosOn

Yes

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

85


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

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

On Off

Completed : X10.5(SCWP.M) –SX35 Sub Chan. Wait. Pos On

On Off

Sub Changer Waiting Pot Pos.? No


Confirmed : X10.5(CAWP.M)–SX35 Sub Chan.Wait. Pot Pos. On

Yes

4 Sub Changer Arm In On

Completed : X10.1(SCAO.M) –SL31 Sub Changer Arm In On

Sub Changer Arm In O.K? No


▪ Check: X10.1(SCAO.M) –SL31 Sub Changer Arm In X10.2(SCAO.M) –SL32 Sub Changer Arm Out

On Off

Yes

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

On Off

▪ Completed: X10.3(SCHP.M) –SX33 Sub Chan. Home Pos. On

Off On

Sub Changer Home Position? No


▪ Check: X10.3(SCHP.M) –SX33 Sub Chan. Home Pos. On

Yes

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 Finish

86


◈ Tool Re-Charge Step Sequence Chart

M06 M-Function 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



▪ 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



▪ 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



▪ 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


▪ Completed: X10.2(SCAO.M) –SL32 Sub Changer Arm Out On




On

Off

Yes

Yes Go to “A”

Off Off

Off

Off

87


Yes



On Off




On

Off

On

Yes

ATC Re-Charge End

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




On Off

Yes

A

Off Off

88


2.16 2060 M06 Command Illegal Position 1) Description

A tool change was instructed (by M06 or manually) in other than the home position. 2) Cause of problem

① The tool had not been called before the instruction. ② A tool change command (M06:) was instructed while the tool magazine, the main

changer, the sub changer or the waiting pot was not in the initial state. 3) Action

① You should call a tool before instructing to change it. T_ _ ; M06 ; or T_ _ M06 ;

② Check the switch on the DGN screen and adjust the distance from the dog as appropriate, or check the switch, wiring cables and I/O module, and make repair or replacement if you encounter a problem.


(Pin) Number

ing

ATC Waiting Pot Mag. Side

X7.7 (WPMS.M

) -SL37 Input Module Slot 8,9 XJ413 (42) SL37


X7.6 (WPSS.M) -SL36 Input Module Slot 8,9 XJ413 (10) SL36

ATC Sub Chg. Home Position

X10.3 (SCHP.M) -SX33 Input Module Slot 8,9 XJ413 (15) SX33

ATC Sub Chg. Arm In

X10.1 (SCAI.M) -SL31 Input Module Slot 8,9 XJ413 (32) SL31

Mag. Tool Pot Int. Tool Out

X10.0 (TPOT.M) -SL39 Input Module Slot 8,9 XJ413 (16) SL39

Main Changer Arm Home Pos.

X8.5 (CAHP.M)

-SX41 Input Module Slot 08 XJ412 (38) SX41

Spd. Tool Unclamp Command

X8.6 (ULMD.M)



X8.7 (CLMD.M)


89


※ T-Code Initial Position

Address X07.6 X07.7 X10.0 X10.1 X10.2 X10.3 X8.5 X8.6 X8.7

Status 0 1 0 1 0 1 1 0 0

Alarm 2059 / 2060 Aux D-Time

2060B

2060A

M06 Initial Position

M06 Command Illegal Position

90



R446.0 TMB145 Alarm 2059/2060 Aux D-Time

A7.3 2060 M06 Command Illegal Position




R730.5 2059B 2059B

R730.6 2060B 2060B

R73206 2060A 2060A

R709.1 M06INP M06 Initial Position



R702.0 TCCMDA T-Code Command Aux




R842.1 ATCALM ATC Alarm

R466.0 M06INPA HM4D M06 Initial Position


HM4D M06 Initial Position

Mag. Tool Pot Tool Out Interlock

91



R466.1 M06INPB HM10 M06 Initial Position

X7.7 WPMS.M Waiting Pot Magazine Side

X7.6 WPSS.M Waiting Pot Spindle Side


X10.1 SCAI.M Cub Changer Arm In

R5300.3 MTOI.M Magazine Tool Pot Tool Out Interlock


F216.2 WPDT-F Waiting Pot Tool Detect

R719.6 ATCMMD ATC Main OP manual Mode

R724.5 1CYATC Manual ATC Change 1 Cycle

F216.5 WPM-FM Waiting Pot Magazine Side S/w

F216.4 WPS-FM Waiting Pot Spindle Side S/w

F219.1 SCI-FM ATC Sub Changer Initial Position

X8.5 CAHP.M Main Changer Arm Home Position

X.8.6 MLMD.M Spindle Tool Unclamp Command

X8.7 CLMD Spindle Tool Clamp Command

X10.0 TPOT.M Magazine Tool Pot –Out Confirm

SL36 SL37 SL39

SX35

SX34

SX33 SL32 SL31

92


(Reference) How to move to DGN (Diagnostic)




[STATUS] key.



1 2

93


◈ 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

No

Yes

★ AL 2245“ATC Door Open /Close Alarm” 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) –YV38 ATC Door Open On

94


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 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

95


2.17 2061 T-Code Command Over Alarm 1) Description

A T code that is not appropriate to the machine is instructed. 2) Cause of problem

A larger pot number than the pot count available in the machine is called. 3) Action

Check the number of the spindle tool data and waiting tool data in "PMC" > "D-Data" and correct it appropriately and try again.

K-Relay K6.6 K6.5 K6.4 K6.3 K6.2 K6.1 K6.0

No. of Tools 120

Tools 60 Tools 40 Tools 90 Tools Matrix


R710.0 TNOVER Tool No. Over Command Error R700.1 TFSTB TF Strobe

A7.4 2061 T-Code Command Over Alarm



R9000.1 X < Y Compare X < Y

R7002.4 TZERCF Tool No. Zero Command Flag

R4012.2 1T0COMMD T0 Command

R710.2 TNZERO Tool No. Zero Command

Tool No. Over Command Error

T-Code Command Over Alarm

96


2.18 2062 M06 Command Overtime Alarm 1) Description

The tool change command (M06) was instructed but not completed within 10 seconds. 2) Cause of problem

In most cases, this happens if a tool is stuck in the changer arm while it is changed.

3) Action

Move the changer arm to the home position manually and find and resolve the cause of trouble.

M06 Command Overtime Aux

M06 Command Overtime Alarm

M06 Command Overtime

M06 Command Overtime Aux 2

97



R625.6 TMB23 M06 Command Overtime A7.5 2062 M06 Command Overtime Alarm


A7.2 2059 T-Code Command Illegal Position

A7.3 2060 M06 Command Illegal Position

A30.0 2241 Waiting Pot or Spindle Tool Data Zero


R714.2 STSECB Spindle Tool Search Aux.


R714.6 4STSECB Spindle Tool Search Aux.

R730.0 TMB23C M06 Command Overtime Aux.


A31.1 2250 ATC OP Manual Mode





R736.0 TMB23A M06 Command Overtime Aux.

R736.1 TMB23B M06 Command Overtime Aux. 2 R649.6 DCL Operator Door Close Confirm

K16.7 KMTM150 Used Variable Orientation Func.

F218.5 MTC-FM Manual Tool Pot Call From matrix

F218.6 MTR.FM Manual Tool Pot Return From matrix


Y10.3 SVON.R TMG Servo On

R711.4 SPSTSH Spindle Tool Search Keep

K18.7 KUCENT Keep U-Center Is Used

R600.3 M06 ATC Change Macro Call


R5321.0 MANM06 Manual ATC Cycle Command

X12.1 ATDO.M ATC Door Open

K10.3 KATVDR ATC Door Not Used

98


▣ Return to the home position of the ATC changer arm

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”.

99


3) Press the CUSTOM1 button from the button bar of the main OP. ☞ The “PMC Switch” screen appears.

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).

100


6-1) If the changer arm is stuck while trying to pull out a tool from the spindle From the “ATC Manual Switch” screen, select “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 spindle 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

From the “ATC Manual Switch” screen, select “TOOL CHANGE STEP FORWARD”.

6-3) If the changer arm has stopped operation irrelevantly to the spindle (in the state of Spindle Unclamp) From the “ATC Manual Switch” screen, select “TOOL CHANGE STEP REVERSE”.

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.

101


① If the spindle is in the process of tool clamping, manually perform the tool unclamping. ▪ How to confirm the state of spindle 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 number of 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 “2243 Must Be ATC M-Changer Man. 1 Cycle” alarm will be displayed on the NC screen.

8) From the "ATC Manual Switch" screen, select

“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 are in the ATC change positions (Y-axis and Z-axis 2nd reference

points): This will be ignored if alarm AL2243 has occurred.

102


③ Switch the mode selection switch on the ATC manual OP to “MA NUAL”. ④ M06 Initial Position

▪ Waiting Pot Spindle Side(X10.3), ▪ Sub Changer Home Position(X10.3), ▪ Sub Changer Arm In (X10.1), ▪ ATC Main Changer Home Position (X8.5) ▪ Operator Door Close Confirm (X4.1, X4.3)

⑤ Servo Ready 7) From the “ATC Manual Switch”, select “DOOR

CLOSE” and press the “START” button to close the door.

8) 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

103


※ Reference) Adjusting the position of the ATC arm (centering)

* If you re-assemble the ATC arm, you must perform the centering of the spline and ATC arm.

1) Preparations for centering the ATC arm ① Move the Y and Z axes to their respective

secondary reference point. ▪ Program : G91 G30 Y0 Z0 ;

② Clamp a spline-specific centering fixture into the spline and perform the spline orientation. ▪ Program : M19 ;

③ Insert the arm fixture to the changer arm, and move the changer arm to the change position manually.

2) Loosen the bolt on the locking element, and

install the ATC arm fixture at the end of the arm.

※ Reference) ATC Arm Fixture

Centering Fixture

25

100

20

30

42 42 M10×1.25 Tap

Φ11 Drill

▪Necessary Parts 3-BB10×40

15

30

Locking Element

Fixture

104


3) Move the ATC changer arm slowly to find out the exact position. ① Use the push bolts on both sides and the pull bolt in the center to adjust the gap between

changer arm fixture and spline fixture to 3.2mm.

② While impacting on the end of the changer arm using a plastic hammer, fit the centering

fixture to the end smoothly.

③ Leave the fixture in the current position and

tighten the element locking bolts from inch by inch to as tight as possible.

④ Remove the fixture and tighten the element

locking bolts in the fixture place from inch by inch to as tight as possible.

Gap: 3.2mm

Fixture

Push Bolt

Push Bolt

Pull Bolt

105


* Insert the intended tool into the spline or tool boy, and move the changer arm near the tool manually. Then, release the changer motor brake and rotate the arm manually until it contacts on the tool. Check inside of the taper area and make a gap between. ▪ Correction Target: 0.3∼0.5mm

4) Install C60075314A cap.

▪ 4-BB5×8

5) Insert all the covers that were previously removed to their respective position, and perform the test run to check if they are installed properly.

0.3∼0.5mm

3.2±0.2mm

Changer Arm

Cap

Cap

106


※ Reference) Reset the reference point for ATC servo magazine

If the ATC sub changer and the tool pot of the magazine do not align properly due to mis-position of the ATC servo pot, you must restore the reference point of the ATC servo magazine manually. 1) Move the tool pot #1 to the changer position, and install the centering fixture between tool pot

and sub changer.

2) Change the value of "Keep Relay K12.2" to 1.

▪ K12.2(KMATC) : If you want to adjust the position of ATC changer, set it to 1. (This will control the servo motor regardless of the changer arm position)

3) Press the MODE key on the start screen [r 0000] of the servo drive to display [ rd-off ].

[ rd-off ] : Ready to operate the jog run

4) From the [ rd-off ] screen, press the down arrow button to display [ Jog.run ].

[ Jog.run ] : Switch to the jog run mode

Sub Changer Centering

Fixture

Centering Fixture

107


5) From the [Jog.run] screen, press the SET key to display [ Jr.0000].

[ Jr.0000 ] : Jog run mode

6) From the [Jr.0000 ] screen, use the up/down arrow keys to

rotate the magazine in a desired direction. In such a way, adjust the pot position.

Fine-tune the magazine position

▪ If you want to fine-tune the magazine position, set parameter #27 to a lower value.

※ Centering the tool pot of the tool magazine

Use the up/down arrow buttons on the [ Jr.0000 ] screen, or press the rotation button on the manual operation panel. While holding the button, insert the center bar into the centering fixture until it is inserted smoothly. ▪ When completed, the coordinates of the tool magazine will match with the actual position.

108


7) When the centering of the tool magazine's tool pot is completed, press the SET key. [ Jog.run ] : Return to the jog run mode

8) In the [ Jog.run ] screen, press the MODE key to display [ rd-off ].

[ rd-off ] : Ready to operate the jog run

9) In the [ rd-off ] screen, press the up arrow key to display [ Org.S - - ]. [ Org.S - - ] : Origin mode

10) From the [Org.S - - ] screen, press and hold the SET key for 7 seconds. The screen will

blink and switch to [r 0001 ]. [ r 0001 ] : Return to the start screen

11) Turn off the machine and turn it back on. This is the completion of resetting the reference

point.

109



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

Confirmed: X12.1(ATDO.M) –SL51 ATC Door Open X12.2(ATDC.M) –SL52 ATC Door Close

On Off

On

Confirmed: 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.


Tool Search O.K?

No

Yes



▪ 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) –YV38 ATC Door Open On

110


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 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

111


2.19 2063 ATC Servo Unit Alarm 1) Description

The servo motor inverter that drives the tool magazine tripped an alarm. 2) Cause of problem

① An error in the servo motor inverter ② An error in the servo motor or the wiring

3) Action

Refer to the servo motor manual, and repair or replace the defective part. ☞ Refer to "Troubleshooting by the servo drive alarm".


(Pin) Numbering

TMG Servo Alarm X13.7

(TALM.M) - Input Module : Slot 7,9 XJ413 (33) ALM


X13.7 TALM.M TMG Servo Alarm

A7.6 2063 ATC Servo Unit Alarm



ATC Servo Unit Alarm

112


Tool Magazine Servo Amp

113


◈ Refer to "Troubleshooting by the servo drive alarm".

(1) UV (Under Voltage) Alarm : This alarm warns that the main unit is running out of direct voltage.

Message on the front

display

Description This alarm is tripped when the internal DC link voltage falls below the set value.

Troubleshooting

▪ Measure the input voltage on the drive terminal box to check if the tester reads between 200V and 220V. If not, take a necessary measure to adjust the voltage to between 200V and 220V.

▪ Check if the motor has a short circuit. If so, replace the motor cables

wherever applicable. ▪ Then, turn off the servo drive and turn it back on. See if there occurs the

same alarm. If so, replace the drive because this alarm is tripped from the defective drive.

Note) The servo drive alarm is tripped to protect the servo drive, the motor, and the magazine. You restart the drive and release the alarm doesn't mean either the drive or the motor has an error. You do not need to replace any of these two.

(2) OH (Over Heat) Alarm : This is a overheat alarm.


display

Description This alarm is tripped if the internal IPM device is overheat or has an error.

Troubleshooting

▪ Turn off the servo drive and wait until it cools down. Then, turn it back on and see if the same alarm occurs again. If the problem persists, replace the drive because the IPM module of the drive is defective.


Select two from L1, L2, and L3, and measure the voltage between two terminals.

114


(3) OV (Over Voltage) Alarm : This alarm warns that the direct voltage to the main unit is excessive.


display


Troubleshooting


▪ Remove the drive and disconnect the regenerative resistor connector to

check if the regenerative resistor (installed at a side of the drive) measures at 26Ω. If not, replace the resistor.


wherever applicable. ▪ Then, turn off the servo drive and turn it back on. See if there occurs the

same alarm. If so, replace the drive because this alarm is tripped from the defective drive.


Regenerative Resistor

Connector

Power Board (PAB)


Select two from L1, L2, and L3, and measure the voltage between two terminals.

115


(4) CO Alarm : An alarm that is tripped from an encoder signal error


display

Description This alarm occurs if the signal from the encoder has an error.

Troubleshooting

▪ Disconnect the encoder data transfer cable from the servo drive, and reconnect it as it may be connected improperly.

▪ Check the wiring of the encoder data transfer cable, and replace it if necessary.

▪ Check if the motor encoder connector is short-circuited. If so, replace the

motor.


Encoder data cable

Motor Encoder Connector

116


(5) OS (Over Speed) Alarm : This is an over-speed alarm.


display

Description This alarm occurs when the motor speed exceeds the limit.

Troubleshooting

▪ Disconnect the encoder data transfer cable from the servo drive, and reconnect it as it may be connected improperly.

▪ Check the wiring of the encoder data transfer cable, and replace it if

necessary. ▪ Check if the motor has a short circuit. If so, replace the motor cables

wherever applicable. ▪ Check if the motor encoder connector is short-circuited. If so, replace the

motor.


Encoder data cable


117


(6) OL (Over Load) Alarm : This is an overload alarm.


display

Description

▪ This alarm occurs if the overload state of the servo motor lasts for more than specified.

▪ Overload detection time 250% ~ : 1 second, 220% ~ : 24 seconds, 200% ~ : 48 seconds 180% ~ : 96 seconds, 160% ~ : 192 seconds, 150% ~ : 384 seconds 140% ~ : 769 seconds, 130% ~ : 1536 seconds

Troubleshooting

▪ Check if the parameters are set properly. ▪ This alarm occurs if the magazine has a tool overload or asymmetric load,

or has a mechanical error. Turn the magazine manually while increasing parameter no. 10 and parameter no. 11 by 10 until the magazine rotates smoothly.

▪ Disconnect the motor power cable and the encoder data transfer cable from the servo drive, and reconnect them as they may be connected improperly.

▪ Check the wiring of the motor power cable and the encoder data transfer cable, and replace them if necessary.

▪ Then, turn off the servo drive and turn it back on. See if there occurs the same alarm. If so, replace the drive because this alarm is tripped from the defective drive.


Encoder data cable

118


(7) OC (Over Current) Alarm : This is an over-current alarm.


display

Description This alarm is tripped when the motor is over-currented.

Troubleshooting

▪ Check if the acceleration parameter (No. 29) and the deceleration parameter (No. 30) are set to less than specified.

▪ Check the wiring of the motor power cable, and replace it if necessary. Note) The servo drive alarm is tripped to protect the servo drive, the motor, and the

magazine. You restart the drive and release the alarm doesn't mean either the drive or the motor has an error. You do not need to replace any of these two.

(8) SE Alarm : This is a double interruption alarm.


display

Description This alarm occurs if the CPU or the MCB of the servo drive has an error.

Troubleshooting

▪ Reset the parameters of the servo drive, and set them as appropriate again. ▪ Then, turn off the servo drive and turn it back on. See if there occurs the

same alarm. If so, replace the drive because this alarm is tripped from the defective drive (a MCB error).


(9) PE (Parameter Error) Alarm : This is a parameter error alarm.


display

Description This alarm occurs if the parameters of the servo drive are out of the set range.

Troubleshooting

▪ Reset the parameters and the compensation values of the servo drive, and set them as appropriate again.

▪ Then, turn off the servo drive and turn it back on. See if there occurs the same alarm. If so, replace the drive because this alarm is tripped from the defective drive (a MCB error).


119


(10) rP (Residue Pulse) Alarm(ALP-rP) : This alarm occurs due to an excessive position deviation.


display

Description This alarm occurs if the residue pulse (RP) exceeds the limit specified for parameter no. 19 while the servo drive is controlling the position information.

Troubleshooting

▪ Check if parameter no. 19 of the residue pulse is set to less than specified. ▪ Disconnect the encoder data transfer cable from the servo drive, and

reconnect it as it may be connected improperly. ▪ Check if the motor has a short circuit. If so, replace the motor encoder

cables wherever applicable. ▪ Check if the motor encoder connector is short-circuited. If so, replace the

motor.


Encoder data cable


120


(11) EN (Battery) Alarm : This alarm occurs due to an encoder backup battery error.

▪ The servo drive that is connected to the motor consumes the battery for driving itself if no main (external) power is applied.

▪ Battery life (Max current consumption: 150㎂) 1.44 ~ 1.5 years at 25℃ 0.89 ~ 0.96 year at 75℃

Message

on the front display

Description This alarm is tripped when the encoder backup battery of the servo drive is discharged or loose.

Troubleshooting

▪ Replace the encoder backup battery of the servo drive. ▪ Remove the servo drive and check the backup battery of the internal

encoder if the battery connector is connected properly. If you find an error from the servo drive, replace the servo drive.


Encoder backup battery connector

Main Control Board (MCB)

Encoder backup battery

121


2.20 2064 ATC Door Open 1) Description

The ATC door is open. 2) Cause of problem

① The signal of closing the door was lost since the door was open abnormally (not in Auto mode or in Manual mode).

② The switch detecting that the ATC door is closed, or any of its component parts has an error.

3) Action

① The switch detecting that the ATC door is closed was adjusted incorrectly. ② Check if there is any problem with the switch or the wiring. If so, repair or replace the

defective part.


(Pin) Numbering

ATC Door Open X12.1

(ATDO.M) -SD51 Input Module Slot 09 XJ413 (24) SD51

ATC Door Close X12.2

(ATDC.M) -SD52 Input Module Slot 09 XJ413 (39) SD52

ATC Door Open Alarm D-Time

ATC Door Open

122



X12.2 ATDC.M ATC Door Close


Y3.1 ATDC.R ATC Door Close

R628.4 TMB45 ATC Door Open Alarm D-Time

A7.7 2064 ATC Door Open




A30.4 2245 ATC Door Open/Close Alarm

K10.3 KATCDR ATC Door Not Used


R709.0 ATCMST ATC macro Start



R702.2 MATCDO Manual Door Open Command

R728.6 MATCDC Manual Door Close Command

R407.2 M222 ATC Door Open

R407.3 M223 ATC Door Close

A31.2 2251 ATC Overtime Alarm

A32.3 2260 Tool Magazine Rotation Overtime

R719.7 TMMDON ATC Manual Mode On

F0.6 SA Servo Ready

ATC Door Close Check(SL51)

ATC Door Open Check(SL52)

123


2.21 2066 Splash Guard (APC) Door Open (PMG) 1) Description

The splash guard door was open. (This alarm applies only to PMG machines) 2) Cause of problem

① The signal of closing the splash guard door was lost since the door was open abnormally (not in Auto mode or in Manual mode).

② The switch detecting that the splash guard door is closed, or any of its component parts has an error.

3) Action

① The switch detecting that the splash guard door is closed was adjusted incorrectly. ② Check if there is any problem with the switch or the wiring. If so, repair or replace the

defective part.


(Pin) Numbering

Splash Guard 1 Close

X16.1 (SG1C.M)

-SL8B Input Module : Slot 10 XJ414 (24) SL8B

Splash Guard 2 Close

X16.3 (SG2C.M)

-SL8D Input Module : Slot 10 XJ414 (6) SL8D

Splash Guard(APC) Door Open

124



R4037.7 SGDC1/2 Splash Guard Door Close 1/2

R453.5 TMB206 Command Delay Time

A8.1 2066 Splash Guard(APC) Door Open





K0.0 KHM63 ACE H63 Machine

K0.1 KHM80 ACE H80 Machine

K10.4 KSGDOR Splash Guard Door Not Used


X16.1 SG1C.M Splash Guard 1 Close


A41.2 2331 Splash Guard Door Open/Close Alarm

R635.6 TMB27 Splash Guard Door Close Check Time

A8.1 MAN Manual Mode


K7.7 KAPC APC Not Used

R4038.0 4SGDOP Splash Guard Door Open Command

R4038.2 4SGDCL Splash Guard Door Close Command

R763.4 MAPCSP Manual APC Stop

R4033.7 APUNLD APC Unload Command

R4034.5 APCLD APC Load Command


F0.6 SA Servo Ready

M259 Command Delay Time

125


2.22 2067 APC Overtime Alarm

1) Description A command of M60 (Pallet Change), M61 (APC Unload) or M62(APC Load) was instructed but not complete within 150 seconds since then.

2) Cause of problem

An error in adjusting the detection switch for each sequence, the solenoid valve, the wiring, or any of related component parts

3) Action

If there is an error in adjusting the detection switch for each sequence or any of related component parts, an alarm occurs for each error sequence, according to which troubleshooting shall be made. ☞ Refer to the “Pallet Change Sequence” chart

APC Overtime Alarm

APC Overtime Alarm AUX. 2

126



R759.1 2067A1 HM10 APC Overtime Alarm Aux.

R759.2 2067A2 HM4D APC Overtime Alarm Aux. 2

R456.0 TMB220 HM4D APC Overtime Check Time


A10.3 2084

A10.4 2085

A9.1 2074

A9.2 2075

A9.3 2076

HM4D APC Overtime Check

127



A40.2 2323 4-th CL/UNCL Alarm



R759.0 APCMST APC Macro Start

A25.3 2204 Feedrate Override 0%

R607.2 M61 APC 1 Unload

R607.3 M62 APC 1 Load

R755.7 SETUP Set Up


R1013.2 SETEN Set-Up Enable Condition

R4030.2 4PMGMST PMG Macro Start

R608.3 M70 Pallet or Station Index

R1002.1 PMGROT Table Side Search (PMG Rotation)

R1010.0 NO-SET Set-Up Not Found

K0.0 KHM63 ACE-H63 Machine

K0.1 KM80 ACE-H80 Machine

A40.1 2322 APC Set Up Station Door Open

K10.2 KAUTDR Auto Door for Setup Door Used

R430.1 TM26 APC Auto Door Close Check Time

R649.6 DCL Operator Door Close Confirm

R648.6 M250A Door interlock Bypass On Aux.

Y12.1 SZAT.R Sub Changer Arm Out

Y12.2 SCS1.R Sub Changer Position 1

K6.3 K40TS Tool Magazine 40Tools Used



X40.2 PMMD.M APC OP Manual Mode-HM4D


128


※ Pallet Changing (M60) Sequence Chart

Pallet Change Start (M60)

No APC Home Position

O.K ?

Yes

1 Pallet Change(Home) Position ▶ Return X to 2nd ref. point / return Y,Z,B to 1st ref. point

Program : G91 G28 Z0.; G91 G28 Y0.; G91 G30 X0.; G91 G28 B0.;

▪ Check: X axis: 2nd ref. point / Y,Z,B: 1st ref. point

Manual APC O.P Auto Mode ?

▪ From the APC manual OP, turn the mode switch to Auto. ▪ Check: X40.2(PMMD.M) –SA91 APC Manual Mode Yes

★ AL 2326 “APC OP Manual Mode” occurs No

APC Initial Position? No

★ AL 2068 “Pallet Change Initial Position Alarm” occurs

▪ Check: X18.5(P18F.M) –SX75 APC 180CW Position X18.6(P18R.M) –SX76 APC 180CW Position X8.2(SUIT.M) –S12 Set-up Door Interlock X18.0(AHOM.M) –SX70 APC Home Position X19.1(APDN.M) –SX81 APC Down X18.1(APOP.M) –SX71 APC Pos. 0/Arm Open

On

On

On

Yes

On

On

On

On

Set-Up Switch On ?

▪Press the Set-Up switch on the APC manual OP. ▪ Check: X40.1(SETU.M) –SB92 Set Up

★ AL 2325 “APC Set-Up Switch Unpush” occurs No

On Yes

2 APC Arm Close ▪ Output: Y12.7(APCL.R) –YV71 APC Arm Close On

▪ Completed: X18.3(SPCL.M) –SX73 APC Arm Close On

APC Arm Close O.K ? No

★ AL 2335 “APC Changer Open/Close Alarm” occurs

▪ Check: X18.3(SPCL.M) –SX73 APC Arm Close X18.1(SPOP.M) –SX71 APC Arm Open

On Off Yes

Go To “A”

129


3 Pallet Unclamp ▪ Output: Y15.0(PAUC.R) –YV61 Pallet Unclamp On

▪ Completed: X7.1(PTCL.M) –SP62 Pallet Clamp

Pallet Unclamp O.K ? No

★ AL 2327 “Pallet Clamp/Unclamp Alarm” occurs

▪ Check: X7.1(PTCL.M) –SP62 Pallet Clamp Off Yes

A

Off

4 APC Changer Up ▪ Output: Y13.3(APUL.R) –YV75 APC Up On

▪ Completed: X19.0(APUP.M) –SX81 APC Up On

APC Changer Up O.K ? No

★ AL 2336 “APC Changer Up/Down Alarm” occurs

▪ Check: X19.0(APUP.M) –SX81 APC Up X19.1(APDN.M) –SX82 APC Down

On Off Yes

APC 180 CW Stopper Out ▪ Output: Y13.7(P8RR.R) –YV75 APC 180CW Stop. Out On

▪ Completed: X19.4(P9FO.M) –SX85 APC 180CW Stop. Out On

APC 180 CW Stopper Out O.K? No

▪ Check: X19.4(P9FO.M) –SX85 APC 180CW Stop. Out On

Yes

5 APC 180 CW Rotation ▪ Output: Y13.1(PCW.R) –YV73 APC Rota. 180CW On

▪ Completed: X18.5(P18F.M) –SX75 APC 180CW Position On

APC 180CW Rotat. End O.K ? No

★ AL 2337 “APC Changer 180CW/CCW Alarm” occurs

▪ Check: X18.5(P18F.M) –SX75 APC 180CW Position X18.6(P18R.M) –SX76 APC 180CCW Position

On Off Yes

APC 180 CCW Position O.K? No

Yes

▪ Check: X18.5(P18F.M) –SX75 APC 180CW Position X18.6(P18R.M) –SX76 APC 180CCW Position

“1” “2”

Go to “1”

Go to “B”

4.1

130


B

7 Pallet Clamp ▪ Output: Y15.1(PACL.R) –YV62 Pallet Clamp On

▪ Completed: X7.1(PTCL.M) –SP62 Pallet Clamp

Pallet Clamp O.K ? No

★ AL 2327 “Pallet Clamp/Unclamp Alarm” occurs

▪ Check: X7.1(PTCL.M) –SP62 Pallet Clamp Yes

6 APC Changer Down ▪ Output: Y13.4(APDV.R) –YV75 APC Down On

▪ Completed: X19.1(APDN.M) –SX82 APC Down On

APC Changer Down O.K ? No

★ AL 2336 “APC Changer Up/Down Alarm” occurs

▪ Check: X19.0(APUP.M) –SX81 APC Up X19.1(APDN.M) –SX82 APC Down On

Off Yes

On

On

8 APC Arm Open ▪ Output: Y12.7(APCL.R) –YV71 APC Arm Close On

▪ Completed: X18.1(SPOP.M) –SX71 APC Arm Open On

APC Arm Open O.K ? No

★ AL 2335 “APC Changer Open/Close Alarm” occurs

▪ Check: X18.1(SPOP.M) –SX71 APC Arm Open X18.3(SPCL.M) –SX73 APC Arm Close

On Off Yes

6.1 APC 180 CW Stopper In ▪ Output: Y13.7(P8RR.R) –YV75 APC 180CW Stop. Out

▪ Completed: X19.4(P9FO.M) –SX85 APC 180CW Stop. Out

APC 180 CW Stopper In O.K? No

▪ Check: X19.4(P9FO.M) –SX85 APC 180CW Stop. Out

Yes

Off

Off

Off

Pallet Change Finish

“1”

5.1 APC 180 CCW Rotation ▪ Output: Y13.1(PCW.R) –YV73 APC Rota. 180CCW On

▪ Completed: X18.6(P18R.M) –SX76 APC 180CCW Position On

APC 180 CCW Rotat. End O.K ? No

★ AL 2337 “APC Changer 180CW/CCW Alarm” occurs

▪ Check: X18.5(P18F.M) –SX75 APC 180CW Position X18.6(P18R.M) –SX76 APC 180CCW Position On

Off Yes

131


2.23 2068 Pallet Change Illegal Position 1) Description

A command of M60, M61, M62, M63 or M64 was instructed when the APC was not in the initial operation state.

2) Cause of problem

① An error in adjusting the switch that checks the initial conditions of APC ② An error in the switch, the wiring, or any of its related parts

3) Action

① An error in adjusting the switch that checks the initial conditions of APC Find the error-causing switch by referring to the ladder diagram or the DGN screen. Correct the switch as appropriate and try again.

② Check the switches, the wiring, and the I/O module in this sequence. Make repair or replacement if necessary. ☞ APC initial conditions

Address X18.5 X18.6 X7.2 X7.5 X8.2 X18.0 X19.1 X18.1 X4.3

Status 1 0

1 1 1 1 1 1 1 0 1


(Pin) Numbering

APC 180 CW Position

X18.5 (P18F.M)

-SX75 Input Module Slot

08,10 XJ410 (47) SX75

APC 180 CCW Position

X18.6 (P18R.M)


08,10 XJ410 (30) SX76

Table Clamp X7.2

(BCLP.M) -SL63 Input Module Slot 08 XJ412 (11) SL63

Tool Measure Sensor Down Check

X7.5 (TLDN.M)

-SD62 Input Module Slot 08 XJ412 (43) SD62

Set Up Door Interlock

X8.2 (SUIT.M)

-S12 Input Module Slot 08 XJ412 (39) S12

APC Home Position X18.0

(AHOM.M -SX70

Input Module Slot 08,10

XJ410 (46) SX70

APC Changer Down X19.1

(APDN.M) -SX82 Input Module Slot 10 XJ413 (28) SX82

APC Pos. 0/Arm Open

X18.1 (APOP.M)


08,10 XJ410 (32) SX71


X4.3 (OSDI.M)

-S13A Input Module Slot 07 XJ411 (06) S13A

132


Pallet Change Illegal Position

M61/M62 Command Illegal Position

M06 Illegal Position Alarm Aux.

133



R759.3 2068A1 HM10 Pallet Change Illegal Position

R456.1 TMB221 M61/M62 Command Illegal Position

A8.3 2068 Pallet Change Illegal Position

R782.3 M60CHK Illegal Position Alarm Check

A9.5 2078 APC Set-Up Station Door Open

K10.2 KAUTDR Auto Door For Set Up Door Is Used

R430.1 TM26 Auto Door Close Check Time

F102.3 MV4

K0.6 KHM1000 If HM1000 Set to 1

R607.1 M61 APC Pallet 1 Loading


R760.0 M61CD Pallet 1 Loading Command

R761.0 M62CD Pallet 2 Loading Command

R782.2 APCINP APC Initial Position

R755.7 SETUP APC Set Up


R1013.2 SETEN Set Up Enable Condition




R760.7 M61MAN APC1 Unload(M61) M Func. End

APC Illegal Position

134



R761.7 M62MAN APC1 Load(M62) M Func. End

A10.3 2084 APC Set Up Station Door Open

A9.1 2074

A9.2 2075

A9.3 2076

A40.2 2023 4-th CL/UNCL Alarm


X18.5 P18F.M APC180CW Position

X18.6 P18R.M APC180CCW Position

X7.2 BCLP.M Table Clamp

K8.5 KROTAR Rotary Table Used

X7.5 TLDN.M Tool Length Sensor Down

K0.7 KTLENG Moving Type Tool Measure is Used

X8.2 SUIT.M Set-Up Door Interlock-HM4D

K10.5 KSETDR Set-Up Door Interlock Not Used

K16.2 KSSPDR Set-Up Supplier Door Not Used

X18.0 AHOM.M APC Home Position

X70.6 SEAR.M Set-Up Arm Return

X19.1 APDP.M APC Down

X18.1 APOP.M APC Position 0/Open

Y15.5 PRUL.R Pallet Rotation Unlock

R756.7 ST2728 Spindle Tool No. 27or28

A41.6 2335 APC Changer Open/Close Alarm

A41.7 2336 APC Changer Up/Down Alarm

A42.0 2337 APC Changer 180CW/CCW Alarm

R648.6 M250A Door Interlock Bypass On Aux.


135


2.24 2086 Main Changer Overtime Alarm 1) Description

The main changer arm home position signal (X8.5) has not been instructed within 5 seconds since the main changer motor rotation command (Y3.4) was instructed.

2) Cause of problem

In most cases, this happens if a tool is stuck in the changer arm while it is changed. 3) Action

Move the changer arm to the home position manually and find and resolve the cause of trouble.


(Pin) Numbering

Main Changer Arm Home Position

X8.5 (CAHP.M)



R439.7 TMB96 4D Main Changer Check Delay Alarm

A10.5 2086 Main Changer Overtime Alarm




Pallet Change Illegal Position

4D Main Changer Check Delay Time

136



Y3.4 CMFW.R Change Motor Forward_HM4D

R5324.5 4ATCS10 Do.10 (Main Changer Home Check)

X8.5 CAHP.M Main Changer Arm Home_ HM4D

▣ Return to the home position of the ATC changer arm

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”.

137


3) Press the CUSTOM1 button from the button bar of the main OP. ☞ The “PMC Switch” screen appears.

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).

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6-1) 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 spindle 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 on the ATC 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 on the ATC manual OP to “TOOL CHANGE STEP REVERSE”.

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

139


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 number of 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 “2243 Must Be ATC M-Changer Man. 1 Cycle” alarm will be displayed on the NC screen.

8) Turn the mode selection switch in 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 restored.

☞ If the Tool Change 1 Cycle operation is not performed, check the “Conditions of Manual Tool Change 1 Cycle” below:

140


※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 are in the ATC change positions (Y-axis and Z-axis 2nd reference

points): This will be ignored if alarm AL2243 has occurred. ③ Switch the mode selection switch on the ATC manual OP to “MA NUAL”. ④ M06 Initial Position

▪ Waiting Pot Spindle Side(X10.3), ▪ Sub Changer Home Position(X10.3), ▪ Sub Changer Arm In (X10.1), ▪ ATC Main Changer Home Position (X8.5) ▪ Operator Door Close Confirm (X4.1, X4.3)

⑤ Servo Ready 7) Turn the switch to “DOOR CLOSE” and press the

START button to close the door.

8) 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

141


2.25 2091 B-Axis Command Error(Inc. Dec. Point) 1) Description

The coordinate instruction on the B axis is invalid. 2) Cause of problem

A number that is not a multiple of 1 degree (i.e., not an integer) was entered in the B-axis coordinate (angle) instruction. ex) A decimal point or a special character “/” is used

3) Action

Check the coordinate value and correct a non-integer number or character.


R600.7 M10 B-Axis(Table) Clamp

F102.0 MV1

B-Axis Command Error(Inc.Dec.Point)

B-Axis Command Error

142



F102.1 MV2

F102.2 MV3

R753.0 BDATA1 B-Axis Data Compare(.020<.XXX)

R753.1 BDATA2 B-Axis Data Compare(.980>.XXX)



R750.5 BCMDER B-Axis Command Error

R435.4 TMB61 B-Axis Command Error D-Time

A11.2 2091 B-Axis Command Error(Inc. Dec. Point)


R750.2 BACLP B-Axis(Table) Clamp Command

R801.3 AL45IT AL45 Interlock Release

R801.0 BUNCLP B-Axis Unclamp By VM4


R9000.0 X=Y Compare X=Y

143


2.26 2093 X-Axis APC Changer Position Switch Alarm 1) Description

One or more axes from X, Y, Z and B are not in the APC changer home position while the pallet change instruction (M60, M61 or M62) was performing.

2) Cause of problem

One or more axis-feeding blocks of the macro program are deleted. 3) Action

Check the macro program of changing pallets and find the cause of problem. Correct the program as necessary.

O9021(M60 APC UNLOAD/LOAD PROGRAM) (2010.01.08_V.A4_YJ YOO) G31 IF[#3010EQ-1]GOTO600 IF[#1019EQ1]GOTO600 #105=#4003 G31 IF[#1031NE1]GOTO8 IF[#1007EQ1]GOTO5 IF[#1006NE1]GOTO401 GOTO8 G31 N5IF[#1006EQ1]GOTO402 GOTO8 N8#1109=1 N10IF[#1001NE1]GOTO10 #1109=0 N20IF[#1001EQ1]GOTO20 M78 M10 G91G28Z0. G91G28Y0. G91G30X0. G91G28B0. G31 N30IF[#1015NE1]GOTO30

IF[#1009EQ1]GOTO100 IF[#1010EQ1]GOTO200 GOTO400 N100M61 GOTO300 N200M62 N300 G31 IF[#1007EQ1]GOTO500 IF[#1031NE1]GOTO500 N310#1133=BCD[#982] #1115=1 IF[#1012NE1]GOTO310 #1115=0 GOTO500 N400#140=10 G65P9999 N401#140=11 G65P9999 N402#140=12 G65P9999 N500G[#105] N600 M99

144





R782.0 APCHP APC Home Position

A11.4 2093 X-Axis APC Change Position switch Alarm






F91.4 ZPY Y-Axis 1st Ref. Return

F94.2 ZPZ Z-Axis 1st Ref. Return


K1.4 KYZAPC


F94.3 ZPB B-Axis 1st Ref. Return

F96.0 ZP2X X-Axis 2nd Ref. Return

X-Axis APC Change Position SW Alarm

APC Home Position

145


2.27 2094 Pallet Number Command Error 1) Description

The PMG machine called pallet no. 0, which is a wrong number. 2) Cause of problem

The PMG machine called pallet no. 0, or it called a larger number of pallets than allowed. 3) Action

Check the allowed number of pallets (see PMC data D752 and D754) for the PMG machine, and correct the number to call as appropriate.


R1001.6 PNZERO Pallet number Command Error

R1001.7 PNOVER Pallet No. Over Command Error

A11.5 2094 Pallet number Command Error







Pallet Number Command Error

146


2.28 2142 Please Turn Off And On NC Power 1) Description

In the Machine Lock state, activate the B axis to reboot NC. 2) Cause of problem

The B axis was activated in the state of Machine Lock. 3) Action

Turn off the main power and turn it back on. Then, set the reference point for each axis manually before restarting the machine.


R644.4 MLKBMV B-Axis Moving At Machine Lock

R644.2 MLKF Please Turn Off And On NC Power

R644.0 MLKA Machine Lock All Axis

F102.3 MV4


G44.1 MLK All Axis Machine

G108.2 ZMLK Z-Axis Machine Lock

R644.1 MLKZ Machine Lock Z-Axis

Please Turn Off And On NC Power

B-Axis Moving At Machine Lock

B-Axis Moving At Machine Lock

147


3. Single Block Alarm

3.1 2160 Lub. Level Low 1) Description

The lubricant tank that supplies lubricant to the axial guide ways, the ball screws, and the bearings has run out of lubricant.

2) Cause of problem

① The lubricant tank has insufficient lubricant. ② An error in the lubricant level switch of the tank or related parts, or problem with the wiring

cables 3) Action

① Refill the lubricant tank in the rear of the machine with lubricant (way lubricant). (it is recommended to make a rule to refill the tank once every 3 or 4 days (based on 8 hours per day))

② Check the lubricant tank, connection line between tank and terminal block of the electric cabinet, and input module, and make repair or replacement if you encounter a problem.


(Pin) Numbering

Lub. Level Check X5.0

(LUB.M) -SV51


XJ411 (3) SV51


X5.0 LUB.M Lub. Level Low

A19.7 2160 Lub. Level Low


Lub. Level Low

148


Lub. Level Lub. Level

Switch

149


3.2 2161 Lub. Pressure Alarm 1) Description

After the lubricant motor of the lubricant tank that supplies lubricant to machine components such as guide ways, ball screws and bearings started driving, the pressure does not increase to a specified level (15Kg/㎠), or it does not fall back to the specified level within 10 seconds ever since.

2) Cause of problem

① The lubricant supply line (Lub. Hose, Lub. Pipe, Lub. Tube, etc) is loose or has a leak. ② An error in the distributor value ③ An error in the lubricant tank or related parts, or a problem with the wiring cables

3) Action

① Check the lubricant supply line (Lub. Hose, Lub. Pipe, Lub. Tube, etc) and make repair or replacement if necessary.

② If there is no particular problem with the lubricant supply line but the lubricant is supplied intensively to a specific component, this is thought to be caused by a defective distributor valve. If this is the case, replace it with a new one.

③ Check the lubricant tank, connection line between tank and terminal block of the electric cabinet, and input module, and make repair or replacement if you encounter a problem.


(Pin) Numbering

Lub. Pressure Check X5.1

(LPRS.M) -SP51


XJ411 (20) SP51

Lub. Pressure Switch

Lub. Pressure Gage

150



R841.6 LPRSAL Lub. Pressure Alarm

A20.0 2161 Lub. Oil Pressure Down

R373.6 AL50R AL50 Reset


R620.0 TM01 Guide Way Lub. Motor On Time

R691.0 NO-MOV No Movement Each Axis

Y0.4 LUBM.R Lubrication For Guide Way

X5.1 LPRS.M Lub. Pressure Check

X5.2 LMS.M Lub. Manual Start

R623.3 TMB4 Lub. Pressure Check D-Time

Lub. Oil Pressure Down

Lub. Pressure Alarm

Lub. Pressure Check D-Time

151


3.3 2162 Parts Count End Alarm 1) Description

The parts count reaches the limit. 2) Cause of problem

The count of the machined parts reaches the maximum value. 3) Action

Adjust the parts count settings, or reset it.


F62.7 PRTSF Parts Count(NC) Max

A20.1 2162 Parts Count End Alarm

? RUN HOUR AND PARTS COUNT [4.36]06700 L1 0000000106710 L1 5406711 L1 406712 L1 4

#0 Part count (0:M02/30,1:M54)M code that counts the number of machined parts

Number of machined partsTotal number of machined parts

Parts Count End Alarm

152


3.4 2164 Oil Cooling Unit Alarm 1) Description

An error occurred in the oil cooling unit that cools down the main spindle. 2) Cause of problem

An error in the oil cooling unit 3) Action

Refer to the oil cooling unit's manual, and check the alarm description and take a necessary action.


(Pin) Numbering

Oil Cooling Unit Fault X2.5

(OCFT.M) -OCFT


XJ411 (47) OCFT

Oil Cooling Alarm X2.7

(OCCF.M) -OCFT1


XJ411 (46) OCFT1


X2.5 OCFT.M Oil Cooling Unit Alarm

X2.7 SOCF.M Oil Cooling Alarm

K19.5 KSOCU Special Oil Cooling Unit



A20.3 2164 Oil Cooling Unit Alarm

Oil Cooling Unit Alarm

153


※ Troubleshooting for oil cooler alarms

RUN No. Cause Action

● AL 1 Overload of the oil motor pump Refer to the user manual of the pump and check the oil circuit.

● AL21 The circuit protector “F2” or “S40” is tripped.

Refer to the user manual and clean the air filter

● AL 4

The temperature switch for protecting the heater is tripped. (only applied to the heater-equipped models)

●

AL 61 Short-circuit of the master temperature sensor ▪Check the sensor if short-

circuited ▪ Check the connector if contacted loose

▪ Replace with a new sensor

AL 62 Short-circuit of the slave temperature sensor

AL 63 Short-circuit of the reference temperature sensor

● AL 71 An error in the CPU of the control board Replace the control board

AL 73 A communication error of the control board

Refer to the user manual and check DIP switch #1

The “H” and current temperature indicators blink

▪ The controlled temperature exceeds the specified upper limit.

▪ It exceeds the alarm limit.

The “45” indicator blinks.

The controlled temperature exceeds 45˚C.

The “L” and current temperature indicators blink

▪ The controlled temperature exceeds the specified lower limit.

▪ It goes below the alarm limit.

The “5” indicator blinks.

The controlled temperature goes below 5˚C.

The “FIL” indicator blinks

It's time to clean the filter. Clean the filter and reset the machine

The “●” symbol above indicates that the indicator is turned off.

154


☞ Troubleshooting for Kaukan Oil Cooler alarms

Item No. Cause Action

1

The machine turns on but no response is made.

1) The PCB is defective. Replace the PCB 2) Fuse A1 for power supply (SMCC-

233) is defective. Replace the fuse.

3) The power supply module SMCC-233 is defective.

Replace SMCC-233

4) The transformer is defective. Replace the transformer

2 E01

1) Negative sequence wiring of the power supply unit

Reconnect any two phases of 3 power phases (see Ch4-4)

2) Reconnect only two power phases of 3 phases

Check if three power phases are correctly wired.

3) Out of AC220±15% Check the AC power source.

3 E02

1) The pump motor overload breaker has triggered.

Reset the QFP switch to release the breaker. (Push button)

2) Resetting the QFP switch does not work (push button not released)

This is because the overload breaker is damaged. Replace QFP.

3) The pump motor is defective. Replace the motor.

4 E03

1) The compressor motor overload breaker has triggered.

Reset the QFP switch to release the breaker. (Push button)

2) Resetting the QFP switch does not work (push button not released)

This is because the overload breaker is defective. Replace QFP.

3) The compressor motor is defective. Replace the motor.

5 E04

1) The pressure switch of the refrigerant is defective.

Replace the switch.

2) Out of effective range (-10℃~45℃)

Wait until the temperature falls in the effective range.

3) The air filter is clogged. Clean the air filter. 4) The condenser is clogged. Clean the condenser.

6 E05

1) The input pipe is not connected properly.

Tighten up the pipe.

2) The input/output pipes are switched with each other.

Reconnect and tighten up the pipe.

3) The oil/water quantity is too low. Find out the cause and make a refill.

4) The woodruff key of the pump or the rotor shaft of motor is worn out.

Replace the pump or motor.

5) Unable to adjust the pump pressure Replace the pump. 6) Defective oil/water pressure switch Replace the switch. 7) Hose, oil/water filter is clogged. Clean the hose, replace the

oil/water filter (optional). 8) Excessive pump pressure Adjust the pump pressure

155


Item No. Cause Action properly, or check and clean the oil/water filter if necessary.

7 E06 1) The oil/water is insufficient. Refill the tank with the oil/water.

8 E07 1) The water in the pipe is not

circulating. The input/output pipe is clogged. Cleaning

2) The float switch is burnt out. Replace the switch.

9 E08 1) The oil/water temperature is below

zero(0℃). Turn off the power and wait until the temperature increases.

2) The refrigerant switch is defective. Replace the switch. 10 E09 The oil/water sensor is defective. Replace the sensor.

11 E10 The room temperature sensor is defective.

Replace the sensor.

12 E11 Excessive oil/water temperature (adjust the effective range of STC45℃ by a technician)

Contact a technician to adjust the temperature range or improve the cooling capacity.

13 E12 1) Insufficient refrigerant Refill the refrigerant. 2) The current cooler has comparably

insufficient cooling capacity. Replace it with a larger-capacity cooler.

▶ If you encounter that the oil/water cooler is overheated during its operation, refill the refrigerant regularly.

▶ Use only the refrigerant that is specified in the nameplate, or consult with a professional.

※ Troubleshooting for Daikin oil cooler alarms

1) If no alarm occurs but the cooler works abnormally

Item No. Cause Action

1

It doesn't work at all. (The power indicator of the control panel does not turn on)

① The main power is not supplied, or the power line (L1, L2) is improperly connected.

Check the power supply line if it is connected properly.

2 The pump does not operate at all.

① The remote control items [10] and [11] are deactivated.

Check if the remote control items are active.

② The pump is locked on operation. (The pump is locked on operation by factory default)

Release the lock at the control panel.

3

The pump is operating but no oil is flowing. Oil circulation is insufficient

① The intake pipe of the pump is loose.

Tighten the packing of the piping.

② The intake strainer is clogged. Unclog the intake strainer. If the oil in the oil tank is contaminated, replace with new oil.

156


Item No. Cause Action with a lot of noise.

③ The oil quantity level in the oil tank has lowered.

Refill the tank with the oil

④ The pressure loss of the oil discharge pipe is great, and the pump relief valve is activated.

Replace the oil pipe with a larger-diameter one, and make the length of the pipe shorter.

⑤ The pressure loss of the oil intake pipe is great, and the pump is cavitating.

---

4

The pump is working but the compressor is not operating.

① The compressor is stopped under the temperature control.

Check if it resumes working properly after the timer setting time.

② The anti-restart timer (30 seconds) for the compressor is ticking.

Check if it works properly when the oil temperature on the mouth is 5℃ or higher.

③ The low oil temperature protection system (below 2℃ on the mouth) is active.

Check if it works properly when the oil temperature on the mouth is 5℃ or higher.

④ The low ambient temperature blocking system (below -2℃ in room temperature) is active.

Check if it works properly when the ambient temperature is 0℃ or higher.

⑤ The capacity is set to 10% in mode 9.

Switch to a proper operation mode.

5

Both pump and compressor are operating but no oil is cooling.

① There is an obstacle near the air intake/exhaust port.

Remove the obstacle.

② The air filter is clogged. Clean the air filter, ③ The room temperature is high and

the pump/compressor is load performing.

Check the catalog for the temperature range available for each model. Select an appropriate model to what you need to use.

④ The heat load is great.

⑤ The temperature is set high. Set the temperature to a proper degree.

⑥ If the temperature of the exhaust air is almost equal to the room temperature while the compressor is operating, this is because the refrigerant is insufficient.

Turn off the fail-safe switch (SW1) on the control board.

6 Operational settings are not allowed.

① If "---" is displayed on the data screen, the sensor used in the applicable operation mode is not properly connected.

Connect the temperature sensor properly.

② If "---" is displayed temporarily when you press the ENT button (right utmost), this is because the

Turn off the fail-safe switch (SW1) on the control panel.

157


Item No. Cause Action fail-safe switch is turned on.

7

The alarm 【64】 and 【65】are displayed and performed differently from the previous models.

① The signal connection of the alarm output is changed partially.

The alarms [60] and [63] are compatible with the previous models (AKS5 and AKZ6 series). However, [64] and [67] are changed in the message and connection method differently from the 7 series. For more details, refer to the "How to use old models" section at the end of each instruction manual.

2) If an alarm occurs, (turn off the machine and restart it if you want to set off the alarm) Alarm

Code

Alarm

Level

Description Cause Action

AA 2 Heater overloaded (S4B1:CN4) (applicable to heater-installed models only)

① For AKZ type, no oil is running.

Check if the hydraulic circuit is connected properly, and the pump is operating normally.

① For AKZJ type, the tank has insufficient oil quantity.

Refill the oil.

A6 2

DC motor is not locked

① DC fan motor is defective.

Replace the DC fan motor.

① There is a problem in communications between fan motor and control device.

Check the connector, check for any short circuit, and replace the control device.

E1 1 System error ① The internal parameter

settings are invalid. Replace the control board.

E3 2

High pressure (high-pressure switch (S3PH:CN6) is tripped)

① The oil or room temperature is beyond the working range.

Use the machine within the working temperature range.

② There is an obstacle near the intake/exhaust opening.

Do not place any object within 500mm near the intake/exhaust port.

③ The filter is clogged or the condenser is contaminated.

Refer to Item 8 above, and clean the air filter.

④ Others Contact us (Daikin) at the

158


Alarm

Code

Alarm

Level


customer service team. E5 2 The

compressor is overheated. (Thermo TH6 on the emission pipe is tripped) (Compressor head thermo (S2B:CN) is tripped)

① The oil or room temperature is beyond the working range.

Use the machine within the working temperature range.

② There is an obstacle near the intake/exhaust opening.


③ The filter is clogged or the condenser is contaminated.

Refer to Item 8 above, and clean up the air filter.

E6 2 The compressor (M2C) is locked.

① The compressor is defective (needs to be replaced).

Replace the compressor.

EH 1

Pump high-currented Circuit Breaker (S1B:CN3) is tripped.

① The pump is overloaded due to use of the high-viscosity oil.

Use only the operating fluid that has the viscosity range of 4 ~ 200 mm2/s within the working temperature range.

② The pump motor is over-currented because the power voltage is lower than the effective range.

Check if the power voltage is lower than the effective range, or check if there occurs a sudden voltage drop for few seconds at the startup of peripheral equipment.

③ Disconnected wiring of the pump motor

Replace the pump motor.

④ The pump is clogged with debris or the motor is defective.

Replace the pump motor.

EJ 1/2 Optional protective device is activated (OP).

① Any optional protection device is activated. (For the unit, there are some devices connected by factory default)

Check the result of detection that is performed by the protective device.

H1 2 An error in the air temperature sensor (TH5: Gas Sync Sensor) (TH3: Ambient Temp Sensor)

①The air sensors used in the control system is short-circuited.

Check if there is any defective sensor on the monitor of the operation panel ("99.9" will be displayed for a defective sensor), and check also if the sensors are connected correctly.

159


Alarm

Code

Alarm

Level


FH 2

The temperature on the intake opening exceeds 60℃.

① The heat of the main body exceeds the cooling capacity of the oil corn. (choice of an inappropriate model)

If the compressor is operating at100% of its capacity in normal conditions (check this on the monitor), select a model one size bigger.

② There is an obstacle near the inlet/outlet opening, which causes deteriorating the cooling capacity.


③ The unit is running under capacity suppressing control because it has exceeded the standard temperature (room temp: 35℃, oil temp: 35℃), causing deteriorated cooling capacity.

If beyond the standard temperature, the cooling capacity is lowered than the nominal capacity by the load control system. Make sure that the capacity of the oil cooling unit exceeds the heat generation of the main unit in the entire operating temperature range.

④ Temperature control is disabled as the machine is operating in mode 9 (capacity direct designation mode)

Switch to a proper operation mode. (In capacity direct designation mode, feedback control of temperature is not enabled.)

⑤ The refrigerant gas is leaking.

If the temperature of the emission air is equal to the room temperature, there is a risk of leak of the refrigerant gas. If this is the case, contact us to the customer service team.

JH 2 Error in oil temp sensor (TH2: outlet oil temp sensor) (TH4: inlet oil temp sensor)

① Short circuit of the oil temp sensors used in the control system

Check if there is any defective sensor on the monitor of the operation panel ("99.9" will be displayed for a defective sensor), and check also if the sensors are connected correctly.

J3 2 An error in the temp thermistor on the emission

① Short circuit or disconnection of the temperature thermistor of

Check if the thermistor is connected correctly.

160


Alarm

Code

Alarm

Level


pipe the condenser. J5 2 Error in the EV

valve outlet opening temp thermistor

① Short circuit or disconnection of the EV valve outlet opening temperature thermistor.


J6 2 An error in the temp thermistor of the condenser

① Short circuit or disconnection of the temperature thermistor of the condenser.


L0 2 Error in the compressor line of the inverter

① Defective compressor or inverter

Replace the control system or the compressor.

LC 2 Communication error between inverter and temp control CPU.

① There occurred a communication error between temperature control MICOM and inverter MICOM.

Replace the control system, or improve the power supply condition (such as noise reduction).

P3 2 Error in the temp thermistor on the cooling fin

① Short circuit or disconnection of the temperature thermistor of the control box.


P4 2 Error in the temp thermistor on the cooling fin

① Short circuit or disconnection of the temperature thermistor on the heat sink.


U0 2

Insufficient gas

① The refrigerant piping is damaged due to excessive vibration in its transportation, leading to a leak of the refrigerant gas.

Repair the damaged refrigerant piping, and refill the refrigerant gas.

U1 1

Power supply reverse-phase connection

① The power supply circuit is connected in reverse phase.

Switch the reverse phases with each other.

② The L3 phase is open. Make sure that the L3 phase is properly connected to the power supply terminal block.

U2 2 Sudden power failure • Insufficient power

① The power voltage is below about 70V.

Check if there occurs an instantaneous voltage drop at the startup of peripheral equipment.

U9 2 Communication ① Communications error Check if the communication line

161


Alarm

Code

Alarm

Level


s error in other systems (communication error between slave and master)

with a slave device. is properly established with the slave device. (this error occurs only if the slave device does not make response in master-slave communication.)

UH 2 System line failure (EEPROM error)

① The parameter settings that are saved in the control board are invalid.

Replace the control board.

UJ 1/2

OP2 activated

① Any optional protection device is activated. (For the unit, there are some devices connected by factory default)

Check the result of detection that is performed by the protection device.

1E ~

- Temperature range warning 1

① The temperature of the target to be monitored has exceeded the specified range. (not a fault of the oil cooling unit)

Check the warning message.

5E - Temperature range Warning 5

162


3.5 2166 Filter Changer of TSC. Alarm 1) Description

The filter of the high-pressure coolant unit (TSC) is clogged, which needs to be replaced. 2) Cause of problem

① The filter of the high-pressure coolant unit (TSC) is clogged. ② Error in the filter sensor, possible disconnection of the wiring through to the terminal block

of the electric cabinet, or defective component parts. 3) Action

① Replace the filter with a new one. ② Check the filter unit, and wiring between filter unit and terminal block of the electric

cabinet as well as the input module, and make repair or replacement if you encounter a problem.


(Pin) Numbering

TSC Filter Check OK X3.3

(FILT.M) -SP16


XJ411 (11) SP16


R627.2 TMB35 Filter Abnormal Status Check Time

F0.6 SA Servo Ready

Filter Changer of TSC Alarm

Filter Abnormal Status Check time

163



A20.5 2166 Filter Changer of TSC. Alarm



K12.7 KCO&MD Cool. Dual High TSC or Did TSC

K11.0 KHFLTSC High TSC Flow Switch Used

K9.2 KHTSC Tank Type High Pressure TSC Used

K4.4 KFIT Filter Check SW is Not Used

164


3.6 2167 High TSC Flow Down Alarm 1) Description

The high-pressure coolant unit (TSC) has insufficient coolant. 2) Cause of problem

① Coolant is not supplied properly because the filter or pump of the high-pressure coolant unit (TSC) is defective.

② An error in the coolant flow sensor, possible disconnection of the wiring through to the terminal block of the electric cabinet, or defective component parts.

3) Action

① Check TSC pump & motor, filter and wiring cables, and make repair or replacement if necessary.

② Check the filter unit, and wiring between filter unit and terminal block of the electric cabinet as well as the input module, and make repair or replacement if you encounter a problem.


(Pin) Numbering

TSC Filter Check OK X3.3

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


R440.6 TMB103 Filter Abnormal Status Check Time F0.6 SA Servo Ready

A20.6 2167 High TSC Flow Down Alarm


Flow Indicator Abnormal Alarm

Flow Indicator D-Time

165




Y8.1 TSC2.R T.S.C Run

K9.2 KHTSC Tank Type High Pressure TSC Used

K11.0 KHFLTSC High ATC Flow Switch Used

166


3.7 2168 Coolant Pressure Down Alarm 1) Description

The coolant pressure alarm has occurred from the high-pressure TSC unit (with tank type or cool jet & dual, middle TSC).

2) Cause of problem

① Insufficient coolant ② Check the recovery pump motor of the coolant tank, coolant pump & motor and pressure

sensor if they work properly. Check the wiring through to the electric cabinet and make repair or replacement if necessary.

3) Action

① Refill the tank with the coolant. ② Check the pump motor, and wiring between pressure sensor of TSC unit and OP, and

between OP and terminal block of the electric cabinet as well as the input module, and make repair or replacement if you encounter a problem.


(Pin) Numbering

Coolant Pressure Check

X3.2 (TSCA.M)

-SP15 Input Module Slot :

07 XJ411 (44) SP15


X3.2 TSCA.M T.S.C Unit Alarm /Coolant Over Flow

F0.6 SA Servo Ready

A20.7 2168 Coolant Pressure Down Alarm


K5.2 KDMTSC Used TSC of Dmvg Type

Coolant Pressure Down Alarm

167


3.8 2170 Tool Life Count End Alarm 1) Description

The tool change signal (of tool life cycle management) is detected. 2) Cause of problem

The tool has reached its life cycle specified in Tool Life Management, triggering the tool change request signal.

3) Action

Take an action according to the Tool Life Management instructions.


F64.0 TLCH Tool Change Request

R652.1 M32H M02/M30 Hold


F2.1 RPDO

Tool Life Count End Alarm

168



K8.7 KTLIFE Make Single Block Stop, Life



A21.1 2170 Tool Life Count End Alarm


K13.6 KFMS FMS Interface is Used

R1486.0 FMS.C FMS Mode From Screen

R6520.5 PGNFND Program Not Fount Aux.

R670.0 STFL Start Flag for brake Cace

R666.5 M286F Tool Pre Check Flag

R670.6 M288F M288 Retract Function Flag

K80.3 KTLCEA Tool Life Count End Alarm Not Used

169


3.9 2171 RST Command Alarm On STL 1) Description

Immediately after NC Reset during the auto operation, the cycle start is performed in Auto mode.

3) Action

If NC reset is performed in auto operation, you must reset it again in Edit mode and then locate the program block before performing the cycle start in Auto mode.

Address Symbol Coil Comment R634.1 MEM Memory Mode R634.2 TAPE Tape Mode R835.7 FRSTAL Flag Reset Alarm X33.7 ST.M Cycle Start A21.2 2171 Reset Command Alarm On Cycle Start

R652.7 ARST Alarm Reset R835.6 RSTALM Aux. Reset Alarm

F1.1 RST NC Reset R634.0 EDIT Edit Mode R652.1 M32H M02/M30 Hold

F0.6 SA Servo Ready F0.5 STL Cycle Start

G44.1 MLK All Axis Machine Lock

Reset Command Alarm On Cycle Start

Flag Reset Alarm

Aux. Reset Alarm

170


3.10 2172 Tool Length Sensor Up Status 1) Description

The Pallet Change command was instructed with the tool length sensor positioned up, or the operator attempted to move the axis in Jog mode without the command of M75.

2) Cause of problem

Mistake by the operator 3) Action

Ensure that the operator positions down the tool length sensor before instructing Pallet Change or moving the axis. M75 : Tool Measure Sensor On M76 : Tool Measure Sensor Up M77 : Tool Measure Sensor Down

Tool Length Sensor Up Status

Tool Length Sensor On

Tool Length Flag

171





F102.0 MV1

F102.1 MV2

F102.2 MV3 Z-Axis Moving Signal

F102.3 MV4

X34.5 PJF.M Jog Feed +Direction

X34.6 NJF.M Jog Feed -Direction


R800.4 SEN2 Tool Length Sensor On


Y3.3 TLUP.R Tool Length Sensor Up

X7.5 TLDN.M Tool Length Sensor Down

A21.3 2172 Tool Length Sensor Up Status


R800.3 M75F Tool Length Flag

R800.6 M73F M74, 5 Not Use Flag


R800.1 M74F Work Measure Flag

F0.6 SA Servo Ready

R609.0 M75 Tool Measure Sensor On

F1.3 DEN Distribution End

K0.7 KTLENG Moving Type Tool Meas. Is Used

172


3.11 2173 Wait. & Mag. Pot Tool Detect 1) Description

While any operation of Tool Change, Tool Search or Sub Changer Waiting Pot Side is performing, the switch for the tool pot tool sensor is turned on.

2) Cause of problem

① A pot that is supposed to be empty has a tool inserted by mistake. ② An error in the tool pot tool sensor of the tool magazine ③ An error in the switch, or the wiring from the switch to the electric cabinet, or any of its

component parts 3) Action

① A tool pot in the spindle where a tool is supposed to be inserted should be empty. ② An error in adjusting the position sensor switch

While checking the indicator on the proximity switch that is installed on the tool pot tool detect cylinder of the tool magazine, adjust the proximity switch as appropriate.

③ An error in wiring or component parts Check the proximity switch, the wiring from the proximity switch to the ATC terminal box and from the terminal box to the electric cabinet as well as the input module if there is a problem. Repair or replace the defective part if necessary.


Cable, Proximity Switch ECBLS0170F -WK215 BKS B20-1-03 Balluff

Switch, Proximity / PNP ESWPX0265F -SX33 BES516-325-E5-C-S4 Balluff


(Pin) Numbering


X7.6 WPSS.M

-SL36 Input Module Slot :

8,9 XJ412 (10) SL36

ATC Waiting Pot Tool Detect

X11.0 WPDT.M

-SX38 Input Module Slot :

09 XJ413A(12) SX38

173



R456.5 TMB225 Wait & Mag. Pot Detect Check Time

A21.4 2173 Wait & Mag. Pot Tool Detect



X7.6 WPSS.M Waiting Pot Spindle Side_HM4D


R5304.3 RTCCMF Re-Change T-Code Command Flag

Wait. Pot Tool Detect(SX5A)

Wait. Pot Spindle Side (SL36)

Wait. & Magazine Pot Tool Detect

Wait & Mag. Pot Detect Check Time

174



X11.0 WPTD.M Waiting Pot Tool Detect

R5319.2 MSCWPP Man Sub Changer Wait.Pot Pos. Command

R5304.5 MAGTOD Magazine Pot Tool Detect

K0.6 KMATRX Matrix Tool Magazine is Used

175


3.12 2175 Hyd. Unit Oil Temperature Alarm 1) Description

A machine featuring a heater-equipped hydraulic unit has an excessive or oil temperature. 2) Cause of problem

① Overheat or over-cooling of the hydraulic oil ② An error in the heater of the hydraulic unit, the wiring through to the electric cabinet, and

any of its component parts 3) Action

① This problem happens because of an error in the heater of the hydraulic unit. Refer to the product manual and take a necessary measure.

② Check the heater, the heater thermometer and the electric cabinet of the hydraulic unit, and the wiring between the electric cabinet and the terminal block of the electric cabinet as well as the input module, and make repair or replacement if you encounter a problem.


(Pin) Numbering

Hyd. Unit Temp High X3.4

(HYDH.M) -TH02


XJ411 (27) TH02

Hyd. Unit Temp Low X3.5

(HYDL.M) -TH03


XJ411 (43) TH03


X3.4 HYDH.M Hyd. Unit Temp High

X3.5 HYDL.M Hyd. Unit Temp Low

A21.6 2175 Hyd. Unit Oil Temperature Alarm


Hyd. Unit Oil Temperature Alarm

176


4. Massage Alarm

4.1 2191 Coolant Chiller Unit Alarm 1) Description

The coolant chiller unit that cools the coolant has a problem. 2) Cause of problem

An error in the coolant chiller unit 3) Action

Refer to the manual of the coolant chiller unit, and check the alarm description and take a necessary action.


(Pin) Numbering

Coolant Chiller Unit Alarm

X4.6 (CCAL.M)

-M251 Input Module Slot :

07 XJ411 (22) M251


X4.6 CCAL.M Coolant Chiller Unit Alarm

A23.6 2191 Coolant Chiller Alarm


K14.3 KCHILL When Chiller Used Set 1

Coolant Chiller Unit Alarm

177


4.2 2193 Safety Switch Locking Alarm 1) Description

The release key of the splash guard's door-close check safety switch is opened. 2) Cause of problem

① The release key of the safety switch is tripped. ② The safety switch has an error or the wiring has a problem.

3) Action

① Turn the release key of the safety switch to set it off. ② Check the operator's side safety switch as well as the wiring, and repair or replace a

defective one if necessary.


(Pin) Numbering

Main Door Unlock Key Switch

X4.2 (OSDO.M)

OSDO Input Module Slot :

07 XJ411 (39) OSDO


X4.3 (OSDI.M)

-S13A Input Module Slot :

07 XJ411 (06) S13A


R649.1 UNLILK Unlocking in Door Lock Status

A24.0 2193 Safety Switch Unlocking Alarm


Safety Switch Locking Alarm

Unlocking In Door Lock Status

Door Lock Timer

178



R439.0 TMB89 Door Lock Time

X4.2 OSDO.M Main Door Unlocking Key Switch

Y11.7 OSDI.M Door Open Condition


179


4.3 2194 Man Axis Moving Interlock 1) Description

One of the axes (X, Y, Z or B) has tripped Axis Interlock. As a result, the Handle or Jog mode for that axis is disabled.

2) Cause of problem

① Any of ATC, APC, the table or the door was not in its initial position. Or, the sensor switch was deactivated.

② With an axis being in the reference point, the operator returned the axis to the reference point in the + direction manually.

3) Action

① Check each and every axis, and adjust the switch as appropriate or take a necessary action. ⓐ For the X axis

- APC Arm Interlock

Address X18.5 (SX75)

X18.6 (SX76)

X18.1 (SX71)

X18.3 (SL76)

Status 1 0

1 1 0 1

- Table/Pallet Unclamp Interlock

Address X7.2 (SL63)

X7.1 (SP62)

Y15.0 (YV61)

Y15.2 (YV63)

Status 1 1 0 0

- Splash Guard Door Interlock

Address X4.2 (SODO)

X4.3 (S13A)

Status 1 1

ⓑ For the Y axis


- APC Arm Interlock


- ATC Interlock

Address X8.5 (SX41)

X8.6 (SX42)

X8.7 (SX43)

X12.1 (SL51)

X12.2 (SL52)

Status 1 0 0 0 1

180


ⓒ For the Z axis - APC Arm Interlock


- ATC Interlock


ⓓ For the B axis

- APC Arm Interlock


- B-Axis (Table) Interlock

Address X7.2 (SL63) X7.1 (SP62)

Status 1 1

② When setting the reference point for each axis, turn the selection switch in the - direction,

or reverse the axis in Handle mode before resetting the reference point.


(Pin) Numbering

APC 180 CW Position X18.5

(P18F.M) -SX75


XJ410 (47) SX75

APC 180 CCW Position X18.6

(P18R.M) -SX76


XJ410 (30) SX76

Table Clamp X7.2

(BCLP.M) -SL63 Input Module Slot 08 XJ412 (11) SL63

Tool Measure Sensor Down Check

X7.5 (TLDN.M)

-SD62 Input Module Slot 08 XJ412 (43) SD62

Set Up Door Interlock X8.2

(SUIT.M) -S12 Input Module Slot 08 XJ412 (39) S12

APC Home Position X18.0

(AHOM.M -SX70


XJ410 (46) SX70

APC Changer Down X19.1

(APDN.M) -SX82 Input Module Slot 10 XJ413 (28) SX82

APC Pos. 0/Arm Open X18.1

(APOP.M) -SX71


XJ410 (32) SX71


X4.3 (OSDI.M)


Pallet Clamp X7.1

(PTCL.M) -SP62 Input Module Slot 08 XJ412 (28) SP62

Main Door Unlock Key X4.2 OSDO Input Module Slot 07 XJ411 (39) OSDO

181



(Pin) Numbering

Switch (OSDO.M)

Pallet Unclamp Y15.0

(PAUC.R) -YV61 Output Module Slot 4 XJ403 (03) KAR57

Table Unclamp Y15.2

(TAUC.R) -YV63 Output Module Slot 4 XJ403 (35) KAR59

Main Changer Arm Home Pos.

X8.5 (CAHP.M)


Spd. Tool Unclamp Command

X8.6 (ULMD.M)



X8.7 (CLMD.M)


ATC Door Open X12.1

(ATDO.M) -SL51 Input Module Slot 09 XJ413 (24) SL51


(ATDC.M) -SL52 Input Module Slot 09 XJ413 (39) SL52

Man Axis Moving Interlock

182



G130.0 B.ITX X-Axis Interlock

R637.0 JX Jog X-Axis Select

G130.1 B.ITY Y-Axis Interlock

R637.1 JY Jog Y-Axis Select

G130.2 B.ITZ Z-Axis Interlock

R637.2 JZ Jog Z-Axis Select

G130.3 B.IT4 B-Axis Interlock

R637.3 J4 Jog B-Axis Select

G8.0 B.IT All-Axis Interlock

X34.5 PJF.M Jog Feed + Direction

X34.6 NJF.M Jog Feed - Direction

X39.2 HX.M MPG Handle X-Axis Select

X39.3 HY.M MPG Handle Y-Axis Select

X39.4 HZ.M MPG Handle Z-Axis Select

X39.5 H4.M MPG Handle 4th-Axis Select

K3.3 K3MPG K3MPG UsedR635.4

183



R635.4 H Handle Mode


K20.0 KZPX X-Axis Ref. Point Return Keep

F94.0 ZPX X-Axis 1st Ref. Return

K20.1 KZPY Y-Axis Ref. Point Return Keep

F94.1 ZPY Y-Axis 1st Ref. Return

K20.2 KZPZ Z-Axis Ref. Point Return Keep


X34.3 AS4.M Jog Axis Selection 4

G43.7 ZRN Reference Point Return

F96.2 ZP2Z Z-Axis 2nd Ref. Return

F102.3 MV4

K16.3 KBXIT B-Axis Move in Z-Axis Home Pos.

A24.1 2194 Man Moving Interlock

▪ X-axis Interlock

X-Axis Interlock

APC Arm Interlock

184



R641.5 F0% Feedrate Override 0%

R698.0 IFZONE Machine Interference Zone Error 1

R631.0 SPCLFH Spindle & Coolant at Feed Hold

R631.4 AXINT Axis Interlock by Spclfh

R641.4 AITRLS Axis interlock Release

R769.7 APCINT APC Arm Interlock

Table/Pallet Unclamp Interlock

B-Axis(Table) Clamp Check Time

185



R731.0 ZXYINT XY-Axis Interlock by Z-Ref. Pos.

G66.0 IGNVRY Ignore Vrdy Off Alarm

R690.3 HOLDON AL88 Alarm Hold on Flag

R649.0 DINON Splash Guard Door Interlock On

R669.0 ZRNB Ref. Point Return for B-Axis

R641.1 ZRNRDY Ref. Point Return One Touch Ready

K50.1 RTIMEM Rigid Tap Interrupt Memory

R2850.5 RTRENB Rigid tape retract Enable

R752.4 TMBINT Table/Pallet Unclamp Interlock

X18.5 P18F.M APC 180 CW Position

X18.6 P18R.M APC 180 CCW Position

X18.1 APOP.M APC Pos. 0/Arm Open


X18.3 APCL.M APC Pos.90/Arm Close


R772.5 APRETC APC Arm Return Confirm

Y8.4 CADV.R Pallet Changer Arm Advance


X16.0 SG1O.M Splash Guard 1 Open


X16.2 SG2O.M Splash Guard 2 Close


R448.4 TMB165 B-Axis(Table) Servo Off D-Time

R624.4 TMB13 B-Axis(Table) Clamp Check Time

Y7.2 TUCL.R Table Unclamp

Y15.2 TAUC.R Table Unclamp


X7.1 PTCL.M Pallet Clamp

R435.2 TMB59 Pallet Unclamp Check Time

Y7.0 PUCL.R Pallet Unclamp

Y15.0 PAUC.R Pallet Unclamp


F3.1 MH

186



R750.5 BCMDER B-Axis Command Error

R750.4 RTCLP Table(Rotary) Clamp



G126.3 SVF4 4th-Axis Servo Off


K0.2 KHM50 Ace-HM50 Machine

X11.7 APLK.M Arm Pin Locking



Y15.3 TACL.M Table Clamp

R797.4 4RTCLP Rotary Table Clamp

▪ Y-axis Interlock

Y-Axis Interlock

Y-Axis(Table) Interlock Aux.

187



R725.3 BITYA Y-Axis Interlock Aux


R752.6 TMBINT1 Table Unclamp Interlock





X12.0 ZAIL.M Z-Axis Interlock

R718.6 ATCINT1 ATC Interlock 1


R408.3 M231 Tool Changer M-Code Aux

R731.0 ZXYINT XY-Axis Interlock by Z-Ref. Pos.

R690.3 HOLDON AL88 Alarm Hold On Flag






X2.6 PFM.M Power Failure Detection

K2.1 KPFM Used Power Back Up Module




ATC Interlock

188



R757.5 APCCHG Pallet Change Command


R718.7 ATCINT ATC Interlock

X8.5 CAHP.M Main Changer Arm Home_HM4D


K12.2 KMATC When Used Maintenance for ATC

X8.6 MLMD.M Spindle Tool Unclamp Command_HM4D

X8.7 CLMD Spindle Tool Clamp Command_HM4D




▪ Z-axis Interlock

Z-Axis Interlock

Z-Axis Interlock Aux.

189



R725.4 BITZA Z-Axis Interlock Aux








X12.0 ZAIL.M Z-Axis Interlock

R718.6 ATCINT1 ATC Interlock 1

G100.2 +Z Jog +Z Axis



R408.3 M231 Tool Changer M-Code Aux

A27.0 2217 Arm Rot. Count Error Alarm









ATC Door Z-Axis Interlock

190



R718.7 ATCINT ATC Interlock


R730.7 ATDZIT ATC Door Z-Axis Interlock

K24.6 KATDOP ATC Door Open Keep

K14.6 KADCZ When Z-Moving After

K24.7 KATDCL ATC Door Close Keep



R709.0 ATCMST ATC Macro Start



▪ B-axis Interlock

B-Axis Interlock

B-Axis Interlock Aux.

191



R725.7 BIT4A B-Axis Interlock Aux


R695.7 BXINT B-Axis Interlock by X-Axis Zone


B-Axis(Table) Interlock

192



Y3.3 TLUP.R Tool Length Sensor Up


R752.5 BXIT B-Axis Interlock Disable

R648.3 BAXINT B-Axis Interlock

K16.6 KPOSSW Keep Position Switch is Used





R624.3 TMB12 B-Axis(Table) Servo On D-Time

R625.2 TMB19 B-Axis(Table) Servo On D-Time

F102.3 MV4

R752.1 BAINT B-Axis(Table) Interlock





X7.0 PTUC.M Pallet Unclamp


X7.3 BULP.M Table Unclamp



Y15.3 TACL.R Table Clamp


G43.7 ZRN Reference point Return

K8.0 KB/ABS B-Axis S/Motor Absolute Used


193


▪ Interlock on all axes







Y3.3 AXINT Axis Interlock by Spclfh

X7.5 TLDN.M Tool length Sensor Down

K0.7 KTLENG Moving type Tool Meas. is Used

R800.4 SEN2 Tool length Sensor On




All-Axis Interlock

194


4.4 2195 OP- Door Close, Must Be D-Open 1) Description

The operator did not open the operator side door or the splash guard door before pressing the Spindle Tool Unclamp button.

2) Cause of problem

The door in the operator side had not been open before the spindle tool unclamp operation was performed.

3) Action

① Be sure to open the door in the operator side before pressing the Tool Unclamp push-button switch.

② Check the operator's side safety switch as well as the wiring, and repair or replace a defective one if necessary.


(Pin) Numbering

Main Door Unlock Key Switch

X4.2 (OSDO.M)

OSDO Input Module Slot 07 XJ411 (39) OSDO


X4.3 (OSDI.M)


OP Door Close, Must By D-Open

195



X35.7 TUN.M Spindle Tool Unclamp

R649.6 DCL Operator Door Close Confirm R648.6 M250A Door Interlock Bypass On Aux.

A24.2 2195 OP-Door Close, Must By D-Open


K10.6 KOPDOR Operator’s Door Interlock Not Used

X4.2 OSDO.M Main Door Unlocking Key Switch





R4035.3 PMANM APC Man. Mode Aux.



R1159.0 PMGMST PMG Macro Start



OP Door Close, Must By D-Open

196


4.5 2196 Screw Conveyor Overload 1) Description

The screw conveyor has an error. 2) Cause of problem

Excessive current in the screw conveyor motor 3) Action

Ensure that -QM62/63 of the electric cabinet is cut off. Check the 3-phase main wiring, the magnet (-KM62/63), and the insulation state of the motor, and make repair or replacement if necessary.

☞ Overload settings

QM62, QM63 : 0.4 KW : 3.0 A


(Pin) Numbering

Screw Conveyor Overload

X2.4 (SCOL.M)

-QM63 -QM62

Input Module Slot 07 XJ411 (31) SCOL

M -XJ411:

X2.4 31

SCOL


C20A: 40, 41 49, 50

a3

a4

SCOLA a3

a4

-QM63

-QM62

Screw Conveyor Motor 1

Screw Conveyor Motor 2

SCOL

A6

Screw Conveyor

197



2.4 SCOL.M Screw Conveyor Overload

A24.3 2196 Screw Conveyor Overload

Screw Conveyor Overload

198


4.6 2197 Chip Conveyor Alarm or Off Mode Alarm 1) Description

An error occurred in the chip conveyor. 2) Cause of problem

An alarm occurred due to an error in the chip conveyor 3) Action

① If the -QM1 brake of the chip conveyor's control box is cut off, check the 3-phase motor of the chip conveyor and take a necessary action if an error is found.

② If –TM1 or –TM2 is tripped, this happens because the rotation confirmation signal that is preceded by the rotation signal is not found. Check the chain and the -SX1 switch of the motor, and take a necessary action if an error is found.


(Pin) Numbering

Chip Conveyor Fault X3.6

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


X3.6 CCFT.M Chip Conveyor Fault

K9.1 KCHIP Chip Conveyor Used

A24.4 2197 Chip Conveyor Alarm or Off Mode Alarm

Chip Conv. AL or Off Mode Alarm

199


4.7 2198 Auto Power Off Ready 1) Description

The Auto Power Off toggle switch was turned on. 2) Cause of problem

The Auto Power Off toggle switch on the main OP was turned on. 3) Action

To deactivate the function, turn the toggle switch off. ☞ The Auto Power Off function will turn off NC 2 seconds after the toggle switch is turned on

and the function is set to "M30;". Then, the main NFB is tripped according to the TM1 timer settings. (Max: 5 seconds)


(Pin) Numbering

Auto Power Off Ready

X36.7 (APOF.M)

-SA35 Matrix Distribution

Board XJM2 (A21) SA35


X36.7 APOF.M Auto Power Off Ready

A24.5 2198 Auto Power Off Ready

Chip Conv. AL or Off Mode Alarm

200


4.8 2202 Machine Lock 1) Description

The Machine Lock Key switch on the main OP is turned on. 2) Cause of problem

① The Machine Lock Key switch on the main OP is set to All Axis or Z Axis. ② Machine Lock Key Switch, Aux. An error in the Function Lock Toggle switch, the wiring

cables or any of its component parts 3) Action

① Turn off the Machine Lock Key switch. ② Check the state of the followings: Machine Lock Key switch (-SK22), soldering inside the

OP (-WJ422), connector (-XC57A51), and pin fixation. And check also the wiring between OP and electric cabinet. Make repair or replacement if necessary.

☞ You must return all axes to their respective reference point after 2202 Machine Lock

alarm is tripped.


(Pin) Numbering

All Axis Machine Lock

X36.5 (MLKA.M)

-SK21 Matrix Distribution

Board XJM2 (A19) SK21A

Z Axis Machine Lock X36.6

(MLKZ.M) -SK22

Matrix Distribution Board

XJM2 (A20) SK22A

Machine Lock

Z-Axis Machine Lock

All-Axis Machine Lock

201



G44.1 MLK All Axis Machine Lock

G108.2 ZMLK Z-Axis Machine Lock

R644.0 MLKA Machine Lock All Axis

A25.1 2202 Machine Lock

X36.5 MLKA.M All Axis Machine Lock

R1485.4 R_MLKA.M All Axis Machine Lock

X36.6 MLKZ.M Z-Axis Machine Lock

R1485.5 R_MLKZ.M Z-Axis Machine Lock

202


4.9 2203 Screw Conveyor CCW Manual Mode 1) Description

The manual toggle switch of the screw conveyor on the main OP was set to "REV." (CCW) so that the screw conveyor is rotating counter clockwise.

2) Cause of problem

The manual toggle switch of the screw conveyor on the main OP was set to "REV." (CCW)

3) Action

① Set the manual toggle switch of the screw conveyor on the main OP to "AUTO" or "FOR." (CW)

② Check the manual toggle switch (-SA38) of the screw conveyor, the soldering (SA38) of the operation panel , the connector (-XJM2) and the pins in this sequence if there is a problem. Make repair or replacement if necessary.


(Pin) Numbering

Screw Conveyor CCW Manual

X37.2 (SCRW.M)


Board XJM2 (A22) SA38A

Screw Conveyor CW Manual

X37.1 (SCFW.M)


Board XJM2 (B22) SA38B



Y2.5 Y2.5 Screw Conveyor 1,2 Reverse(CCW)

R688.2 SCRV.R Screw Conv. 1,2 Reverse(CCW)

X37.2 SCRW.M Screw Conveyor CCW Manual

Screw Conv. CCW Manual Alarm

203


204


4.10 2204 Feedrate Override 0% 1) Description

The Feedrate Override switch on the main OP is set to 0％. 2) Cause of problem

① The Feedrate Override switch on the main OP is set to 0％. ① An error in the Feedrate Override switch on the main OP, wiring cables or any of its


① Change the Feedrate Override switch on the main OP to other than 0%. ② Check the state of the followings: Feedrate Override switch (-SR21), soldering inside the

OP and the connector (-XJM2). Make repair or replacement if necessary.


(Pin) Numbering

Feedrate Override 1 X33.0

(FV1.M) -SR21


XJM2 (B05) SR21A


(FV2.M) -SR21


XJM2 (A06) SR21F


(FV3.M) -SR21


XJM2 (B06) SR21B


(FV4.M) -SR21


XJM2 (A07) SR21E


(FV5.M) -SR21


XJM2 (B07) SR21C


(FV6.M) -SR21


XJM2 (A08) SR21G

205



X33.0 FV1.M Feedrate Override 1






A25.3 2204 Feedrate Override 0%

Federate Override 0%

206


4.11 2205 Measurement Device Low Battery 1) Description

The measurement battery of the touch sensor in the interface unit has run out. 2) Cause of problem

① The measurement battery of the touch sensor in the interface unit has run out. ② An error in the battery case, wiring cables or any of its component parts

3) Action

① Replace the battery of the measurement device with a new one. ② Check the battery case, wiring cables and connector (-XJ412) in this sequence. Make

repair or replacement if necessary.


(Pin) Numbering

Measurrement Device Low Battery

X9.6 (MDLB.M)

-BAT Input Module : Slot 8 XJ412 (1) BAT


X9.6 MDLB.M Measurrement Device Low Battery

A25.4 2205 Measurrement Device Low Battery


K3.2 KMDALM Alarm of Measuring Device Used

Measurement Device Low Battery

207


4.12 2206 Measurement Device Alarm 1) Description

An error is detected from the interface unit of the measuring touch sensor. 2) Cause of problem

An error in the measuring touch probe, interface unit, wiring cables or any of its component parts.

3) Action

Check the measuring touch probe, interface unit, wiring cables and connector (-XJ412) in this sequence. Make repair or replacement if necessary.


(Pin) Numbering

Measurrement Device Alarm

X9.7 (MDAL.M)

-ARR Input Module : Slot 8 XJ412 (33) ARR


X9.7 MDAL.M Measurrement Device Alarm

R800.1 M74F Work Measure Flag

R800.2 SEON Tool Measurrement Sensor On

A25.5 2206 Measurrement Device Alarm


K3.2 KMDALM Alarm of Measuring Device Used

Measurement Device Low Battery

208


4.13 2207 Machine Interference Zone Error 1) Description

The machine has entered the machine interference zone. (To prevent possible conflicts between axes)

2) Cause of problem

① The machine has entered the machine interference zone. ② An error in the machine interference zone settings

3) Action

① Rotate the problem-making axis reversely in Handle or Jog mode to remove it. ② Check the values of D860∼D868 in the PMC G data array, and correct them as

appropriate.

(Note) How to correct PMC data


209



(3) Press the [SETTING] button. ▪ The Setting screen appears where the cursor is

positioned at the “PARAMETER WRITE” item on the top. ※ If the screen is not displayed as shown in the right



★ The “SW0100 Parameter Enable Switch ON” alarm occurs.


(6) Locate the Data screen.

① Press the soft keys one after another to move to the Keep Relay screen. ② Press to activate the vertical soft key in the lower right corner and press the [KEEP

RELAY] key.

210



1 2

211


(7) Keep pressing the Page Down button until you see the Group No.5 (D860-D876) of the data table.

(8) Move the cursor to a desired item and enter a value. Then, press INPUT.

(9) When done, move back to “SETTING” and turn off “PARAMETER WRITE”(1 => 0). Then,

press the “RESET” key to release the alarm.

212




K8.4 KMCIFZ M/C Interference Zone Check Not Used

R407.2 M222 ATC Door Open

R407.3 M223 ATC Door Close

R5320.5 4MATCDO Man ATC Door Open Command

R5320.6 4MATCDC Man ATC Door Close Command

R91.4 YINTLT Y-Axis Position Interlock Large Tool

G132.1 +MIT2 Y Axis +Direction Interlock


A25.6 2207 Machine Interference Zone Error

R697.0 IFZN-X X-Axis Interference Zone 1

R697.1 IFZN-Y Y-Axis Interference Zone 1

R697.2 IFZN-Z Z-Axis Interference Zone 1

R800.4 SEN2 Tool Length Sensor On

Machine Interference Zone Error

213


4.14 2208 Machine In Service Mode 1) Description

For the repairing purpose, the machine is in the state of Operator Door Interlock Bypass. 2) Cause of problem

To open the operator door for the repairing reason, the Door Interlock Bypass command (M250) is instructed in MDI mode.

3) Action

① In MDI mode, instruct M251. ② Press the NC Reset button on the main OP.



A25.7 2208 Machine In Service Mode

R410.6 M250 Machine Service Mode On

R410.7 M251 Machine Service Mode Off

F1.1 RST NC Reset

R652.1 M32H M02/M30 Hold

K51.0 KSMODE Machine Service Mode Select

F0.6 SA Servo Ready

Machine In Service Mode

Door Interlock Bypass On Aux.

214


4.15 2215 Tool Length Sensor Up/Down Alarm 1) Description

The Tool Length Sensor Up or Down command was instructed but not complete within 5 seconds since then. Or, the Tool Length Sensor Up or Down command was instructed on a machine that was not equipped with the tool length sensor.

2) Cause of problem

① An error in adjusting the position sensor switch ② An error in the Tool Length Sensor Up/Down switch, the wiring, or any of its component

parts ③ A program error

3) Action

① Turn the Tool Length Sensor switch up or down while adjusting the position sensor switch.

② Check the Tool Length Sensor Up/Down switch, the connector (-XJ412) and the attachment of the pin, the wiring through to the electric cabinet, and the input module (AID32E). Make repair or replacement if necessary.

③ The Tool Length Sensor Up or Down command is valid only for machines that have configured the K0.7(Moving Type Tool Meas. is Used) settings.


(Pin) Numbering

Tool Measure Sensor Up

X7.4 (TLUP.M)

-SD61 Input Module : Slot 8 XJ412 (27) SD61

Tool Measure Sensor Down

X7.5 (TLDN.M)

-SD62 Input Module : Slot 8 XJ412 (43) SD62

Tool Measure Sensor Up

Y3.3 (TLUP.R)

-YV67 Output Module :

Slot1 XJ412 (27) YV67

Tool Length Sensor Up/Down Alarm

215



R436.1 TMB66 Tool Length Sensor Up/Down Check

K0.7 KTLENG Moving Type Tool Meas. is Used

R609.1 M76 Tool Measure Sensor Up

R609.2 M77 Tool Measure Sensor Down

A26.6 2215 Tool Length Sensor Up/Down Alarm


Y3.3 TLUP.R Tool Measure Sensor Up

X7.4 TLUP.M Tool Measure Sensor Up

X7.5 TLDN.M Tool Measure Sensor Down

Tool Length Sensor Up/Down Check

SD61

SD62

216


4.16 2218 First, There Must Be Z-Ref. Return 1) Description

With the reference point for the Z axis not being set, the operator attempted to set the reference point for the X or Y axis on a machine where the K1.3 is set to 1 (set this value to 1 if restoring the reference point for the Z axis).

2) Cause of problem

With the reference point for the Z axis not being set, the operator attempted to set the reference point for the X or Y axis.

3) Action

Restore the reference point for the Z axis before restoring the reference points for other axes.


R731.0 ZXYINT XY-Axis Interlock By Z-Ref Position

A27.1 2218 Fiest, There Must Be Z-Ref. Return



F0.6 SA Servo Ready

K1.3 KZXYIT

First, There Must Be Z-Ref. Return

First, There Must Be Z-Ref. Return

217


4.17 2221 5-Th Clamp/Unclamp Alarm 1) Description

While the optional 5th axis was enabled, the Clamp/Unclamp operation did not match the corresponding completion signal, or it has passed 100 seconds since both Clamp/Unclamp sensor signals were switched on or off simultaneously.

2) Cause of problem

① An error in adjusting the pressure switch ② An error in the wiring or any of its component parts

3) Action

① An error in adjusting the pressure switch Adjust the distance across the switches.

② An error in the wiring or any of its component parts Check the sensor switch, the wiring from the sensor switch to the electric cabinet as well as the I/O module if there is a problem. Repair or replace the defective part if necessary.

218



R435.1 TMB58 5-Th Clamp/Unclamp Check Time

A27.4 2221 5-Th Clamp/Unclamp Alarm


K7.4 K5THA 5Th-Axis Used

K18.7 KUCENT Keep U-Center Is Used

R740.2 5ACLP 5th-Axis Clamp Command

X5.6 5CLP.M 5th-Axis Unit Clamp

R740.3 5AUNCP 5th-Axis Unclamp Command

X5.7 5ULP.M 5th-Axis Unit Unclamp

R604.3 M38 5th-Axis Clamp

R604.4 M39 5th-Axis Unclamp

R653.0 MEND M-Function Finish

X5.5 5NEG.M 5th-Axis Neglect

5-Th Clamp/Unclamp Alarm

5-Th Clamp/Unclamp Check Time

219


4.18 2222 Program Start Check Alarm 1) Description

In PMG (automated operation) mode, M23 was not instructed at the beginning of any program.

2) Cause of problem

In PMG (automated operation) mode, M23 was not instructed at the beginning of any program.

3) Action

In PMG (automated operation) mode, M23 should be instructed at the beginning of any program.

Program Start Check Alarm

Program Check Time

220



R629.5 TMB54 Program Check Time

A27.5 2222 Program Start Check Alarm



R520.1 MILK M23 Function Interlock

R520.0 PGSTMC Program Start M Code

R643.3 MDI MDI Mode

G46.1 SBK Single Block

R602.4 M23 Program Start M Code

R634.1 MEM Memory Mode


K18.0 KPSTP2 Pallet Mag. Stopper2 Used(Set Up)

221


4.19 2223 B-Axis Moving Interlock Alarm 1) Description

With the "K8.6" value being set to 1, the B axis was instructed to move while the X axis was not positioned in the center. (Set the value to 1 if you instruct to move the B axis only when the X axis is positioned in the center)

2) Cause of problem

The B axis was instructed to move while the X axis was not positioned in the center (X1050.). 3) Action

First, move the X axis to the center (X1050.) and then, instruct to move the B axis.


R695.7 BXINT B-Axis Interlock By X-Axis Zone

F102.3 MV4

A27.6 2223 B-Axis Moving Interlock Alarm


K8.6 KBIZON B-Axis Is Not Used Interlock Zone

R9000.0 X=Y Compare X=Y

B-Axis Moving Interlock Alarm

B-Axis Interlock By X-Axis Zone

222


4.20 2234 Gear Shift Lost 1) Description

None of the High, Middle, and Low checking switches of the spindle head gear range is detected to trip.

2) Cause of problem

The check switch for the main spindle gear range has short-circuited or any of its component parts is defective.

3) Action

Check the gear box switch of the main spindle if it works properly on the DGN screen, and take a necessary measure.


Switch, Limit ESWLM0018A -SL12, 13, 14 WLD2 Hyun Jeon Co., Ltd.


(Pin) Numbering


(GSL.M) -SL12 Input Module Slot 08 XJ412 (32) SL12


(GSM.M) -SL13 Input Module Slot 08 XJ412 (48) SL13


(GSH.M) -SL14 Input Module Slot 08 XJ412 (15) SL14


(SGRM.V) -YV14 Output Module Slot 4 XJ403 (6) KAR52


(SGRH.V) -YV15 Output Module Slot 4 XJ403 (23) KAR53


(SGRL.V) -YV16 Output Module Slot 4 XJ403 (38) KAR54

Cylinder

Piston

SL12 SL13 SL14

YV14

YV15 YV16

223


Note) How to move to DGN (Diagnostic)




[STATUS] key.



1 2

224


Reference) How to read DGN (Diagnostic)

Ex) X 0007 0 0 1 1 0 0 1 0 Bit 1, 4 and 5 in Address X7 turn ON while Bit 0, 2, 3, 6 and 7 turn OFF.

Symbol 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

Gear Shift Lost

P T

Tool Unclamp

P T

A B

P T

A B

P T


Tool Clamp

Gear Shifter

L M H

Φ1.0 Φ1.2 Φ1.0

C D E

Sol. C Sol. D Sol. E Low Off Off On Middle On Off On High OFF On Off

C D E

225



R1649.0 M150SF Multi M150 And SF Command

K16.7 KMTM150 Used Variable Orientation Func.



R657.6 SHRH Spindle Gear Range High

R659.0 IGSL Initial Gear Shift Low

R659.1 SFON Initial S-Function On

A29.1 2234 Gear Shift Lost

R659.5 GRL Gear Shift Low







X6.2 GSM.M Gear Shift Middle




Gear Shift Range Low

Gear Shift Range Middle

Gear Shift Range High

226


4.21 2240 ATC Not Use (K7.6 Set) 1) Description

With "K7.6" (disable ATC) being set, the tool change (M06;) or tool call (T__:) command was instructed.

2) Cause of problem

The Keep Relay settings were incorrect. 3) Action

If ATC has no particular problem, change Keep Relay "K7.6" from 1 0. Then, instruct Tool Change or Tool Search.




F7.3 TF T Function Strobe

A29.7 2240 ATC Not Used (K7.6 Set)


ATC Not Use (K7.6 Set)

227


4.22 2241 Wait. Pot or Spindle Tool data Zero 1) Description

When the waiting pot or the tool data of the spindle was set to 0, the Tool Change command was instructed.

2) Cause of problem

① The command of "T00;" is instructed so that the waiting pot is empty. ② The command of "T00;" (M06) is instructed so that the spindle tool is empty. ③ The data value of D452 (Waiting Tool No.) or D450 (Spindle Tool No.) is erased.

3) Action

① Call another tool. ☞ Just in case, ensure that the waiting pot is empty.

② Change to a different tool. ☞ Just in case, ensure that the spindle is empty.

③ Enter an actual tool number in D452 (waiting tool no.) or D450 (spindle tool no.) of the PMC DATA table.

Wait. Pot or Spindle Tool Data Zero

228



R408.3 M231 Tool Changer M-Code Aux.

G54.0 UI1000 ATC Macro Start Finish

R711.0 WSZERO Wait. Pot & Spdl Data Zero



R708.3 M46F Wait. Pot & Spdl Tool Compare

R724.5 1CYATC Man ATC Change 1 Cycle

R723.2 MMCHST Man Main Changer Start

A30.0 2241 Wait. Pot or Spdl Tool Data Zero

R605.4 M47 Tool Data Compare(TN=STN) Off


R5052.7 GP2294 GP Wait. Pot and Spdl Tool Zero

229


4.23 2243 Must Be ATC M-Changer Man. 1 Cycle 1) Description

This alarm prompts the operator to perform ATC Changer Arm 1 Cycle manually so as to align the main changer arm since it was step-operated manually.

2) Cause of problem

The ATC changer arm was step-operated manually. 3) Action

Perform ATC Changer Arm 1 Cycle manually to align the main changer arm.


(Pin) Numbering

Main Changer Arm Home_HM4D

X8.5 (CAHP.M)

-SX41 Input Module : Slot 8 XJ412 (27) SD61


X8.5 CAHP Main Changer Arm Home_HM4D

A30.2 2243 Must Be ATC M-Changer Man 1 Cycle

K55.4 KMSMIU ATC M-Changer Step(-) Keep


R5052.7 GP2293 GP Must Be ATC Man 1 Cycle

Must Be ATC M-Changer Man. 1 Cycle

230


4.24 2245 ATC Door Open Close Alarm 1) Description

The ATC Door Close or Open command was instructed but not complete within 20 seconds since then. Both command signals were instructed simultaneously, or the ATC door was not closed while in APC operation.

2) Cause of problem

① An error adjusting the ATC Door Open/Close check limit switch ② The limit switch for checking ATC Door Open/Close or any of its component parts has

an error. 3) Action

① Instruct ATC Door Open/Close alternatively while adjusting both the limit switch and the dog as appropriate.

② Check the limit switch, wiring cables, and I/O module in this sequence. Make repair or replacement if necessary.

Signal Address Device Symbol

I/O Connector

(Pin) Numbering

ATC Door Open X12.1

(ATDO.M) -SL51 Input Module Slot 09 XJ413 (24) SL51


(ATDC.M) -SL52 Input Module Slot 09 XJ413 (39) SL52

ATC Door Open Y3.0

(ATDO.R) -YV37 Output Module Slot 01 XJ400 (3) KAR25

ATC Door Close Y3.1

(ATDC.R) -YV38 Output Module Slot 01 XJ400 (20) KAR26

ATC Door Close Check(SL51)

ATC Door Open Check(SL52)

231



R627.5 TMB38 ATC Door OP/CL Check Time


R763.2 MAPCST MAN APC Start

R789.5 4MPLTCL Man Pallet Clamp

R763.0 APCMAN APC manual Mode


A30.4 2254 ATC Door Open/Close Alarm



R5050.6 GP2245 GP ATC Door Open/Close Alarm


ATC Door Open/Close Alarm

ATC Door Open/ Close Check Time

232



Y3.0 ATDO.M ATC Door Open



F96.2 ZP2Z Z-Axis 2nd Ref. Return


F0.6 SA Servo Ready

R723.4 MMCHSP Man Main Changer Stop

R719.4 MCHSP Man Changer Stop


233


4.25 2247 T-Code or M06 Commanded States 1) Description

A T code is being called, or the M06 command is performing. 2) Cause of problem

The ATC operation was activated while the T code was being called, or the M06 command was performing.

3) Action

Instruct a command only when the current operation is complete.


R702.1 TCCMD T-Code Command

R702.3 TPSCMD Tool Pot Search Command

R455.1 TCCMDR Tool Change Command

R4010.4 1RTCMDF Re-Change T-Code Command Flag

R719.6 ATCMMD ATC Main OP Manual Mode

R719.2 MCHST Man Changer Start

A30.6 2247 T-Code or M06 Commanded States



T-Code or M06 Commanded States

234


4.26 2250 ATC OP Manual Mode 1) Description

With the ATC magazine being set to Manual mode, you set the mode selection switch of the main OP to AUTO (Edit, Memory, Tape or MDI).

3) Action

In AUTO (Edit, Memory, Tape or MDI) mode, set the mode switch on the touch panel to AUTO.


R1484.0 RT_MANMD ATC Manual Mode From Macro Ex.

R8326.1 TMMD.M Sub Changer Manual Mode



A31.1 2250 ATC OP Manual Mode

R5050.7 GP2250 GP ATC OP Manual Switch On

ATC OP Manual Mode

235


4.27 2251 ATC Overtime Alarm 1) Description

The tool call (T__;) or tool change (M06) command was instructed. However, none of the operations were complete within 45 seconds since then.

2) Cause of problem

The machine stopped operation due to an error while performing the tool search or the tool change sequence. The operator will be notified of the overtime alarm for each sequence before this ATC overtime alarm. ☞ See Appendix (ATC Troubleshooting)

3) Action

See the sequence chart or the alarm table, and solve the problem.

ATC Overtime Alarm

ATC Overtime

236



R628.1 TMB42 ATC Over Time

A31.2 5521 ATC Overtime Alarm



R5051.0 GP2251 GP ATC Overtime

R702.0 TCCMDA T-Code Command Aux.


G455.0 M06CDF M06 Command Flag


R408.3 M231 Tool Change M-Code Aux.


R649.6 DCL Operation Door Close Confirm


R702.2 RTMDCC Re-Chare T-Code Command


Y9.6 TMBK.R TMG Servo Motor Brake Release



R718.4 TSMDM ATC Sub Changer Manual Mode

F0.6 SA Servo Ready


237



Tool Search Start (T _ _;)

No

★ AL 2250 “ATC OP Manual Mode” occurs ATC Sub Changer O.P Auto Mode?

▪ Turn the mode switch in the manual OP to Auto.

Yes

Searched tool No =Spd. Tool No? Yes

No

Searched tool No =Wait. Tool No? Yes

★ Tool Search Complete

No

Double Tool Search? Yes

★ 1st Tool to Tool Magazine, And 2nd Tool In Valid

No

TMG & ATC Initial Position? No

★ AL 2059 “T-Code Command Illegal Position” occurs

▪ Check: X7.7(WPMS.M) –SL37 Wait. Pot Mag. Side X7.6(WPSS.M) –SL36 Wait. Pot Spidle Side X10.3(SCHP.M) –SX33 Sub Chan. Home Pos. X10.1(SCAI.M) –SL31 Sub Changer Arm In X10.2(SCAO.M) –SL32 Sub Changer Arm Out

On

On

On Off

Off Yes

1 Sub Changer Mag. 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


On Off



▪ Check: X10.4(SCPP.M) –SX34 Sub Chan. Mag. Pos. On

Yes



238





On

Off

Yes


On Off


On Off



▪ Check: X10.5(CAWP.M)–SX35 Sub Chan.Wait. Pot Pos. On

Yes






On Off

Yes


On Off


Off On



▪ Check: X10.3(SCHP.M) –SX33 Sub Chan. Home Pos. On

Yes

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



▪ Check: X7.6(WPSS.M) –SL36 Waiting Pot Spindle Side X7.7(WPMS.M) –SL37 Waiting Pot Mag. Side

On Off

Yes

Tool Search Finish

239


※ Tool Recharge Step Sequence Chart

M06 M-Function End

4 Sub Changer Mag. 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 On

Off

Off




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



▪ Check: X7.6(WPSS.M) –SL36 Waiting Pot Spindle Side X7.7(WPMS.M) –SL32 Waiting Pot Mag. Side On

Off

Yes


On Off


On Off



▪ 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






On

Off

Yes

Yes Go to “A”

Off Off

Off

Off

240


Yes



On Off




On

Off

On

Yes

ATC Re-Charge End






On Off

Yes

A

Off Off

241


4.28 2259 Wait Pot No. = Spindle Pot No. 1) Description

The spindle tool number is identical to the tool number of the waiting pot. 2) Cause of problem

① D450 and D452 have the same data value. ② The same number is detected. This is because of an incorrect count of the tool number or

a manual operation by the operator. 3) Action

① Check the number of each tool, and assign a unique number to each tool. ② If you need to change only the tool number of the spindle, simply instruct “M45T****” in

MDI mode.


(Pin) Numbering

TMG Servo On Y10.3

(SVON.R) - SVON


XJ402 (66) SVON

D450 : Tool number of the spindle

D452 : Tool number of the waiting pot

242



R715.4 WP=SP Wait Pot No. = Spindle Pot No.

R700.3 TCMDF T-Code Command Flag



R701.2 TFINP1 T-Code Initial Pos.1(TCMDF)



R713.4 T0SKIPA T0 Skip Aux.

A32.2 2259 Wait pot is Spindle Same Counter



K7.6 KATC ATC Used

Wait Pot Is Spindle Same Counter

243


4.29 2260 Tool Mag. Rotation Over Time 1) Description

The tool magazine fails to complete the rotation within 230 seconds after instructed to do so by the operation signal (CW: Y39.0, CCW: Y39.1).

2) Cause of problem

① The number of a tool to be inserted in the waiting pot is 0. ② The tool detection switch for the waiting pot that was supposed to be empty was tripped.

3) Action

① Instruct the T code to call tools. ② Check the proximity switch, the wiring, and the I/O module in this sequence. Make repair

or replacement if necessary.


(Pin) Numbering

TMG Servo On Y10.3

(SVON.R) - SVON


XJ402 (66) SVON

TMG Servo Motor Brake Release

Y9.6 (TMBK.R)

- KA85 Output Module Slot :

03 XJ402 (10) KA85


R445.6 TMB143 ATC Mag. Rotation Overtime

A32.3 2260 Tool Mag. Rotation Overtime

Tool Mag. Rotation Over Time

Man Mag. Rotation Over time

244




K7.6 KATC ATC Used



Y9.6 TMBK.R TMG Servo Motor Brake Release

R743.2 TSHPB TMG Search On By PB S/W

R446.1 TMB146 Man Mag. Rot. Overtime


A32.3 2260 Tool Mag. Rotating Overtime


F0.6 SA Servo Ready

245


4.30 2262 ATC Magazine Guard Door Open 1) Description

The door of the tool magazine is open. 2) Cause of problem

The door of the tool magazine is open or there is an error in the switch or any of its component parts.

3) Action

Close the tool magazine door. Check the safety switch, the wiring, and the I/O module in this sequence, make repair or replacement if necessary.


(Pin) Numbering

Tool Magazine Door Interlock

X12.3 (MDI2.M)

-S85A Input Module : Slot 9 XJ413 (6) S85A


X12.4 (MDIT.M)

-S85 Input Module : Slot 9 XJ413 (23) S85

Mag. Door Lock(Sol. Type)

Y11.6 (MDIT.R)

-KA36 Output Module Slot :

03 XJ402 (1) KA36

246



R436.4 TMB69 Mag. Door S/W Check Time


ATC Magazine Guard Door Open


Magazine Door S/W Check Time

247



F212.6 AL81-FM Door Open Alarm of Matrix Mag.


R723.1 MSCHSP Man ATC Sub Changer Stop

R725.2 MSCHST Man Sub Changer Start

R719.3 MSCSTF Man Changer Start Flag

R5320.0 4MSCSTF Man Sub Changer Start Flag




R709.0 ATCMST ATC Macro Start


R718.0 MTMFWD Man Tool Mag. Forward

R718.1 MTMREV Man Tool Mag. Reverse



K9.6 KMDINI ATC Magazine Door SW. Ignore

K7.6 KATC ATC Used

R717.7 MDIT Tool Magazine Door Interlock

X12.3 MDI2.M Tool Magazine Door Interlock

Y11.6 MDIT.R Mag. Door Lock(Sol. Type)

X12.4 MDIT.M Tool Magazine Door Interlock

248


249


4.31 2264 Tool Magazine Servo Battery Alarm 1) Description

A battery alarm occurred from the servo drive unit that drives the tool magazine. 2) Cause of problem

① The battery of the servo drive unit that drives the tool magazine has been discharged. ② An error in the servo drive unit or the battery case, the wiring, or the connector

3) Action

① Replace the current battery with a new one. ② Refer to the service manual of the servo drive, and make repair or replacement if

necessary. ☞ Refer to "Troubleshooting by the servo drive alarm".


(Pin) Numbering

Tool Magazine Battery Alarm

X5.4 (BALM.M)

BALM Input Module Slot : 7,

9 XJ413 (19) BALM



Servo Drive Battery

250



X5.4 BALM.M Tool Magazine Battery Alarm

A32.7 2264 Tool Magazine Battery Alarm



☞ Refer to "Troubleshooting by the servo drive alarm".

1) UV (Under Voltage) Alarm : This alarm warns that the main unit is running out of direct voltage.

Message on the front display


Troubleshooting



wherever applicable. ▪ Then, turn off the turret servo drive and turn it back on. See if there occurs

the same alarm. If so, replace the drive because this alarm is tripped from the defective drive.

Note) The turret servo drive alarm is tripped to protect the servo drive, the motor, and the turret unit. You restart the drive and release the alarm doesn't mean either the drive or the motor has an error. You do not need to replace any of these two.

Tool Magazine Servo Battery Alarm

251


2) OV (Over Voltage) Alarm : This alarm warns that the direct voltage to the main unit is excessive.



Troubleshooting


▪ Remove the drive and disconnect the regenerative resistor connector to

check if the regenerative resistor (installed at a side of the drive) measures at 26Ω. If not, replace the resistor.


wherever applicable. ▪ Then, turn off the turret servo drive and turn it back on. See if there occurs

the same alarm. If so, replace the drive because this alarm is tripped from the defective drive.



Connector

Power Board (PAB)


252


3) OH (Over Heat) Alarm : This is a overheat alarm.


Description This alarm is tripped if the internal IPM device is overheat or has an error.

Troubleshooting

▪ Turn off the turret servo drive and wait until it cools down. Then, turn it back on and see if the same alarm occurs again. If the problem persists, replace the drive because the IPM module of the drive is defective.


4) OC (Over Current) Alarm : This is an over-current alarm.


Description This alarm is tripped when the motor is over-currented.

Troubleshooting

▪ Check if the acceleration parameter (No. 29) and the deceleration parameter (No. 30) are set to less than specified.

▪ Check the wiring of the motor power cable, and replace it if necessary. Note) The turret servo drive alarm is tripped to protect the servo drive, the motor, and the

turret unit. You restart the drive and release the alarm doesn't mean either the drive or the motor has an error. You do not need to replace any of these two.

253


5) CA Alarm : This is an encoder-related alarm, against which the troubleshooting action differs according to the drive version (11 bit old drive, and 17 bit new drive).

Message on the

front display

Description 11 Bit ▪ This alarm occurs if A, B, or Z of the encoder signals has an error.

17 Bit ▪ This alarm occurs when the turret servo drive is turned on before

the encoder is reset.

Troubleshooting

11 bit

▪ Disconnect the encoder data transfer cable from the turret servo drive, and reconnect it as it may be connected improperly.


▪ Check if the motor encoder connector is short-circuited. If so,

replace the motor.

17 bit

▪ Turn off the turret servo drive to reset the motor encoder. 5 seconds after the encoder is reset, turn back on the turret servo drive. The alarm will be released.

▪ This action applies to turret servo drive versions of DVSD-TT-14A through DVSD-TT-14A-04. For later versions than DVSD-TT-14A-05, the CA alarm is deleted.

Encoder Data Transfer Cable


254


6) CO Alarm : This alarm applied to the 17-bit turret servo drive version of DVSD-TT-14A-05 or later, which is related to a signal error in the encoder.

Message on the

front display

Description This alarm occurs if the signal from the encoder has an error.

Troubleshooting



▪ Check if the motor encoder connector is short-circuited. If so, replace the

motor.




255


7) OS (Over Speed) Alarm : This is an over-speed alarm.


Description This alarm occurs when the motor speed exceeds the limit.

Troubleshooting


▪ Check the wiring of the encoder data transfer cable, and replace it if

necessary. ▪ Check if the motor has a short circuit. If so, replace the motor cables

wherever applicable. ▪ Check if the motor encoder connector is short-circuited. If so, replace the

motor.



Motor Power Connector

256


8) OL (Over Load) Alarm : This is an overload alarm.


Description

▪ This alarm occurs if the overload state lasts for more than specified. ▪ Overload detection time 250% ~ : 1 second, 220% ~ : 24 seconds, 200% ~ : 48 seconds 180% ~ : 96 seconds, 160% ~ : 192 seconds, 150% ~ : 384 seconds 140% ~ : 769 seconds, 130% ~ : 1536 seconds

Troubleshooting

Use the Keep Relay settings to set the turret to be in the state of Unclamp. Turn the turret manually and see if it rotates smoothly. If not, increase parameter no. 10 and parameter no. 11 by 10 and check the turret again. If the problem persists, the turret itself has a problem. ▪ Check if the parameters are set properly. (Note) For the 11-bit AS turret servo drive of DASD-CT15SPXC-05 or later

versions, and the 17-bit new turret servo drive of DVSD-TT-14A-04 or later versions, parameter no. 4 is set to 2048 by default. If you change the value, you will have the overload alarm.

▪ This alarm occurs if the turret has a tool overload or asymmetric load, or has a mechanical error. Turn the turret manually while increasing parameter no. 10 and parameter no. 11 by 10 until the turret rotates smoothly.

▪ If you are using a separate Clamp/Unclamp solenoid relay, the turret will be clamped and overload the turret motor if the relay has an error, causing the overload alarm to be tripped. If this is the case, check the relay and take a necessary measure.

▪ Disconnect the motor power cable and the encoder data transfer cable from the turret servo drive, and reconnect them as they may be connected improperly.

▪ Check the wiring of the motor power cable and the encoder data transfer cable, and replace them if necessary.

▪ Then, turn off the turret servo drive and turn it back on. See if there occurs the same alarm. If so, replace the drive because this alarm is tripped from the defective drive.


Motor Power Cable


257


9) SE Alarm : This is a double interruption alarm.


Description This alarm occurs if the CPU or the MCB of the turret servo drive has an error.

Troubleshooting

▪ Reset the parameters of the turret servo drive, and set them as appropriate again.

▪ Then, turn off the turret servo drive and turn it back on. See if there occurs the same alarm. If so, replace the drive because this alarm is tripped from the defective drive (a MCB error).


10) PE (Parameter Error) Alarm : This is a parameter error alarm.


Description This alarm occurs if the parameters of the turret servo drive are out of the set range.

Troubleshooting

▪ Reset the parameters and the position correction values of the turret servo drive, and set the parameters again as appropriate and set the reference point again.

▪ Then, turn off the turret servo drive and turn it back on. See if there occurs the same alarm. If so, replace the drive because this alarm is tripped from the defective drive (a MCB error).


258


11) RP (Residue Pulse) Alarm(ALP-rP) : This alarm occurs due to an excessive position deviation.


Description This alarm occurs if the residue pulse (RP) exceeds the limit specified for parameter no. 19 while the turret servo drive is controlling the position information.

Troubleshooting

▪ Check if parameter no. 19 of the residue pulse is set to less than specified. ▪ Disconnect the encoder data transfer cable from the turret servo drive, and

reconnect it as it may be connected improperly. ▪ Check if the motor has a short circuit. If so, replace the motor encoder

cables wherever applicable. ▪ Check if the motor encoder connector is short-circuited. If so, replace the

motor.




259


12) EN (Battery) Alarm : This alarm occurs due to an encoder backup battery error.



Message on the

front display

Description This alarm is tripped when the encoder backup battery of the turret servo drive is discharged or loose.

Troubleshooting

▪ Replace the encoder backup battery of the turret servo drive. ▪ Remove the turret servo drive and check the backup battery of the internal

encoder if the battery connector is connected properly. If you find an error from the servo drive, replace the servo drive.


Encoder Backup Battery Connector

Main Control Board (MCB)

Encoder Backup Battery

260


4.32 2265 VPF Off of Tool Magazine Alarm 1) Description

The position of the servo motor that drives the tool magazine is unknown. 2) Cause of problem

An error in the servo drive unit or the battery case, the wiring, or the connector 3) Action

Find and replace a defective part


(Pin) Numbering

Tool Magazine Battery Alarm

X13.4 (VPF.M)

VPF Input Module Slot : 7,

9 XJ413 (19) VPF


R702.1 TCCMD T-Code Command


R455.1 TCCMDR Tool Change Command

R836.2 VPF1C VPF Off of Tool Magazine

R443.6 TMB127 VPF Check Time

A33.0 2265 VPF Off of Tool Magazine


VPF Off of Tool Magazine Alarm

VPF Off of Tool Magazine

261



F0.6 SA Servo Ready



X13.4 VPF.M TMG Servo Verify


262


4.33 2266 Servo Mag. Tool Number Error 1) Description

The tool number could not be detected within 10 seconds after the tool magazine started to rotate.

2) Cause of problem

An error in the servo motor or the servo drive unit 3) Action

Check the servo motor and the servo drive unit if they work normally. Replace any defective part.


R836.0 TX=YER Tool Search Error

R443.4 TMB125 Tool Compare Check Time

A33.1 2266 Servo Mag. Tool Number Error




R710.6 WTP=0 Wait. Tool Pot Tool Data “0”

R713.4 T0SKIPA T0 Skip Aux.

Servo Mag. Tool Number Error

Tool Compare Check Time

263


4.34 2270 ATC Mag. Pot Tool Out SW. Alarm 1) Description

The position sensor on the hydraulic cylinder that performs the Tool Pull Out operation turned off.

2) Cause of problem

① An error in adjusting the Tool Magazine Tool Pull Out limit switch ② An error in the limit switch or any of its electric parts

3) Action

① An error in adjusting the position sensor switch Adjust the limit switch on the hydraulic cylinder that performs the Tool Magazine Pot Tool Out operation as appropriate.

② An error in the wiring or any of its component parts Check the limit switch, the wiring from the limit switch to the electric cabinet as well as the I/O module if there is a problem. Repair or replace the defective part if necessary.


(Pin) Numbering

Tool Pull-Out Confirm

Y12.6 (TPOC.R)

-YV39 Input Module Slot : 02 XJ401 (30) KAR39

Mag. Tool Pot-Out Confirm

X10.0 (TPOT.M)

-SL39 Input Module Slot : 09 XJ413 (16) SL39

Mag. Tool Pot-Out Confirm Switch

Mag. Tool Pot-Out Confirm Switch

264



Y4.6 TLPO.R Tool Pull-Out Confirm

K0.6 KHM1000 If1000, Set To 1

Y12.6 TPOC.R Tool Pool Out Confirm

X10.0 TPOT.M Mag. Tool Pot-Out Confirm

R5300.3 MTOI.M Mag. Tool Pot Tool Out Interlock



A33.5 2270 ATC Mag. Pot Tool Out SW. Alarm

ATC Mag. Pot Tool Out SW. Alarm

265


4.35 2272 ATC Sub Changer Position Check Alarm 1) Description

An operation signal (Home Position, Mag. Position, Pot Position) of the sub changer was instructed. However, none of the operations were complete within 10 seconds since then. Or, the position switch of the sub changer was turned off.

2) Cause of problem

① An error in adjusting the position switch of the sub changer ② An error in the position switch of the sub changer, the wiring, or any of its component

parts 3) Action

① An error in adjusting the position sensor switch Adjust the proximity switch on the rear of the sub changer as appropriate.

② An error in the wiring or any of its component parts Check the proximity switch, the wiring from the proximity switch to the electric cabinet as well as the I/O module if there is a problem. Repair or replace the defective part if necessary.


(Pin) Numbering

Sub Changer Home Position

X10.3 (SCHP.M)

-SX33 Input Module : Slot 8,

9 XJ413 (15) SX33

Sub Changer Mag. Pot Position

X10.4 (SCMP.M)

-SX34 Input Module : Slot 8,

9 XJ413 (31) SX34

Sub Changer Wait. Pot Position

X10.5 (SCWP.M)


ATC Sub Changer Position Check Alarm

266



R626.7 TMB32 Tool Changer Pos. Check Time

A33.7 2272 ATC Sub Changer Pos. Check Alarm

R352.7 ARST Alarm Rest


Y4.2 SCP1.R Sub Changer Position 1










Tool Changer Position Check Time

267



X10.4 SCMP.M Sub Changer Mag. Pot Position

X10.5 SCWP.M Sub Changer Wait. Pot Position

F0.6 SA Servo Ready



Home Pos. (SX33)

Mag. Pot Pos. (SX34)

Wait Pot Pos. (SX35)

268


4.36 2273 ATC Sub Tool Arm In/Out Alarm 1) Description

The Sub Changer Arm In/Out operation was instructed. However, none of the operations were complete within 5 seconds since then. Or, both the Sub Changer Arm In/Out position switches were turned on or off.

2) Cause of problem

① An error in adjusting the Sub Changer Arm In/Out position switch ② An error in the position switch of the sub changer, the wiring, or any of its component

parts 3) Action

① An error in adjusting the position sensor switch ② Adjust the Sub Changer Arm In/Out proximity switch as accurate as possible. ③ An error in the wiring or any of its component parts

Check the proximity switch, the wiring from the proximity switch to the electric cabinet as well as the I/O module if there is a problem. Repair or replace the defective part if necessary.


(Pin) Numbering

Sub Changer Arm In

X10.1 (SCAI.M)


Sub Changer Arm Out

X10.2 (SCAO.M)


ATC Sub Tool Arm In/Out Alarm

Arm In (SL32)

Arm Out (SL31)

269



R627.0 TMB33 Tool Arm In/Out Check Time

A34.0 2273 ATC Sub Tool Arm In/Out Alarm



Y4.0 SCAI.R Sub Changer Arm In


Y2.5 Y2.5

X10.1 SCAI.M Sub Changer Arm In

Y4.1 SCAO.R Sub Changer Arm Out

Y12.1 SCAT.R Sub Changer Arm Out

X10.2 SCAO.M Sub Changer Arm Out

F0.6 SA Servo Ready



ATC Arm In/Out Check Time

270


4.37 2321 APC Initial Position Alarm 1) Description

APC is not in the initial operating conditions. 2) Cause of problem

① An error in adjusting the position sensor switch ② An error in the APC position sensor switch or any of its electric parts

3) Action

① An error in adjusting the position sensor switch Adjust the APC proximity switch as correct.

② An error in the wiring or any of its component parts Check the switch, the wiring from the switch to the electric cabinet as well as the I/O module if there is a problem. Repair or replace the defective part if necessary.

※ APC Initial Position

Address X18.5 X18.6 X18.1 X18.3

Status 0(Off) or1 (On) 1(On) or 0(Off) 1(On) 0(Off)


(Pin) Numbering

APC 180 CW Position

X18.5 (P18F.M)

-SX75 Input Module : Slot

8,10 XJ410 (47) SX75


X18.6 (P18R.M)


8,10 XJ410 (30) SX76

APC Pos.0/ Arm Open

X18.1 (APOP.M)


8,10 XJ410 (32) SX71

APC Pos.90/ Arm Close

X18.3 (APLC.M)

-SL73 Input Module : Slot

8,10 XJ410 (15) SL73

APC Initial Position Alarm

271













X18.1 APOP.M APC Pos.0/Arm Open


R772.5 APRETC APC ARM Return Confirm

Y8.4 CADV.R Pallet Changer Arm Advance






X14.1 ARET.M Pallet Changer Arm 1 Return

X14.3 RETS.M Pallet Changer Arm Return Slowdown

APC Arm Interlock

272



X14.0 AADV.M Pallet Changer Arm 1 Advance

X14.4 PMPS.M Pallet Changer Arm 1 Middle Position

X15.1 AAB2.M Pallet Changer Arm 2 Return

X15.3 ABS2.M Pallet Changer Arm 2 Return Slowdown

X15.0 AAF2.M Pallet Changer Arm 2 Advance

X15.4 ABP2.M Pallet Changer Arm 2 Middle Position

APC CCW (SX76)

APC CW (SX75)

APC 180 CCW Position (SX76)

APC 180 CW Position (SX75)

APC Arm Open(SX71)

APC Arm Close (SL73)

0.8~1.2mm


273


4.38 2322 APC Set-Up Station Door Open 1) Description

The APC set-up station door was open. 2) Cause of problem

① The set-up station door was open. ② An error in the safety switch that detects the door opening, the wiring, or defective


① Close the set-up station door. ② Check the safety switch that detects the door is open, the wiring from the switches to the

electric cabinet as well as the I/O module if there is a problem. Repair or replace the defective part if necessary.


(Pin) Numbering

Setup Door Interlock 2_HM4D

X8.1 (SSDI2.M)


Setup Door Interlock_HM4D

X8.2 (SUIT.M)


Setup Door Open Y37.1

(SETD.R) -E12


XJM3 (A18) -KA38

APC Set-Up Station Door Open

274


HD4D Set-Up Door Interlock Check

APC Set-Up Station Door Open

275



R762.0 2322A1 HM10 APC Set-Up Station Door Open

R762.1 2322A2 HM4D APC Set-Up Station Door Open

R456.7 TMB227 HM4D Setup Door Interlock Check Time


R763.4 MAPCSP Manual APC Stop

R763.2 MAPCST Manual APC Start

R788.3 4MAPSTF Manual APC Start Flag


R760.0 M61CD APC1 Unload Command

R761.0 M62CD APC2 Load Command

X29.1 SETU.M Set Up

X72.3 SEU2.M Set Up 2




R1026.1 MCHAST Man Pallet Changer Start

R1056.2 MCHASP Man Pallet Changer Stop

R1075.2 MSESTP Man Set-Up Stop

R1063.1 MSEUST Manual APC Start

R1056.3 MCHASTF Man Pallet Changer Start Flag

R1075.3 MSESTF Manual Set-Up Start Flag

R1003.7 MPMROT Man. Magazine Rotation Keep

R1001.5 PMGINX Pallet Search Command

R1071.0 SETPUL Set-Up Pallet Unload Command

R1072.0 SETPLD Set-Up Pallet Load Command

Set-Up Door Open

276




K8.3 KDCLAR Alarm Reset By Door Close

K10.5 KSETDR Set-Up Door Interlock Not Used


K11.3 KSET Set-Up Station Not Used


K18.3 KSEITK Setup Station Interlock is Used, PMG

R762.3 SETDIT Setup Door Open

K19.3 KMPS Used Multi Pallet Station

X8.2 SUIT Setup Door Interlock_HM4D

X8.1 SDI2.M Setup Door Interlock2_HM4D

Y37.1 SETD.R Setup Door Open

R1385.7 PSETDCL Setup Door Close From MPS

Set Up Door Interlock (S12)

Set-Up Station Door Interlock

277


4.39 2323 4-Th Clamp/Unclamp Alarm 1) Description

It has passed 15 seconds since the position signal of the pallet or the table clamp/unclamp operation did not match the corresponding instruction signal.

2) Cause of problem

① An error in adjusting the position switch that checks the position of the pallet or table Clamp/Unclamp operation

② An error in the position switch that checks the position of the pallet or table Clamp/Unclamp operation, or any of its component parts

3) Action

① Adjust the position switch that checks the position of the pallet or table Clamp/Unclamp operation as accurate as possible.

② Check the switch, the wiring cables, and the I/O module in this sequence. Make repair or replacement if necessary.


(Pin) Numbering

Pallet Unclamp Y15.0

(PAUC.R) -KAR57 Output Module : Slot 4 XJ403 (3) -YV61

Pallet Clamp Y15.1

(PACL.R) -KAR58 Output Module : Slot 4 XJ403 (20) -YV62

Table Unclamp(I) Y15.2

(TAUC.R) -KAR59 Output Module : Slot 4 XJ403 (35) -YV63

Table Clamp Y15.3

(TACL.R) -KAR60 Output Module : Slot 4 XJ403 (2) -YV64

Pallet Unclamp(R) X7.0

(PTUC.M) -SP61 Input Module : Slot 8 XJ412 (12) -SP61

Pallet Clamp X7.1

(PTCL.M) -SP62 Input Module : Slot 8 XJ412 (28) -SP62

Table Clamp X7.2

(BCLP.M) -SL63 Input Module : Slot 8 XJ412 (44) -SL63

Table Unclamp(R) X7.3

(BULP.M) -SP65 Input Module : Slot 8 XJ412 (11) -SP65

278


4-Th Clamp/ Unclamp Alarm

279


B-Axis(Table) Clamp/ Unclamp Check Time

280



R626.4 TMB29 B-Axis(Table) Cl/Uncl Check Time

F0.6 SA Servo Ready






R457.0 TMB228 B-Axis(Table) Cl/Uncl Check Time

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



A40.2 2323 4-th Clamp/Unclamp Alarm


K7.5 K4THA 4th-Axis Not Used

R4030.2 4PMGMST PMG Macro Start





R4005.5 K80PMG Keep Relay HM80 for PMG

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


R1114.7 4PMUC.R PMG Pallet Unclamp

X7.0 PTUC.M Pallet Unclamp



Y7.3 TCLP.R Table Clamp

281


Pallet Clamp (SP62)

Table Clamp (SL63)

282


4.40 2324 Table or Pallet Clamp Alarm 1) Description

The pallet or the table is not in the state of being clamped. 2) Cause of problem

① An error in adjusting the position switch that checks the position of the pallet or table Clamp/Unclamp operation

② An error in the position switch that checks the position of the pallet or table Clamp/Unclamp operation, or any of its component parts

3) Action

① Adjust the position switch that checks the position of the pallet or table Clamp/Unclamp operation as accurate as possible.

② Check the switch, the wiring cables, and the I/O module in this sequence. Make repair or replacement if necessary.


(Pin) Numbering

Pallet Unclamp Y7.0

(PUCL.R) -KAR57 Output Module : Slot 2 XJ401 (3) -YV61

Pallet Clamp Y7.1

(PCLP.R) -KAR58 Output Module : Slot 2 XJM3 (20) -YV62

Table Unclamp Y7.2

(TUCL.R) -KAR59 Output Module : Slot 2 XJ401 (35) -YV63

Table Clamp Y7.3

(TCLP.R) -KAR60 Output Module : Slot 2 XJ401 (2) -YV64

Pallet Unclamp X7.0

(PTUC.M) -SX61 Input Module : Slot 8 XJ412 (12) -SX61

Pallet Clamp X7.1

(PTCL.M) -SX62 Input Module : Slot 8 XJ412 (28) -SX62

Table Unclamp X7.2

(BCLP.M) -SL63 Input Module : Slot 8 XJ412 (44) -SL63

Table Clamp X7.3

(BULP.M) -SL65 Input Module : Slot 8 XJ412 (11) -SL65

283


Table or Pallet Clamp Alarm

Table(B-Axis) Clamp Alarm D-Time

284


Table/Pallet Unclamp Interlock

B-Axis or Pallet Unclamp Interlock

B-Axis(Table) Servo Off D-Time

285



R628.3 TMB44 Table(B-Axis) Clamp Alarm D-Time


R637.0 JX Jog X-Axis Select

R637.1 JY Jog Y-Axis Select

R637.2 JZ Jog Z-Axis Select

X34.6 NJF.M Jog Feed -Direction

X34.5 PJF.M Jog Feed +Direction

R634.6 JOG Jog Mode

X28.2 HX.M MPG Handle X Axis Select

X28.3 HY.M MPG Handle Y Axis Select

X28.4 HZ.M MPG Handle Z Axis Select

G70.4 SRVA Spindle Reverse

G70.5 SFRA Spindle Forward



R752.7 PALINT B-Axis or Pallet Unclamp Interlock




X7.0 PTCL.M Pallet Unclamp




R760.0 M61CD APC 1 Unload Command

R761.0 M62CD APC 1 Load Command

R770.0 M63CD APC 2 Unload Command

R771.0 M64CD APC 2 Load Command

R608.3 M70 Pallet or Station Index





286



X36.3 DRN.M Dry Run

Y13.6 P8FR.R APC Rotation 180 CW Stopper Out

Y13.7 P8RR.R APC Rotation 180 CCW Stopper Out


R767.6 PLTCL Pallet(Table) Clamp Command

R765.3 4PLTCL Pallet Clamp Command

R767.7 PLTUNC Pallet(Table) Unclamp Command

R4030.5 4PLD/UL Pallet Load/Unload


F0.4 SPL Feed Hold

R448.4 TMB165 B-Axis(Table) Servo Off D-Time

R624.4 TMB13 B-Axis(Table) Clamp Check Time



R435.2 TMB59 Pallet Unclamp Check Time

F3.1 MH




Pallet Clamp (SP62)

Table Clamp (SL63)

287


4.41 2325 APC Set-Up Switch Unpush 1) Description

When the M60 (Pallet Change), M61 (APC 1 Load), M62(APC 2 Load) command was instructed, the operator did not press the Set-Up switch on the APC manual OP.

2) Cause of problem

① The operator put a workpiece on the table deck but did not press the Set-Up switch. ② An error in the Set-Up push-button switch or any of its component parts

3) Action

① After you put a workpiece on the table deck, press the Set-Up push-button switch on the APC manual OP. ▪ The indicator of the Set-Up switch turns yellow.

② Check the Set-Up related switches, the wiring cables from the switches to the electric cabinet, and the input module in this sequence if there is a problem. Make repair or replacement if necessary.


(Pin) Numbering

Set Up X29.1

(SETU.M) -SB92 Matrix Distribution

Board XJM3 (A06) SB92

APC Set-Up Switch Unpush

288





R755.7 SETUP Set Up

R761.7 M62MEN APC 1 Load(M62) M Function End

R771.7 M64MEN APC 2 Load(M64) M Function End

R1420.1 RPMG Pallet Schedule Operator By CW

R1159.0 PMGMST PMG Macro Start



R1010.0 No-Set Set-Up Not Found



289



R762.2 2325A1 HM4D APC APC Setup SW Unpush Aux.

A40.4 2325 APC Set-Up Switch Unpush

R774.5 SETUA Setup Aux. for HM4Digt

K4.6 KFIX Hyd. Fixture Used

R755.0 SETUP1 Set Up 1

K10.7 KSETUP Set-Up Switch Unpush Used



R774.6 SEUPA Setup Aux.

290


4.42 2326 APC OP Manual Mode 1) Description

With the mode toggle switch on the APC manual OP being set to Manual, the mode switch on the main OP was set to one of Edit, Memory, Tape or MDI mode.

2) Cause of problem

① The mode toggle switch on the APC manual OP was set to Manual. ② An error in the mode toggle swish or any of its component parts

3) Action

① Set the mode toggle switch on the APC manual OP to AUTO. ② Check the mode toggle switch, and the wiring between the switch and the electric



(Pin) Numbering

APC OP Manual Mode_HM4D

X29.2 (SETU.M) -SA91


XJM3 (B06) SA91


R1484.1 RP_MANMD APC Manual Mode from Executer

R1420.1 RPMG Pallet Schedule Operation By CW




X29.2 PMMD.M APC OP Manual Mode_HM4D

R763.0 APCMAN APC Manual Mode

A40.5 2326 APC OP Manual Mode

APC OP Manual Mode

291


292


4.43 2333 APC Not Use (K7.7 Set) 1) Description

With "K7.7" (disable APC) being set, a pallet change command (M60;, M61;, M62;) was instructed.

2) Cause of problem

The Keep Relay settings were incorrect. 3) Action

If APC has no error, set "Keep Relay K7.7" from 1 0 and perform the pallet change operation.



R607.1 M60 APC Pallet Change



A41.4 2333 APC Not Use (K7.7 Set)


APC Not Use (K7.7 Set)

293


4.44 2335 APC Changer Open/Close Alarm 1) Description

It has passed 5 seconds since the APC Changer Arm Open/Close sensor signal did not match the corresponding instruction signal, or both sensor signals turned on simultaneously.

2) Cause of problem

① An error in adjusting the APC Changer Arm Open/Close position sensor switch ② An error in the APC Changer Arm Open/Close position sensor switch, or any of related

parts 3) Action

① Adjust the APC Changer Arm Open/Close position sensor switch as accurate. ② Check the sensor switch, and the wiring between the sensor switch and the electric



(Pin) Numbering

APC Pos.90/Arm Open

X18.1 (APOP.M) -SX71

Input Module : Slot 8,10

XJ410 (32) SX71

APC Pos.90/Arm Close

X18.3 (APCL.M) -SL73


XJ410 (15) SL73

APC Arm Close Y12.7

(APCL.R) -YV71 Output Module : Slot 4 XJ403 (46) KAR40

APC Arm Open Y13.0

(APOP.R) -YV72 Output Module : Slot 4 XJ403 (12) KAR41

APC Arm Open(SX71)

APC Arm Open Slow Down (SX72)

APC Arm Close Slow Down (SX74)

APC Arm Close (SL73)

294



R456.2 TMB222 APC Changer Open/Close Check Time

A41.6 2335 APC Changer Open/Close Alarm






Y12.7 APCL.R APC Arm Close


X19.1 APDN.M APC Down

Y13.0 APOP.R APC Arm Open

X18.1 APOP.M APC Pos.0/Arm Open

R763.4 MAPCSP Man APC Stop


APC Changer Open/Close Alarm

APC Changer Open/ Close Check Time

295


4.45 2336 APC Changer Up/Down Alarm 1) Description

It has passed 5 seconds since the APC Changer Up/Down sensor signal did not match the corresponding instruction signal, or both sensor signals turned on simultaneously.

2) Cause of problem

① An error in adjusting the APC Changer Up/Down position sensor switch ② An error in the APC Changer Up/Down position sensor switch, or any of related parts

3) Action

① Adjust the APC Changer Arm Up/Down position sensor switch as accurate. ② Check the sensor switch, and the wiring between the sensor switch and the electric



(Pin) Numbering

APC UP X19.0

(APUP.M) -SX81 Input Module : Slot 10 XJ410 (12) SX81

APC Down X19.1

(APDN.M) -SX82 Input Module : Slot 10 XJ410 (28) SX82

APC Up Y13.3

(APUP.R) -YV75 Output Module : Slot 4 XJ403 (11) KAR44

APC Down Y13.4

(APDN.R) -YV76 Output Module : Slot 4 XJ403 (27) KAR45

APC Up (SX83)

APC Down (SX84)

APC Up (SX83)

APC Down (SX84)

0.8~1.2mm


296



R456.3 TMB223 APC Changer Up/Down Check Time

A41.7 2336 APC Changer Up/Down Alarm




Y13.3 APUP.R APC Up

X19.0 APUP.M APC Up

Y13.4 APDN.R APC Down

X19.1 APDN.M APC Down






APC Changer Up/Down Alarm

APC Changer Up/ Down Check Time

297


4.46 2337 APC Changer 180CW/CCW Alarm 1) Description

It has passed 5 seconds since the APC Changer Up/Down sensor signal did not match the corresponding instruction signal, or both sensor signals turned on simultaneously.

2) Cause of problem

① An error in adjusting the APC Changer Up/Down position sensor switch ② An error in the APC Changer Up/Down position sensor switch, or any of related parts

3) Action

① Adjust the APC Changer Arm Up/Down position sensor switch as accurate. ② Check the sensor switch, and the wiring between the sensor switch and the electric



(Pin) Numbering

APC Rotation 180 CW

Y13.1 (PCW.R) -YV73 Output Module : Slot 4 XJ403 (28) KAR42

APC Rotation 180 CCW

Y13.2 (PCCW.R) -YV74 Output Module : Slot 4 XJ403 (44) KAR43

APC Up Y13.3

(APUP.R) -YV75 Output Module : Slot 4 XJ403 (11) KAR44

APC 180 CW Position

X18.5 (F18F.M) -SX75


XJ410 (47) SX75


X18.6 (F18R.M) -SX76


XJ410 (30) SX76

APC UP X19.0

(APUP.M) -SX81 Input Module : Slot 10 XJ410 (12) SX81

298



R456.4 TMB224 APC Changer 180CW/CCW Check Time

A42.0 2337 APC Changer 180CW/CCW Alarm




Y13.1 PCW.R APC Rotation 180 CW


Y13.2 PCCW.R APC Rotation 180 CCW


X19.0 APUP.M APC Up

Y13.3 APUP.R APC Up




APC Changer 180CW/CCW Alarm

APC Changer180CW/ CCW Check Time

299








F0.6 SA Servo Ready

APC CCW (SX82)

APC CW (SX81)

APC 180 CCW Position (SX82)

APC 180 CW Position (SX81)

0.8~1.2mm

Proximity Dog

300


HMC Maintenance Manual HM 8000 Revision History

Version Year/Month Revision history Created by

01 2012. 10 Created a draft (HM8000ALE2A) Jung, Sam

Young

02

03

04

05

06

07

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09

10

Documents

HMC Maintenance Manual (Alarm) - CNCzone