HMC Maintenance: Machine Tools

Machine Tools
HMC Maintenance
(HP5100)
HP5100 HP51MTE87
Contents
Alarm
No. Alarm Name Page
number
1 2001 OP Emg. Stop PB or LS Off 126
2 2002 Main Spindle Servo Alarm 128
3 2003 Circuit Protector Trip 130
4 2004 Hyd. Pump Motor Overload 132
5 2005 Hyd. Pressure Down Alarm 134
6 2009 ATC Servo or Inverter Alarm 137
7 2010 Spindle Tool Unclamp Cmd. Fault 138
8 2015 Spindle Tool Unclamp Alarm 140
9 2020 Coolant & Lub. Pump Overload 142
10 2021 Air Pressure Down Alarm 175
11 2023 M06 Command Overtime Alarm 162
12 2036 Magazine Rotation or Matrix Illegal Position Alarm 167
13 2037 M06 Command Illegal Pos. 171
14 2041 APC Overtime Alarm 173
15 2042 M61 / M62 Command Illegal Position 176
16 2048 ATC Door Open 180
17 2050 Lub. Level Low or Pressure Down 184
18 2051 Oil cooling Unit Alarm 186
19 2052 Filter Change Alarm For TSC Unit 195
20 2060 Spindle Tool CL/UNCL Overtime Alarm 196
21 2063 ATC Arm Pin Alarm 198
22 2064 Waiting Tool Pot Spindle/Magazine Side Alarm 200
23 2065 Changer Arm Position Check Alarm 203
24 2073 Pallet or Table CL/UNCL Switch Alarm 207
25 2074 ATC Overtime Alarm 211
26 2075 ATC Magazine Rotation Over Time Alarm 215
27 2077 Waiting Pot & Spindle Tool No. Zero 218
28 2078 ATC OP Manual Mode 220
29 2080 ATC or APC Interlock Alarm 222
30 2081 ATC Magazine Guard Door Open 226
31 2084 APC Set-Up Station Door Open 228
124
HP5100 HP51MTE87
Alarm
No. Alarm Name Page
number
32 2085 APC Set-Up Location S/W Unpush 229
33 2086 APC OP Manual Mode 231
34 2090 Table Or Pallet Clamp Alarm 233
35 2094 Chip or Screw Conveyor Alarm 236
36 2107 Operator’s Door Open 238
37 2118 Operator’s Door Open Alarm 239
38 2120 Y-Z Interference Zone Alarm 241
39 2126 APC Up / Down Alarm 243
40 2127 APC Changer 180CW/CCW Alarm 246
41 2154 Waiting Pot Clamp Alarm 249
42 2155 Tool Magazine Pot Detect Switch Alarm 251
43 2158 Waiting Pot Spindle/Magazine Side Command 254
44 2160 APC Pallet Check Switch Alarm 256
45 2163 ATC Door Open/Close Alarm 258
46 2200 T-code Or M06 Commanded Status 260
47 2215 VPF Off Of Tool Magazine 261
Appendix1 X-Y Signal Address 263

Appendix2 M-CODE LIST 268
Appendix3 Repairing Method of Spindle Amp Alarms 274
Appendix4 ATC Main Changer Sequence Chart 280
Appendix5 Pallet Change Sequence Chart 281
Appendix6 Recovering ATC Breakdowns 283
Appendix7 Repairing Method of Servo Driver Alarms 286
125
HP5100 HP51MTE87
2001 OP Emg. Stop PB or LS Off
Either the Emergency Stop Push Button Switch has been pressed on the
Status
operation panel, or more than one of Emergency Stop Axis Limit Switches
of each axis have been activated.
① The Emergency Stop Push Button Switch has been pressed on the
Cause
operation panel (Main O.P, ATC O.P).
② The Axis (X,Y,Z Axis) Emergency Stop Limit Switch has been pressed.
③ The operation panel Emergency Stop Switches, axis emergency stop
Limit Switches, or other related parts are faulty.
④ The connecting cable has been disconnected.
① Check if the red spade-shaped push button switch has been pressed on
Solution
the operation panel (Main O.P, ATC O.P). If it is pressed, turn the
switch clockwise to release it.
② When each axis's(X, Y, Z Axis) emergency stop Limit Switch has been
activated, simultaneously press the operation panel Machine Ready
Switch and the Emergency Release Switch to set the machine at
Machine Ready. (If the switch is released, the machine returns to
emergency status.) Transfer the problem axes in Jog or Handle Mode
to release it from the axis emergency stop Limit Switch.
③ Check the operation panel Emergency Stop Switches, axis emergency
stop Limit Switches, or other related parts for problems. Make any
necessary replacements or repairs.
④ Connecting Cable Disconnection: Refer to the Electric drawings and use
a Electric tester to check the Terminal Block for each terminal to find
the problem area. Connect the cable or replace with a new cable.
Part Name Part Number Symbol Model Maker

Switch, Emergency P/B
ESWPB0439 SB1 B130-81L 2B KACON
(for Main)
ESWPB0226 SB7 KH-3046ER-RED Kunhung
(for ATC)
ESWPB0248 SB9 AH30-VR02 Fuji
(for APC)
126
HP5100 HP51MTE87
Connector Numbering
Signal Address Symbol I/O Status
(Pin) Tube
-SB1,124,SEMG,
Emergency X8.4 Input Module
SL1,2,3,12A,13A, T/Block(31) ESP
Stop ESP.M Slot 02
15ª
Machine X32.4 Distributed I/O
-SB11 XC56A(A04) SB11
Ready MRD.M Module A
OP Emg. Stop PB
or LS Off
ddress Symbol Coil Comment

A0.0 2001 OP Emg. Stop or LS Off
R650.2 APONI Auto Power On Initial Flag
R652.7 ARST Upper Alarm Reset
X8.4 ESP.M Emergency Stop
X32.4 MRD.M Machine Ready
127
HP5100 HP51MTE87
2002 Main Spindle Servo Alarm
Status The Alarm shows on the Main Spindle Drive Unit
① Main Spindle Drive Unit troubled

Cause
② The Spindle Motor, power cable, or signal cable troubled
① Check the Alarm number appearing in the Main Spindle Drive Unit on
Actions the operation panel
② Take appropriate actions according to the alarm number.
☞ Refer to appendix (Repairing Spindle Amp Alarms)
③ Check the spindle motor three-phase power and Feedback cable
connections
128
HP5100 HP51MTE87
Main Spindle
Servo Alarm
Address Symbol Coil Comment

A0.1 2002 Main Spindle Servo Alarm
F45.0 ALMA Spindle Alarm
R652.7 ARST Alarm Reset
129
HP5100 HP51MTE87
2003 Circuit Protector Trip
Status Circuit Protect has been activated in the electrical cabinet.
① Circuit Protect has been activated. (Detection of abnormal electric

Cause current)
② Control power faulty
③ Circuit protect faulty
① Find the reason for tripping the Circuit Protector.
Solution
☞ (ex) If QF22 has been tripped, first check for short-circuiting in the
QF22's secondary L+ cable. After repairing, replace the tripped Circuit
Protector.
② If the alarm shows without tripping the circuit protector, measure
resistance at each auxiliary a contact to find the short-circuited Circuit
protector, and replace it with a new one.
☞ The normal resistance measure for contact points when Circuit
Protect is On is “0”Ohm.
③ Check the I/O board: If ①~② are normal, the I/O board is faulty.
Part Name Part Number Symbol Model Maker

QF14,15,22, 5SX9100
Protector, Auxiliary ENFBX0290S Siemens
QF23,27,28,81 INO+1NC(6.0A)
Protector, Circuit ENFBX0283S QF14 5SX2216-7 Siemens
Protector, Circuit ENFBX0264S QF22,81 5SX2101-7 Siemens
Protector, Circuit ENFBX0551 QF28 5SX2125-7 Siemens
Connector Numbering
Signal Address Tool Symbol I/O
(Pin) Tube
Input
X2.3 -QF 14,15,21,22,
Circuit Protect Trip Module T/Block(07) TRIP
TRIP.M 23,81,27,28
Slot 07
Circuit Protector
Trip
130
HP5100 HP51MTE87

A0.2 2003 Circuit Protector Trip
X2.3 TRIP.M Emergency Stop
Input
InputModule(AID32E) :Slot
M odule(AID 32E ) : S lot 7
X2.3
X2.3(TRIP.M)
(T R IP .M )
1515
TR IP -Q F23 A C 100V C ontrol
-Q F14 T ranse Form er P ower TR IP E
T R IP A -Q F81 A TC M otor B rak e
-Q F21 D C 24V C ontrol TR IP D TR IP F
T R IP C -Q F28 S olenoid D C P ower S ource
-Q F22 T ool M agazine M otor B rake TR IP H
1L+
Circuit
C ircuit Protector
P rotector TTrip
rip
131
HP5100 HP51MTE87
2004 Hyd. Pump Motor Overload
Status Overcurrent detected in the Hyd. Pump Motor.
① Burnout of the Hyd. Pump Motor or power Cable

Cause
② Fault in the Load Setting value of the Overcurrent Detecting circuit
breaker or the Circuit Breaker itself
① Check the Hyd. Pump Motor or Power Cable. If there are problems,
Solution
repair or replace with a new one.
② Check the load Setting value of the Overcurrent Detecting circuit
breaker. If it is wrong, reset it. If the circuit breaker itself is faulty,
replace with a new one. (The problem circuit breaker can be found by
the KA11 contact and and 1L+ contact and resistance check)
☞ QM31 Setting Overload: 2.2Kw : 9.6A
QM32 Setting Overload: 2.2Kw : 10.0A
QM36 Setting Overload: 2.2Kw : 10.0A, 3.7Kw : 17A
Product Product # Symbol Model Maker
Breaker, Auxillary ENFBX0290R QM31, 32 3RV1901-1F(2NO) Siemens
3RV1011-1KA10(9-
Breaker, Circuit ENFBX0285R QM31, 32 Siemens
12A)
Tool Connector Numbering

Signal Address I/O
Symbol (Pin) Tube
Hydraulic Motor X2.1

-QM31 Input Module Slot 07 XJ411 (32) HOL
Overload HOL.M
Hyd. Pump Motor

Overload

A0.3 2004 Hyd. Pump Motor Overload
R652.7 ARST Upper Alarm Reset
X2.1 HOL.M Hydralic. Motor Overload
132
HP5100 HP51MTE87
In p ut Module(AID32E)
Input M od u le(AID32E ) : :Slo t7
Slot7
X 2.1 (HOL.M)
X2.1 (HO L.M )
XJ41132
(32)
-Q M 31 H yd. P um p M otor(M ain)
HO LA
-Q M 32 H yd. P um p M otor(P M G )
HO LB
-Q M 36 F ixture Hyd. P um p M otor
1L+
Hyd. Pump
Hyd. Pum p M otor O
Motor v erload
Overload
133
HP5100 HP51MTE87
2005 Hyd. Pressure Down Alarm
The Hyd. Pressure Switch has been activated because the pressure in the
Status
Hyd. Power Unit has fallen below the Hyd. Pressure Switch set point.
① Hyd. Power Unit malfunction, or the oil pressure has fallen below 20
Cause
kg/㎠.
② Hyd. Pressure Switch or other parts faulty
① Turn the Hyd. Power Unit pressure adjustment valve clockwise to set
Solution
the pressure at 50Kg/㎠.
② Hyd.Power Unit, Pressure Switch itself,cables, or related parts faulty.
Check Hyd. Power Unit, Pressure Switch, all cables between Switch and
the operation panel and input modules. Repair or replace with new
ones.

Signal Address I/O
Symbol (Pin) Tube
Hyd.Pressure
X3.0 Input Module Slot
Check -SP01 XJ411 (12) SP01
HPRS.M 07
(Main)
Hydraulic 1,2,3 Y38.4 Distributed I/O
-KA31 XCE57B(A18) KA31
Motor Run HYDM.R Module B
Hyd. Pressure
Down Alarm
Aux. Hyd. Pressure

OK Flag
134
HP5100 HP51MTE87
Hyd. Pump On
Check Time
Hyd. Pressure OK
Hyd. Pressure
Check Time (Main)

A0.0 2001 OP Emg. Stop PB or LS Off
A0.1 2002 Main Spindle Servo Alarm
A0.2 2003 Circuit Protector Trip
A0.3 2004 Hyd, Pump Motor Overload
A0.4 2005 Hyd. Pressure Down Alarm
A0.6 2007 Spindle Stop Signal Alarm
A0.7 2008 -
A1.0 2009 Spindle Servo or Inverter Alarm
A1.6 2015 Spindle Tool Unclamp Alarm
F0.6 SA Servo Ready
F1.0 AL NC Alarm
K5.0 KHPRS Hyd. Pressure Switch Not Used
K11.7 KFXHYD When Motor Of Hyd. Fixture Used
135
HP5100 HP51MTE87

R440.2 TMB99 Hyd. Pressure Check Time (Fixture)
R441.2 KMB107 Hyd. Pressure D-Time Initial
R625.3 TMB20 Hyd. Motor On Check Time Delay
R629.2 KMB51 Hyd. Pressure Check Time (Main)
R630.0 MRYA Aux. Machine Ready
R630.3 HPOK Hyd. Pressure OK
R647.0 APOFF Auto Power Off
R763.6 MAPCFG Man APC Command Flag
R841.0 APOKF Aux. Hyd. Pressure OK Flag
R1420.7 PMGSEL PMG Operation Selected
X3.0 HPRS.M Hyd. Pressure Check (Main)
Y38.4 HYDM.R Hyd. 1,2,3 Motor Run
136
HP5100 HP51MTE87
2009 ATC Servo or Inverter Alarm
Status The alarm shows on the inverter of the Servo Motor driving the ATC
① Servo Motor Inverter troubled

Cause
② Servo Motor or Connection cable troubled
Refer to the Servo Motor Manual and Repair troubled part or replace with
Solution new ones.☞ Refer to the Appendix (Repairing method by Servo Driver
Alarms)

Signal Address I/O
Symbol (Pin) Tube
ATC Servo or X9.6 Input Module Slot
-A81 XJ412 (01) TALM
Inverter Alarm TALM.M 08
ATC Servo or
Inverter Alarm

A1.0 2009 ATC Servo or Inverter Alarm
K7.6 KATC ATC Not Used
X9.6 TALM.M ATC Servo or Inverter Alarm
137
HP5100 HP51MTE87
2010 Spindle Tool Unclamp Cmd. Fault
The clamp/unclamp command signal in the spindle tool during M06

Status troubled. The tool clamp command signal is confirmed before the
unclamp command signal.
① Fault in the unclamp command signal from ATC servo amp.
Cause
② Error in the ATC Servo amp parameters input
①. Check the signal cable connections for unclamp command from
Solution ATC servo amp
②Check the parameters for the ATC Servo Amp Unclamp command
location control
▣PARAMETERS FOR ATC SERVO
ATC SERVO HP51

NO. DEF. TYPE
HP41
FUNCTION RANGE
67 CLAMP POSITION (*1) 1~360 289 D 277 (270)
68 UNCLAMP POSITION 1~360 25 D 25
note *1) ( ) used HSK Tool
NO.67 "289" -> "277" : CHANGE DC24V SOL. (INCLUDE DIODE)

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

Signal Address I/O
Symbol (Pin) Tube
Tool Clamp X8.5 Input Module Slot
-SX51 XJ412 (38) SX51
Command (CLMD.M) 08
Tool Unclamp X8.6 Input Module Slot
-SX52 XJ410 (22) SX52
Command (ULMD.M) 08
138
HP5100 HP51MTE87
Spindle Tool Unclamp

Cmd. Fault
Tool Clamp
Command Fault
Tool Clamp
Command Fault
Tool Clamp
Command Fault

A1.1 2010 Spindle Tool Unclamp Cmd. Fault
R0705.5 TCFLT Tool Clamp Command Fault
F0.6 SA Servo Ready
R652.6 ERST External Reset
R705.4 TUCCFG ATC Unclamp Command Flag
R705.5 TCFLT Tool Clamp Command Fault
R2409.0 M06CDF M06 Command Flag
X8.5 CLMD.M Tool Clamp Command
F0.6 SA Servo Ready
R705.4 TUCCFG ATC Unclamp Command Flag
X8.6 ULMD.M Tool Unclamp Command
139
HP5100 HP51MTE87
2015 Spindle Tool Unclamp Alarm
The Spindle Tool Clamp Detection Switch in the Spindle Tool Clamp Status
Status
(Spindle Tool Unclamp Output Off) is off, or the Spindle Tool Unclamp
Detection Switch is On
① Fault in the adjustment of the Spindle Tool Clamp Detection Switch or
Cause
the Spindle Tool Unclamp Detection Switch
② Fault in the Switch itself or the connection cable, or related parts
① Readjust the Switch
Solution
② Check the proximity Switch, connecting cable, and I/O board. Repair
faulty part or replace with new ones.
Product Product # Symbol Model Label

Switch, Proximity /
ESWPX0265 - BES516-325-E5-C-S4 Balluff
PNP
Cable, Proximity S/W ECBLS0170F -SX11/12 BKS B20-1-03 Balluff

Signal Address I/O
Symbol (Pin) Tube
Spindle Tool Clamp -SX11 XJ412 (31) SX11
TCL.M 08
Spindle Tool X6.5 Input Module Slot
-SX12 XJ411 (47) SX12
Unclamp TUCL.M 08
Spindle Spindle Tool

Tool Clamp
Unclamp
0.8~1.2mm
Proximity Switch Dog
Spindle Tool
Unclamp Alarm
140
HP5100 HP51MTE87

A1.6 A1.6 Spindle Tool Unclamp Alarm
R841.2 SPTCLF Spindle Tool Clamp Flag
X6.4 TCL.M Spindle Tool Clamp
X6.5 TUCL.M Spindle Tool Unclamp
141
HP5100 HP51MTE87
2020 Coolant & Lub. Pump Overload
Status Overcurrent detected in the coolant or lubricant Pump Motor.
① Burnout of the coolant or lubricant Pump Motor or power cable

Cause
② Fault in the Overcurrent detecting Circuit Breaker Load settting value ,
or the circuit breaker itself
① Check the coolant or lubricant Pump Motor and power Cable. Repair
Solution
faulty part or replace with new ones.
② Check the Overcurrent detecting Circuit Breaker Load settting value
and reset it. If there is a problem with the circuit breaker itself, replace
with a new one.
☞ QM10 (Spindle & Y-Axis Servo Fan Motor Use) Setting Overload: 1.5A
QM40 (Flushing Coolant Pump Motor Use) Setting Overload: 8.0A
QM41 (Flood Coolant Pump Motor Use) Setting Overload: 8.0A
QM51 (Lub. Pump Motor Use) Setting Overload: 0.9A

3RV1011-1AA10
Breaker, Motor Circuit ENFBX0255R QM10 Siemens
(1.0-1.6A)
3RV1011-1GA10
(4.5-6.3A)
3RV1011-1JA10
(7.0-10.0A)
3RV1011-0JA10
(0.7-1.0A)
Breaker, Auxillary ENFBX0290R QM10,40,41,51 3RV1901-1F(2NO) Siemens

Signal Address I/O
Symbol (Pin) Tube
Coolant & Lub.
X2.2 -QM10~
Motor Input Module Slot 07 XJ410 (48) MOL
MOL.M -QM185
Overload
Coolant & Lub. Pump

Overload
142
HP5100 HP51MTE87

A2.3 2020 Coolant & Lub. Pump Overload
X2.2 MOL.M Coolant & Lub. Pump Overload
Input
Input Module(AID32E)
Module(AID32E) :: Slot
Slot77
X2.2
X2.2 (MOL.M)
(MOL.M)
XJ411 48
(48)
-QM10 Spindle&Y-Axis Servo Fan motor
MOLA
-QM40 Flushing Coolant Pump Motor
MOLB
-QM41 Flood Coolant Pump Motor
MOLC
1L+
-QM51 Lubrication Pump Motor
MOLM
1L+
Hyd.Pump
Hyd. Pump Motor
Motor Overload
Overload
143
HP5100 HP51MTE87
144
HP5100 HP51MTE87
(Reference) Servo ATC Recovery

1) ATC Structure
-. Magazine
Servo Motor
With Brake
-. Reduction Gear
-. Tool Pot Guide

& Clamp Device
Changer Arm
Home Position
Detection
Proximity S/W
Unique Tool
Locking Device
Air Cylinder
Reduction Gear Spline Shaft
ATC Servo
Motor
Drive Cam Ass’y
145
HP5100 HP51MTE87
2) ATC Main Sequence
Initial Condition Changer Arm

① Arm & Servo Home Position X8.7 (SX53) CAHP.M
② 2nd Reference Point & M19 X7.0 (SX5A) WPSS.M
③ Pot Spindle Si de X7.2 (SD32) WPCL.M Arm
& Clamp Forward
④ Arm Pin Release X15.5 (SD56) ATAR.M
Gripping Tool

☞Output : Y39.6(STUN.R), KAR11-YV11,Distribute I/O B (A23) On
☞Completion : X6.4(TCL.M), SX11, Input Module Slot8(Pin31) Off
X6.5 (TUCL.M), SX12, Input Module Slot8(Pin47) On Spindle Tool
Arm Pin
Locking Arm Out
Changer Arm Pin Locking
&
☞ Output : Y 0.2(ATAL.R), YV55,Output Module Slot01(Pin04) On
Rotation
☞ Completion : X15.3(ATAL.M), SD55, Input Module On
Slot06 (Pin11)
X15.5(ATAR.M), SD56, Input Module Slot06(Pin43) Off
Tool Change
Spindle Tool Clamp

Arm In
☞ Output : Y39.6(STUN.R), KAR11-YV11,Distribute I/O B (A23) Off
☞ Completion : X6.4(TCL.M), SX11, Input Module Slot8(Pin31) On
X6.5 (TUCL.M), SX12, Input Module Slot8(Pin47) Off Spindle Tool Clamp
Arm Pin
Release
Changer Arm Pin Release
Arm
☞ Output : Y 0.2(ATAL.R), YV55,Output Module Slot01(Pin04) On Forward
☞Completion:X15.3(ATAL.M),SD55, Input Module Slot06(Pin11) On
X15.5 (ATAR.M), SD56, Input Module Slot06(Pin43) Off
Changer Arm Home Position Changer Arm Home

☞Input Signal : X8.7(CAHP.M),SX53, Input Module Slot8(Pin37) On
146
HP5100 HP51MTE87
3) Trouble Shooting
(1) Operating the Maintenance screen (ATC manual operation)

① Select "JOG” Mode on the Main O.P.
② Press the“CUSTOM” Key.
☞ The“CUSTOM WINDOW”sceen appears.
③ Press the“MANUAL”Function Key.

☞ The ATC, APC Manual screen appears.
147
HP5100 HP51MTE87
④ Press“ATCON".
☞ The“ATC MANUAL MODE”is On.
148
HP5100 HP51MTE87
☞ Step Selecting method: Use the cursor keys to move the cursor up and down
on the Main O.P, and select.
⑤ Manual operation: After selecting the designated command and pushing Cycle Start, the
step operates and is completed when an "*" appears in the "status" space on the right.
Initial Condition Status
(2) Canceling the AL2065 (Verifying the Arm Home Position)

① Meaning of the Alarm : The alarm becomes activated when there is a change in t
he Main Changer Arm Home Position due to the Servo System or from other causes.
That is, the case where there is a difference between the reference point (X7.6)
memorized in the servo system and the reference point that recognizes
proximity switches (X8.7) by the present arm position.
② Objective of the Alarm: The alarm aims to increase the stability of the Servo
Mechanisms (e.g. Clamping/Unclamping), which must work based on the Arm's
actual location, by maintaining the same Arm position setting regardless of
continuous tool exchanges.
③ Troubleshooting the Alarm
☞ Checking for Problems with the Changer Arm Home Position Detection Proximity
S/W
After checking for problems with switch looseness/ Dog looseness/
contamination/firing range, proceed normally.
149
HP5100 HP51MTE87
☞In case of alarm, when the changer arm home dog is deflected or even if the
position is normal, observe inside the Cam to see if the Turret Can Follower
Bearing is positioned on the Cam's Center area. Since this area is very small, it is
convenient to use a mirror and worklight.
Is the Cam Follower

Bearing in the middle of
the central area?
Central
Mirror Area
A≒B
☞After verifying the Cam Follower Bearing location, use those observations to
cancel the #2065 Alarm by Origin Initialization from the Servo Drive..
Cam
Case S/W & Dog align Solution
Follower
Normal Faulty Reorder the Switch, secure, and Initialize
A Normal Normal Initialize
Faulty Normal Realign the Changer Arm using Inching,
B
Faulty Faulty reorder the Switch, and Initialize
150
HP5100 HP51MTE87
(2) -1 Case “A”
① Press the "MODE" Key once on the Servo Drive start

screen [r 0000]
② Press the "DOWN" Key once on the

[rd-oFF] screen
③ Press the "SET" Key for five seconds on the

[Or9.S--] screen. The letters will blink, then complete
Servo Origin Initialization.
④ Power Off → On
⑤ Move back to Maintenance Mode. Execute the

remaining Recovery processes. Verify normal ATC
activity, and close Maintenance Mode.
151
HP5100 HP51MTE87
(2)-2 Case “B”
① Press the MODE Key once and the "DOWN" Key

four times on the Servo Drive start screen[r 0000] to
display the [JOG run]. Press the "SET" Key once to
display the [Jr.0000].
② Appropriately use the "UP/DOWN" Key (which

drives the Arm 20rpm every time it is pressed) to
position the Cam Follower Bearing in the center of the
middle section. If necessary, reorder the S/W and press
the "Set" Key once to exit to the [JOG run] screen.
③ Press the "UP" key three times on the [JOG run] screen.
④ Press the "SET" Key for five seconds on the

[Or9.S--] screen. The letters on the screen will blink,
and then complete the Servo Origin Initialization.
⑤ Power Off → On
⑥ Move back to Maintenance Mode. Execute the

152
HP5100 HP51MTE87
3) Ordinarily, ATC related trouble shooting that could possibly occur during ordinary
arm driving
Case Status
1 Power interruption before unclamp or after clamp, emergency situation
Power interruption during arm driving after unclamp and before clamp, or
2
emergency situation
Power interruption during unclamp or right after clamp, emergency
3 situation
Arm gets jammed during unclamp or right after clamp (in most cases)
(2)-3 Case “1”
① Power On → Machine Ready Operation Case “1”
② Maintenance Mode On
③ Use Reverse Step operation to return to the
Arm Home Position
☞ If the problem occurred after Clamping,

use the available Forward Step control. The
point at which the problem occurred can be
judged based on the Forward Step control's
availability, and is the D450=D452 status.
That is, the PMC Ladder is set so that the for
ward step control is only available after clam
ping is verified.
④ Maintenance Mode Off

⑤ Take necessary measures after confirming whether AL2065 ooccurred or not
⑥ If there is a record of turning off Power, manually recover the reference point (not
necessary for emergency).
⑦ M19 / G91 G30 X0 Y0 Z0 in MDI Mode
⑧ Check the tool number (D450 / D452) on the G.Data Table and make any necessary
changes.
⑨ Maintenance Mode On
⑩ Execute 1 Cycle several times to accurately judge the cause of the problem, and to
check for any additional problems.
⑪ Maintenance Mode Off
⑫ Insert the tool that was to be exchanged before the problem arose. Recheck the
program, and continue the original process.
153
HP5100 HP51MTE87
(2)-4 Case “2”

A
① Power ON à Machine Ready operation
③ With the reverse step operation,
returns to arm home position
☞ Remove all the tools clamped to the ①
changer arm and reverse operate. At
B ②
this time, in the figure below, in
position A, when the tool is removed
it is very dangerous therefore it must
be done at B.
④ Maintenance Mode Off Case “2”
⑤ Take necessary measures after
confirming whether AL2065 ooccurred Press the locking pin on the
back of the arm as hard as
or not. ①
possible and then remove the
⑥ If there is any history of power OFF, tools clamped to the arm.
manual return to the reference point
Check the CT/DIN Shape
(not necessary for emergency). state of
②
⑦ M19 / G91 G30 X0 Y0 Z0 based on roller
MDI rotation
and degree
⑧ Check the tool number (D450 / D452) of wear,
on the G.Data and change it if etc. and
necessary. take proper
measures if
⑨ Maintenance Mode On necessary.
⑩ Accurately check the cause by
executing 1 cycle several times and
check if there are any additional
problems.
⑪ Maintenance Mode Off
⑫ After changing the tool that was to be
changed before the problem re-check
the program and continue operating.
154
HP5100 HP51MTE87
(2)-5 Case “3” (Machine is Jammed) Trouble Shooting Process
Case Tool Data Status

3-1 D450≠D452 Cannot pull out tools after Unclamping.
Cannot rotate Changer Arm because it is jammed in
3-2 D450=D452
tools after Clamping.
Case “3”
☞ It is very important to distinguish the two states, and it is accurate to

determine using the position of the changer arm home position dog.
Case 3-1 Case 3-2
C. Arm home position

dog is located below
the proximity switch
▶ Reverse operation C. Arm home position
dog is located above
the proximity switch
▶ Forward operation
① Power ON à Machine Ready operation

☞ Even if it is due to being mechanically jammed and not power
interruption, the probability that AL2009 will occur from the servo system
is very high. AL2009 caused by overload is power OFF level, so for
release power OFF / ON operation is essential.
155
HP5100 HP51MTE87
③ Distinguish the occurred situations and perform the trouble shooting.

(Refer to the next page)
.
Case Tool Data Status
▪ If the Changer Arm falls out easily during Reverse Step

Control, return it to the Cam Home Position and execute
the next step.
3-1 D450≠D452 ▪ If the Arm does not fall out and the Overload Alarm(#2009)
is set off, turn on the power and press the Changer Arm
Roller using a screwdriver. Carefully recover using Reverse
control and execute the following step.
▪ If the Changer Arm falls out easily during Forward Step
Control, return it to the Cam Home Position and execute
the next step.
3-2 D450=D452 ▪ If the Arm does not fall out and the Overload Alarm(#2009)
is set off, turn on the power and press the Changer Arm
Roller using a screwdriver. Carefully recover using Forward
control and execute the following step.
④ Finding the origin of jamming and Troubleshooting (see below)
⑤ Maintenance Mode Off
⑥ Check for AL2065 activation and take appropriate steps.
⑦ If there is a record of turning off Power, manually recover the reference point
(unnecessary in the case of emergency).
⑧ M19 / G91 G30 X0 Y0 Z0 in MDI Mode
⑨ Check the tool number (D450 / D452) on the G.Data Table and make any necessary
changes.
⑩ Maintenance Mode On
⑪ Execute 1 Cycle several times to accurately judge the cause of the problem, and to
check for any additional problems.
⑫ Maintenance Mode Off
⑬ Insert the tool that was to be exchanged before the problem arose. Recheck the
program, and continue the original process.
☞ Notes to be checked when removing jams
ⓐ Do not carelessly use manual Unclamp operation.
(Note) If the jam occured during Unclamping, be careful of tools falling from the
Spindle.
156
HP5100 HP51MTE87
ⓑ If the tool had not fallen due to weak Kicking, send the Arm to its home position.
Carefully hit with a rubber hammer and repeat the manual unclamping
process to pull out the tool. After completion, it is recommended to reset the
tool push amount.
ⓒ Release the Collet and check for any damage/abrasion/loosening.
ⓓ Recheck the Centering in order to check the M19, change in the 2nd reference point,
and change or Slip in the Changer Arm.
ⓔ Check for any abration, dents, or scratchers on the Changer Arm Roller. Also check the
spring strength of the Release Pin.
ⓕ Remove any contamination on the ATC main drive, and check for any abnormal noise.
ⓖ Repeatedly move the standby Pot in/out to decide its location and to check for any
speed disorder.
ⓗ Check the Customer Use Tools and Pull Stud for any wear, standard disorder, or
loosening.
ⓘ In the case of CT/DIN Tools, make sure that it has been loaded into the magazine in
the right direction.
4) ATC Centering
☞ If the Tool Change is not smooth directly after installation or during use, the ATC and
Main Spindle must be aligned(centered).
Centering Tools for ATC Centering
Tool 3
Tool 2
Tool 1
(1)Preparation for ATC Centering

① Remove the tool from the Main Spindle to empty the Spindle, and release the two
Driving Keys attached on the side of the Spindle.
② Attach the Centering Tool(1) to the Spindle.
157
HP5100 HP51MTE87
③ Send each Axis to the Tool Change Position.

☞ B-Axis: X, Y, Z Axis: 2nd reference point (G91 G30 X0. Y0. Z0.)
④ Execute Spindle Orientation.
☞ M19;
⑤ Confirm the Pot number of the tool missing rom the Tool Magazine and call the tool.
☞ ex) Tool No. 15 : “MDI” Mode T15; “Cycle Start”
⑥ Open the ATC Door.
☞ ex) “MDI” Mode M222 ; “Cycle Start
(2) Insert the ATC Centering Tool(2) into the Changer Arm Gripper.
① Manually control the ATC from“Maintenance” Mode.
② Select“JOG” Mode.
③ Press the “CUSTOM” Key.
④ Press "MAN" from among the Function Keys.
⑤ Press“ATCON".
⑥ Manually select the Toggle S/W from the manual ATC menu.
⑦ Use the arrow keys to move the curosr to “ATC ARM FORWARD STEP,”then press‘Cycle
Start’to rotate the Changer Arm towards the Spindle until just before the
Arm Out position.
⑧ Insert the Centering Tool(2), fitting it to the Arm Gripper Key.
(3) Check the alignment between the

Centering Tool (2)
Changer Arm and Spindle.
① Check the gap between Tool(1) and
Tool(2) using a gap gauge.
☞ Objective : DIN: 3.2mm, BT: 2.0mm
② Insert Tool(3) into the center hole to
check if the locations of Tool(2) and Centering Tool (3)
Tool(1) are accurate.
Gap
Measurement
Area
(4) Adjusting the gap between Tool(1) and Tool(2): Set the gap to the front and back of
the Changer Ass'y.
☞ Objective : DIN: 3.2mm, BT: 2.0mm
(5) Adjusting the Center Location of Tool(2) and Tool(1)
① If Centering is incorrect, remove Centering Tool(3), change Keep Relay K 7.6 from “1”
158
HP5100 HP51MTE87
to“0, then use MPG to move the X and Y Axes and check Centering.
☞ Do not use Keep Relay K7.6 “0”→ ATC
② When Centering is microadjusted, enter the coordinates into the X, Y Axis 2nd
reference point.
☞ 2nd reference point Parameter: N1241
③ Remove Centering Tool(3) and change the Keep Relay K7.6 back from “0” to “1”.
④ Use Forward Step to return the Changer Arm to its Home position, then remove
Centering Tool(1) from the main axis.
⑤ Execute tool exchange once in unloaded "MDI” Mode, then manually send the Changer
Arm to Tool Exchange position and reconfirm Centering.
159
HP5100 HP51MTE87
2021 Air Pressure Down Alarm
The Air Pressure Switch has been activated because the pressure in the
Status
Air Equipment for Tool Change has fallen below the Air Pressure Switch
set point.
① The factory air pressure has fallen below standard (below 4kg).
Cause
② Breakage of the Air Pressure Switch or other parts
① Raise the factory air pressure to above 4kg/㎠ (normally to about
Solution
6kg/㎠).
Check the pressure recorded on the Air pressure gauge attached to the
Air Service Unit at the back of the machine. If the air pressure is below
4kg/㎠, turn the pressure control handle to the right. If the air pressure
does not rise, the factory air pressure is weak. Check the factory air
pressure.
② Fault in cables or other parts: make any necessary repairs or
replacements.

Signal Address I/O
Symbol (Pin) Tube
X3.1
Air Pressure Check -SP12 Input Module Slot 07 XJ410 (28) SP12
EPRS.M
Y1.5 Output Module Slot T/Block
Pallet Air for Table -YV63 YV63
PAIR.R 01 (18)
Air Pressure Down

Alarm
Air Pressure Check

Time
160
HP5100 HP51MTE87

A2.4 2021 Air Pressure Down Alarm
F0.6 SA Servo Ready
K5.1 KAPRS Air Pressure S/W Not Used
R629.0 TMB49 Air Pressure Check Time
X3.1 APRS.M Air Pressure Check
Y1.5 PAIR.R Pallet Air For Table
161
HP5100 HP51MTE87
2023 M06 Command Overtime Alarm
Status The Tool Change Command(M06) could not be completed within 5 seconds.
This is generally an alarm set off when the Changer Arm and Tool jam
Cause
during Tool Change.
This is generally an alarm set off when the Changer Arm and Tool jam
Solution
during Tool Change.
☞ M06 Initial Position
Address X7.6 X7.2 X7.1 X7.0 X8.7
Status 1 1 0 1 1
☞ T-Code Initial Position
Address K61.1 X7.6 X7.3 X7.1 X8.7
Status 1 1 1 1 1
(Reference) Recovering ATC Breakage

If the Changer Arm stopped in the middle of Tool Change(M06), you must
manually return the Changer Arm to its home position. Because the necessary
measures differ with each situation, you must accurately find the cause of the
problem and take appropriate measures.
☞ Since this is done with tools attached to the Changer Arm, be careful not to drop
the tools. Just in case tools fall, set up a wooden pallet to protect tools or the
machine cover below the ATC.
(1) Changer Arm stop during Spindle Tool Clamp Status

The Changer Arm stopped between the Home Position and the Spindle.
(2) Changer Arm stop during Spindle Tool Unclamp Status

The Changer Arm stopped after falling out from the Spindle and before rotating
180˚ to insert the tool into the Spindle.
(3) Arm Jam during Unclamping or directly following Clamping

The Changer Arm stopped while stuck in the Spindle.
(4) Alarm 2065 (“Changer Arm Position Check Alarm”) activated

despite having returned the Changer Arm to Home Position
The Changer Arm has been returned to Home Position, but for some reason
this position does not match the Servo reference point or the ATC machine
reference point set in the Cam bundle.
162
HP5100 HP51MTE87
(1) Recovery Process for when the Changer Arm has stopped during
Spindle Tool Clamp Status
1) In Emergency Stop status, or in Power Off

status, remove the stop cause and turn the
machine on to Ready mode.
2) Select "JOG" mode from the main operation panel.
3) Press the "CUSTOM" NC Function Key.

The“CUSTOM WINDOW”screen appears.
4) Press the "PMC-SW”soft key. The ATC, APC

Manual screen appears.
5) When the ATC, APC Manual screen appears,

press the “ATC-ON”soft key to select the ATC.
The ATC Manual Mode changes from
“DISABLE”to “ON”.
163
HP5100 HP51MTE87
6) Move the cursor keys to choose "ATC ARM

REVERSE STEP,”and repeatedly press the
main operation panel's cycle start button to
move the Changer Arm to Home Position.
7) Repeatedly press the main operation panel's

Cycle Start button to move the Changer Arm to
Home position, where it no longer moves. (If
the Changer Arm stops moving, it has been
returned to Home Position.)
※ If the Changer Arm jams after replacing
tools and Spindle Tool Clamping, select
"ATC ARM FORWARD STEP”to manually
send it to other sections.
Verification : D450 = D452 in PMC G.DATA
mode
8) Move the cursor Key to select“ATC ARM 1

CYCLE,”and press the main operation panel's
Cycle Start button. The Changer Arm will
execute Tool Change once, and the inner Cam
and Changer Arm will be reordered.
9) At completion, press the “OFF”soft key. The

ATC Manual Mode will change
from“ON”to“DISABLE.”
164
HP5100 HP51MTE87
10) Press (in order)“SYSTEM” => PMC => PMC DATA => G.DATA, confirm the tool
numbers of the Spindle and Standby Port from D450, D452, and reset.
D450 : Spindle tool number
D452 : Standby port tool number
11) When each axis is returned to its reference point, the ATC breakage recovery
is complete.
165
HP5100 HP51MTE87

A2.6 2023 M06 Command Overtime Alarm
A4.3 2036 T-Code Command Illegal Pos.
A4.4 2037 M06 Command Illegal Pos.
A9.4 2077 Wait.Pot & Spdl Tool Data Zero
A9.5 2078 ATC Op Manual Mode
F0.5 STL Cycle Start
F218.5 MTC-FM Man Tool Pot Call From Matrix
F218.6 MTR-FM Man Tool Pot Return From Matrx
F45.7 ORARA Spindle Orientation Complete
K0.3 KHP5500,KHP6300 If It Is A Ace-Hp5500,Hp6300
K10.3 KATCDR ATC Door Not Used
K16.7 KMTM19 Used Variable Orientation Func
K6.0 KMATRX Matrix Tool Magazine Is Used
R2401.5 RTCCMF Re-Change T-Code Command Flag
R2401.7 TCCMDF T-Code Command Flag
R2410.7 2081F
R600.3 M06 ATC Change Macro Call
R625.6 TMB23 M06 Command Overtime
R625.6 TMB23 M06 Command Overtime
R631.3 CYSTP Cycle Stop
R705.7 ATCSER ATC Clamp Command Switch Error
R721.0 MANM06 Manual 1 Cyc ATC Start
R749.6 ATCAUT ATC Mag. Auto Mode
X8.0 ATDO.M ATC Door Open
Y1.2 MTO2.R Mag. 2 Tool Pot Tool Out
Y1.3 MTPO.R Mag.1 Tool Pot Tool Out
166
HP5100 HP51MTE87
Magazine Rotation or Matrix Illegal Position Alarm

2036
(Check Condition for T-code Command
(M6INPA,TFINP))
Tool Change was attempted in a different position from the default
Status
position.
① Faulty adjustment of the switch that confirms the default position of
Cause
the ATC or Tool Magazine
② Fault in pertinent parts
①. Check the switch with PMC-DGN and adjust the position with the Dog.
Solution
②. Check the Limit Switch, connection cable ,I/O Module to find the faulty
area.
Address X7.6 X7.2 X7.1 X7.0 X8.7
Status 1 1 0 1 1
Address K61.1 X7.6 X7.3 X7.1 X8.7
Status 1 1 1 1 1

Signal Address I/O
Symbol (Pin) Tube
Waiting Pot Spindle X7.0
-SX5A Input Module Slot 08 XJ412 (12) SX5A
Side WPSS.M
Waiting Pot X7.1
-SX5B Input Module Slot 08 XJ412 (28) SX5B
Magazine Side WPMS.M
Waiting Pot Clamp X7.2
-SD32 Input Module Slot 08 XJ412 (44) SD32
Check SD32.M
Waiting Pot
X7.3
Unclamp -SD33 Input Module Slot 08 XJ412 (11) SD33
SD32.M
Check
ATC Servo Home X7.6
-A81 Input Module Slot 08 XJ412 (10) THOMEI
Position MCAH.M
ATC Home Position X8.7
-SX53 Input Module Slot 08 XJ412 (37) SX53
Check CAHP.M
167
HP5100 HP51MTE87
(Reference) DGN (Diagnostic) Check Process

1) Finding the DGN
(1) Press the "SYSTEM" key from the right side of the Main operation panel CRT.
▪ The following will appear in the Soft Key space below the CRT.
〔PARAM〕〔DGNOS〕〔PMC〕〔SYSTEM〕〔(OPRT)〕
(2) Press the〔PMC〕Soft Key.
〔PMCLAD〕〔PMCDGN〕〔PMCPRM〕
(3) Press the〔PMCDGN〕Soft Key.
〔TITLE〕〔STATUS〕〔ALARM〕〔TRACE〕
(4) Press the〔STATUS〕Soft Key.
〔NO.SRH〕〔〕〔〕〔〕〔〕
(5) Enter the intended DGN number. Ex) When looking for X4.1 : “X”, “4”, “.”, “1”,
(6) Press the〔NO.SRH〕among Soft Key.
▪ A diagnostic screen showing the needed number will appear.
2) How to read the DGN
Ex) X 003 00110010
Of Address X3, Bit 1, 4, and 5 are On, and Bit 0, 2, 3, 6, and 7 are Off.
Shown As 0 0 1 1 0 0 1 0
Bit No Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
Waiting Pot
Spindle side
(SX5A—X7.0)
Changer Arm
Home Position
Proximity S/W
(SX53--X8.7)
168
HP5100 HP51MTE87
Magazine Rotation or Matrix Illegal Position

Alarm
(Check Condition For T-code Command
(M6INPA, TFINP))

A4.3 2036 T-code Command Illegal Pos.
F212.4 TMN-FM ATC Manual Mode From Matrix
F218.6 MTR-FM Man Tool Pot Return From Matrx
F1212.2 L-OP LCB Auto Operate
K16.5 KTBU Used Tool Broken Unit (LCB)
R411.3 M255 Spindle Tool Number Set
R411.4 M256 Next Tool Number Set
R460.0 TTF T-code Strobe
R700.2 WPTNCM Same T Is Comd With Wait Pot
R700.7 TCMDFA T-code Command Flague Aux.
R701.5 M6INPA M06inp Aux.
R701.5 M6INPA M06inp Aux.
R701.6 TFINP T-code Initial Position
169
HP5100 HP51MTE87

R708.2 STSECH Spindle Tool Search
R710.1 WPTZER Wait. Pot Tool Data Zero
R749.6 ATCAUT ATC Mag. Auto Mode
R842.1 ATCALM ATC Alarm
R2401.5 RTCCMF Re-change T-code Command Flag
R2408.6 MAG.1F Mag.1 Flag
R2408.7 MAG.2F Mag.2f
R2410.7 2081F
170
HP5100 HP51MTE87
2037 M06 Command Illegal Pos.
There is an error in reading the Waiting Port Tool number.

Status Problems with the ATC Initial Position (X, Y, Z Axis returned to 2nd
reference point) and the Changer Arm Location
① The tool is not detected by the Waiting Port. (PMC Parameter D452)
Cause ② The X, Y, Z Axes are not located at their 2nd reference points.
③ The Changer Arm is not in its home position.
① Check for the existence of tools in the Waiting Port.
Solution ② Check the status of the Waiting Port Tool Clamp. (SD32--X7.2)
③ Check if the X,Y,Z Axes are each at its 2nd reference point.(G91 G30
X0.Y0.Z0.)
☞ If each is at its 2nd reference point, the reference point confirmation
LED blinks.
Address X7.6 X7.2 X7.1 X7.0 X8.7
Status 1 1 0 1 1
④ Check the position of the Changer Arm, and reposition it referring to
the release of AL2065.

Signal Address I/O
Symbol (Pin) Tube
Side WPSS.M
Waiting Pot X7.1
Waiting Pot Clamp X7.2
Check SD32.M
ATC Servo Home X7.6
Position MCAH.M
Check CAHP.M
171
HP5100 HP51MTE87
M06 Command Illegal Pos.

A4.4 2037 M06 Command Illegal Pos.
F218.6 MTR-FM Man Tool Pot Return From Matrix
R702.0 TCCMDA T-code Command Aux.
R704.1 ATCS2 Do.2(pot Spindle Side Check)
R708.2 STSECH Spindle Tool Search
R708.6 ATDRCL ATC Door Close Comd
R709.0 ATCMST ATC Macro Start
R709.2 M06INP M06 Initial Position
R710.1 WPTZER Wait. Pot Tool Data Zero
R842.1 ATCALM ATC Alarm
R2401.7 TCCMDF T-code Command Flag
R2410.7 2081F
172
HP5100 HP51MTE87
2041 APC Overtime Alarm
The M60(pallet Change) or M61(APC Unload), M62(APC Load) commands

Status
could not be completed within 30 seconds.
Faulty adjustment of each sequence's process completion detection
Cause
switch, or disorder in the process Solenoid Valve, connection cable, or
other related parts.
If there is a problem with each sequence's process completion detection
Solution
switch or with related parts, each sequence's alarm should be set off.
Check the parts corresponding to the activated alarms and take necessary
measures.
☞ Refer to the“Pallet Change Sequence" chart
APC Overtime
Alarm
APC
Overtime
Check

A5.0 2014 APC Overtime
A9.0 2073 Pallet or Table CL/UNCL S/W Alarm
K7.7 KAPC APC Not Used
R626.3 TMB28 APC Overtime Check
173
HP5100 HP51MTE87
☞ Pallet Change Sequence
START (M60 Command)
▶ Return to Y,Z-Axis 2nd reference point

① Y,Z-Axis 2nd Ref. Position Program : G00 G91 G30 Y0. Z0.;
Y,Z-Axis 2nd ▶ Executing Return to X,Y,Z-Axis 2nd reference

Ref. POS.？ No point
Program : G00 G91 G30 Y0. Z0.;
Yes
▶ Return to B-Axis Reference point
② B-Axis Ref. Position
Program : G00 G91 G28 B0.;
▶ Return to B-Axis Reference point

B-Axis Ref. Program : G00 G91 G28 B0.;
Position.？ No
★ 2042 M61/M62 Command Illegal POS occur.
Yes
X10.0 PCL.M -SP61 On X10.1 TACL.M -SL62 On
APC Initial X11.1 PNO1.M -SX75, X11.2 PNO2.M -SX76 On/Off

Position？ No X11.6 APUP.M -SX81 On X11.7 APDN.M -SX82 Off
X12.1 ACUP.M -SX81 Off
Yes
Pushed Set- ★2085 APC Set-Up Location S/W Unpush occur

Up Button？ No
Verification Signal : X16.6 SETU.M On
-
SB93
Yes
Output Signal : Y7.2 PUCL.R -KAR62/-YV62 On
③ Pallet Unclamp Completion Signal : X10.0 PCL.M -SP61 Off
Pallet ★ 2073 Table or Pallet CL/UNCL Switch Alarm

Unclamp No Verification Signal: X10.0 PCL.M -SP61 Off
？
Yes
Output Signal : Y39.2 APUP.R -KAR75/-YV75
④ APC Up Completion Signal : X11.6 ACUP.M -SX81
★ 2126 APC Up/Down Alarm occur

APC Up O.K？
No
Verification Signal : X11.6 ACUP.M -SX81 On
Yes
174
HP5100 HP51MTE87
Pallet 1 Position？ GO TO 1
No
Yes
⑤ APC Arm 180 CW Rotation Output Signal : Y39.0 PCW.R -KAR73/-YV73
Completion Signal : X11.2 PNO2.M -SX76
APC Arm 180 CW Rot. ★ 2127 APC Changer 180CW/180CCW Alarm

End？ No On
Verification Signal : X11.2 PNO2.M
Yes
2
Output Signal : Y39.3 APDN.R -KAR76/-YV76

⑥ APC Down
Completion Signal : X11.7 APDN.M -SX82
APC Down O.K？ ★ 2126 APC Up/Down Alarm occur

No Verification Signal : X11.7 APDN.M -SX82
Yes
Output Signal : Y7.2 PUCL.R -KAR62/-YV62
⑦ Pallet Clamp
Completion Signal : X10.0 PCL.M -SP61
Pallet Clamp ★ 2073 Table or Pallet CL/UNCL Switch Alarm

O.K？ No Verification Signal : X10.0 PCL.M -SP61 On
Yes
End
Pallet 2 Verification Signal : 1 POS. X11.1 PNO1.M -SX75 Off

Position？ 2 POS. X11.2 PNO2.M -SX76 On
Yes
APC Arm 180 CCW Rotation Output Signal : Y39.1 PCCW.R -KAR74/-YV74
⑤
APC Arm 180 CCW ★ 2127 APC Changer 180CW/180CCW Alarm

Rot. End？
No Verification Signal : X11.1 PNO1.M -SX75 On
Yes
2
175
HP5100 HP51MTE87
2042 M61 / M62 Command Illegal Position
The M61 or M62 command was given in a condition other than the APC
Status
initial condition.
① Faulty adjustment of the APC intial condition detection switch

Cause
② Fault in the detection Switch, connection cable, or related parts
① Faulty adjustment of the APC initial condition detection switch

Solution Check the Ladder Diagram or D.G.N to find the problem Switch and to
adjust and fix it.
② Check (in order) each section's Switch, connection cable, and I/O board
to find and repair or replace the faulty part.
☞ APC Initial Condition
Address X5.4 X10.3 X10.1 X10.0 X11.7 X11.6 X11.2 X11.1 X11.0
0 1
Status 1 0 1 1 1 0 1
1 0
Signal Connector Numbering

Address Symbol I/O
(APC Initial Condition) (Pin) Tube
X5.4 Input Module
Set Up Door Interlock -S91 XJ411 (19) S91
SUIT.M Slot 07
Pallet Clamp X10.0 Input Module
-SP61 XJ413 (16) SP61
(Index/Rotary) (ON) PCL.M Slot 09
Table Clamp X10.1 Input Module
-SL62 XJ413 (32) SL62
(Index/Rotary) (ON) TACL.M Slot 09
Table Unclamp X10.3 Input Module
-SL64 XJ413 (15) SP64
(Index/Rotary) (OFF) TAUL.M Slot 09
X11.0
Pallet Rot. Lock Input Module
PLOC.M -SX89 XJ413 (12) SX89
(Setup S-D.O.) Slot 09
(SSDC.M)
Pallet No.1 Detection X11.1 Input Module
-SX75 XJ413 (28) SX75
(ON/OFF) PN01.M Slot 09
Pallet No.2 Detection X11.2 Input Module
-SX76 XJ413 (44) SX76
(OFF/ON) PN02.M Slot 09
APC Up Check X11.6 Input Module
-SX81 XJ413 (10) SX81
(OFF) APUP.M Slot 09
APC Down Check X11.7 Input Module
-SX82 XJ413 (42) SX82
(ON) APDP.M Slot 09
M61/M62 Command Illegal Pos.
176
HP5100 HP51MTE87
M60 Illegal Pos. Check

Time

A5.1 2042 M61/M62 Command Illegal Pos.
R629.6 TMB55 M60 Illegal Pos. Check Time
A5.1 2042 M61/M62 Command Illegal Pos.
A9.0 2073 Pallet Or Table Cl/Unclamp SW Al
A10.3 2084 APC Set-up Station Door Open
A10.4 2085 APC Set-up, location S/W Unpush
F102.3 MV4 B-axis Moving Signal
K10.2 KAUTDR Auto Door For Setup Door Is Us
K10.5 KSETDR Set-up Door Interlock Not Used
K16.2 KSSPDR Setup Supplier Door Not Use
R430.7 TM32 APC Auto Door Close Check Time
R452.0 TMB193 Setup Supplier Door Close C-tm
R607.2 M61 APC 1 Load Macro Call
R629.6 TMB55 M60 Illegal Pos. Check Time
177
HP5100 HP51MTE87

R757.2 APCINP APC Initial Position
R760.0 M61CD Pallet1 Load Command
R762.0 M61MEN M61 Finish
R1011.2 PDTB.MR Pallet Detection In Buffer
X5.4 SUIT.M Front(set Up) Door Interlock
(Reference) Adjusting the Table and Pallet Switch

① Pallet Clamp / Unclamp Check
☞ Pallet Clamp Adjusted Pressure : 35kg/㎤
Pallet Unclamp Adjusted Pressure : 8kg/㎤
② Pallet No 1 Detection / No 2 Detection

2~2.5mm
APC Up / Down Check
Proximity Dog
Switch
Pallet No.1
APC UP Check
APC Down Check
③ Table Clamp / Unclamp Check Pallet No.2
178
HP5100 HP51MTE87
☞ For the Table Clamp, change the B Axis reference point by about 0.5 degrees so that it
rests where the Curvic Coupling does not normally sit, execute Tool Clamp, and verify the
DGN. At this point both switches must be turned off.
Table
Clamp
Table
Unclamp
179
HP5100 HP51MTE87
2048 ATC Door Open
Status The ATC Door is open
① The ATC Door is open.

Cause ② Faulty adjustment of the ATC Door Close Check Reed Switch
③ Fault in the ATC Door Close Detection Switch or related parts
① Manully operate the ATC, or command“M222”(ATC Door Close) in MDI
Solution mode.
② Loosen the Reed Switch Holder security Screw and move it towards the
Shaft. Find the location where the Sensor LED lights up, and secure.
③ Check (in order) the Reed Switch, connection cable, and I/O board.
Make any necessary repairs or replacements.
Connector Numbering
Signal Address Symbol I/O
(Pin) Tube
X8.0
ATC Door Open -SD51 Input Module Slot 08 XJ412 (07) SD51
ATDO.M
X8.1
ATC Door Close -SD52 Input Module Slot 08 XJ412 (24) SD52
ATDC.M
X32.5 Distributed I/O
Cycle Start -SB12 XC56A(B04) SB12
ST.M Module A
Reed
Switc
Reed
Switc ATC Door
Close ATC Door
Check Open
Check
180
HP5100 HP51MTE87
ATC Door Open Alarm
ATC Door Open Alarm

D-time

A5.7 2048 ATC Door Open Alarm
A20.2 2163 ATC Door Open/Close Alarm
R628.4 TMB45 ATC Door Open Alarm D-time
R635.7 AUT Auto Mode
R707.0 M1CYLE Man 1 Cycle Operation
R733.1 MM Maintenance Mode For ATC/APC
X32.5 ST.M Cycle Start
F0.6 SA Servo Ready
R407.2 M222 ATC Door Open
R407.3 M223 ATC Door Close
R628.4 TMB45 ATC Door Open Alarm D-time
R718.0 TMB45A ATC Door Open Alarm D-time
R721.0 MANM06 Manual 1 Cycle ATC Start
181
HP5100 HP51MTE87

R2410.7 2081F
R4005.3 TMB45B ATC Door Open Alarm In Matrix
X8.1 ATDC.M ATC Door Close
(Reference) Operating the Maintenance screen (ATC manual operation)
① Select the "JOG" Mode from the Main O.P.

② Press the“CUSTOM” Key.
▪ The“CUSTOM WINDOW”screen appears.
③ Press the "MANUAL" Function Key“MANUAL".

▪ The ATC, APC Manual screen appears.
④ Press“ATCON.”
▪ The“ATC MANUAL MODE”is On.
182
HP5100 HP51MTE87
☞ Choosing a Step: Use the cursor keys

to move the cursor up and down on
the Main O.P and select.
⑤ Manual operation : Select the
appropriate command and Push
Cycle Start button to begin the
corresponding Step. The process is
complete when an "*" appears in the
Initial Condition Status
"Status" space on the right.
183
HP5100 HP51MTE87
2050 Lub. Level Low or Pressure Down
There is not enough lubricant in the lubricant tank connected to the

Status various Guide Ways or Ball Screw and Bearing, the pressure does not rise
to the standard level(15Kg/㎠) even after the lubricant motor is activated,
or the pressure did not fall within ten seconds of rising.
① There is not enough lubricant in the lubricant Tank.
Cause ② The lubricant supply Line (Lub. Hose, Lub. Pipe, Lub. Tube etc.) has
burst or has slipped.
③ Breakage of the Distributor Valve
④ Breakage of the lubricant tank or disorder in the connection cable or
related parts
①Add lubricant to the lubricant tank in the back of the machine.
Solution ☞ It is recommended to regularly supplement lubricant every 3~4
days (when the machine is active for 8 hours a day).
② Find the faulty lubricant supply Line (Lub. Hose, Lub. Pipe, Lub. Tube
etc.) and repair the problem area.
③ If lubricant is being supplied only to a specific area despite all lubricant
supply Lines being normal, the distributor valve is malfunction. Make
necessary repairs or replace with a new one.
④ Differentiate between the lubricant Tank, from the Tank to the
electrical cabinet terminal, or by Input Module. Check each group and
make necessary repairs or replacements.

Signal Address I/O
Symbol (Pin) Tube
Lub.Level Low -SV51 XJ411 (03) SV51
LUB.M 07
Lub.Pressure Check -SP51 XJ411 (20) SP51
LPRS.M 07
Lub. Manual Start -M51 XJ411 (35) SB51
LMS.M 07
Lubrication For Y2.4 Output Module Slot
-QM51 T/Block(07) KM51A
Guideway LUBM.R 02
Lub. Pressure Lub. Pressure
Switch Gage
Lub. Level Lub. Level

Switch
184
HP5100 HP51MTE87
Lub.Level Low Or
Pressure Down
Lub.Pressure Alarm

A6.1 2050 Lub.Level Low Or Pressure Down
R620.0 TM01 Guideway Lub.Motor On Time
R623.3 TMB4 Lub.Pressure Check D-time
R691.0 NO-MOV No Movement Each Axis
R691.6 AL50R AL50 Reset
R841.6 LPRSAL Lub.Pressure Alarm
R841.6 LPRSAL Lub.Pressure Alarm
X5.0 LUB.M Lub.Level Low
X5.1 LPRS.M Lub.Pressure Check
X5.2 LMS.M Lub.Manual Start
Y2.4 LUBM.R Lubrication For Guideway
185
HP5100 HP51MTE87
2051 Oil cooling Unit Alarm
Status There is a problem with the Oil Cooling Unit, which cools the Main Spindle.
Cause Fault in the Oil Cooling Unit
Refer to the Oil Cooling Unit Manual to find the meanings and measures for
Solution
each Alarm, and take necessary measures.

Signal Address I/O
Symbol (Pin) Tube
X2.5
Oil Cooling Alarm -OCFT Input Module Slot 07 XJ411 (47) OCFT
OCFT.M
Oil Cooling X4.0
-M73 Input Module Slot 07 XJ411 (07) OCFT1
Alarm(Special) SOCF.M
Oil Cooling Unit

Alarm

A6.2 2051 Oil Cooling Unit Alarm
K19.5 KSOCU Special Oil Cooling Unit
R652.3 TMB20 Hyd. Pump On Check Time
X2.5 OCFT.M Oil Cooling Unit Fault
X4.0 SOCF.M Oil Cooling Alarm (Special)
186
HP5100 HP51MTE87
1) There is a problem, but no alarm is activated
No. Status Cause Solution

It does not ① There is no main power, or the • Check the wiring to see if
function at all. electric connection of the power power is being supplied to the
(The operation (L1, L2) is faulty. power terminals.
1
panel's power
lamp does not
turn on.)
① The remote control • Check the connection of
The pump
input【10】,【11】is turned off. remote control input.
2 cannot be
② Operation is locked. (Operation is • Disable the Lock rom the
activated
locked when shipped.) operation panel.
① The pump's absorption pipe is • Check the pipe packing, and
loosened. tighten as necessary.
② The absorption strainer is • Clean the absorption strainer.
clogged. • If the oil inside the oil tank is
The pump contaminated, please replace
operates, but the oil.
there is no oil ③ The oil level inside the oil tank is • Fill in more oil.
flow. low.
3
The oil flow is ④ The oil discharge pipe has • Replace the inner rim of the
weak and the suffered significant pressure oil pipe with a larger rim, and
pump is very damage, and the pump relief is shorten the pipe length.
loud. activated.
⑤ The oil absorption pipe has
suffered significant pressure
damage, and the pump has
developed cavitation.
The pump ① The machine stops according to ---
4 operates, the temperature adjustment
but the control.
compressor ② The compressor reset prevention • Check if the compressor
does not. timer(30 seconds) is active. resets after the timer runs
out.
③ Low oil temperature protection • Check to see if it works
(entry oil temperature is ２℃ normally when the entrance
or less) is operating. oil temperature is above 5℃.
④ Low outer air protection（room • Check to see if it works
temperature is －２℃ or normally when the room
187
HP5100 HP51MTE87

less）is operating. temperature is above 0℃.
⑤ Mode 9 is set at 10%. • Reset to a more
approrpriate operation
mode.

① There is blockage near the • Remove the blockage.
absorption pipe or exhaust
pipe.
② The air filter is • Clean the air filter.
contaminated.
③ The room temperature is • heck the operation
high, and the machine is capacity according to
underoperating. temperature range from
The pump and
④ There is a high temperature the catalogue, and
compressor operate,
5 load. choose a model with the
but the oil does not
appropriate capacity.
cool.
⑤ The set temperature is • Reset to an appropriate
high. temperature.
⑥ Even if the compressor • Recharge refrigerants.
operates, there is a lack of
refrigerant gas if expelled
gas is the same
temperature as room
temperature.
① If the Data line is shown as • Connect the temperature
“---,“ the sensor using that sensor.
operation mode is not
connected.
The function cannot
6 ② When the ENT key (right • Turn off the error
be set.
key) is pressed, a protection SW (SW1) on
momentary display of “--- the control board.
“ is simply error protection
being turned on.
① The signal connection of • Output from
The【64】,【65】alar
alarm output is partially 【60】,【63】are
m output is diferent
7 altered. compatible with previous
from previous signal
models (AKS5 series and
outputs.
AKZ6 series), but the
188
HP5100 HP51MTE87
signals and connections

has been changed for
【64】, 【67】in the 7
series. See details in the
"Using Previous Models"
section at the end of the
guide.
189
HP5100 HP51MTE87
2) When an alarm is activated (To release Alarm, turn off the power and turn it
back on.)
Alarm Alarm
Status Cause Solution
Code Level
AA 2 Overheating the ① In the case of AKZ Check if the oil pressure circuit is
heater models, there is no oil correctly connected, and if the
(S4B1:CN4) flow. pump is operating normally.
(limited to ① In the case of AKZJ Supplement oil.
models with models, there is not
heater enough oil in the tank.
attached)
A6 2 ① Faulty DC Fan Motor Replace the DC Fan Motor
① There is faulty Check the connection for any
Faulty DC Fan
communication between disconnection, and replace the
Motor Lock
the Fan Motor and the control engine.
control engine
E1 1 System ① Internal Parameter Replace the control board
problem problem.
E3 2 ① The oil temperature or Operate only within the usage
room temperature range.
exceeds the allowed
High pressure range.
problem (High ② There is blockage near Do not place anything that might
pressure the absorption or block ventilation within 500 mm
alteration(S3PH exhaust pipe. of the absorption pipe or
:CN6) exhaust pipe.
activated) ③ The filter is clogged or Refer to the repair and
the condenser is inspection in #8 to clean the air
contaminated. filter.
④ Other Contact the Daikin service team.
E5 2 ① The oil temperature or Operate only within the usage
Compressor room temperature range.
Overheating exceeds the allowed
(Discharge Pipe range.
Thermer TH6 ② There is blockage near Do not place anything that might
activated) the absorption or block ventilation within 500 mm
(Compressor exhaust pipe. of the absorption pipe or
Head Thermer exhaust pipe.
(S2B:CN) ③ The filter is clogged or Refer to the repair and
activated) the condenser is inspection in #8 to clean the air
contaminated. filter.
E6 2 ① Compressor Replace the compressor.
Compressor(M
breakage.(needing
2C) Lock
replacement)
190
HP5100 HP51MTE87
Alarm Alarm
Code Level
EH 1 ① Overload due to viscous Use oil that has 4~200 mm2/s
oil use. viscosity in the permitted
temperature range.
② Pump motor electric Check if the power electric
current increased pressure is lower than the usage
Pump high
because the power range. Check if the electric
electric current
electric pressure is lower pressure drops between
circuit breaker
than the usage range. myelination when other
(S1B:CN3)
machines are activated.
③ Disconnection of the Replace the pump's electric
activated
pump's electric motor motor
wiring
④ The pump is jammed or Replace the pump's electric
the electric motor breaks motor
because of foreign
substances.
EJ 1/2 ① Protection machinery Check what the activated
Field Additional connected to the field (In machinery has detected.
the case of Unit Form,
Protection
there are cases in which
Activated(OP.) it is connected upon
shipping) is activated
H1 2 Disorder in the ① Disconnection or short- Confirm the problem sensor
Air Temperature circuiting in the air from the control panel's monitor
sensor channel sensor needed mode (problem sensor showing
(TH5:air for control. "99.9"), then check the wiring.
temperature
conformity
sensor)
(TH3:room
temperature
sensor)
FH 2 ① The air's exothermic If the compressor is working at
Entrance oil amount exceeds the oil 100% capacity in normal mode
temperature con's cooling capacity. (can be confirmed in monitor
exceeds 60℃ (wrong model chosen) mode), choose a model one size
bigger.
② There is blockage near Do not place anything that might
the absorption or block ventilation within 500 mm
exhaust pipe, lowering of the absorption pipe or
cooling ability. exhaust pipe.
③ Underperformance due to If the nominal temperature is
exceeding nominal exceeded, undercontrol lowers
temperature (Room cooling ability below nominal
191
HP5100 HP51MTE87
Alarm Alarm
Code Level
temperature 35℃, Oil ability. Check to see if the oil
temperature 35℃). con's cooling ability exceeds the
exothermic amount.
④ Temperature cannot be Use a proper mode (When the
controlled because capacity is directly specified,
operating in Mode there is no temperature
9(capacity directly feedback control.)
specified)
⑤ Refrigerant gas is If the expelled gas is the same
leaking. temperature as room
temperature while the
compressor is operating,
refrigerant gas may leak.
Contact our company's service
team.
JH 2 Disorder of Oil ① Disconnection or short- Confirm the problem sensor
temperature circuiting of the oil from the control panel's monitor
sensor temperature channel mode (problem sensor showing
(TH2:Exit oil sensor needed for "99.9"), then check the wiring.
temperature control.
sensor)
(TH4:Entrance
oil temperature
sensor)
J3 2 Disorder of the Disconnection or short- Check the wiring of the
discharge Pipe circuiting of the thermister.
temperature discharge Pipe
thermister temperature thermister.
J5 2 Disorder of the ① Disconnection or short- Check the wiring of the
EV Valve Exit circuiting of the EV Valve thermister.
temperature Exit temperature
thermister thermister.
J6 2 Disorder of the ① Disconnection or short- Check the wiring of the
Condenser circuiting of the thermister.
temperature Condenser temperature
thermister thermister.
L0 2 Disorder of the ① Compressor or Inverter Replace the Control Engine or
Invertor or Breakage Compressor
Compressor
channel
LC 2 Transfer ① Communication problem Replace the control engine or
disorder between the reform the power environment
between the temperature control (noise alleviation needed)
INV- computer and the
192
HP5100 HP51MTE87
Alarm Alarm
Code Level
temperature invertor computer.
control CPUs
P3 2 Disorder of the ① Disconnection or short- Check the wiring of the
Electric Field circuiting of the Electric thermister.
Box Field Box temperature
temperature thermister
thermister
P4 2 Disorder of the ① Disconnection or short- Check the wiring of the
Heat Protection circuiting of the Heat thermister.
Fin Protection Fin
Temperature Temperature thermister
thermister
U0 2 ① Excessive transfer Repair the refrigerant pipe and
Not enough movement has damaged recharge the refrigerant gas
gas the refrigerant pipe, and
refrigerant gas is leaking.
U1 1 ① The electric connection is The wiring must be reconnected.
on the wrong side.
Power
② The L3 is defecitvely Check to see if the L3 is
Reversal
connected connected properly to the power
terminal.
U2 2 ① Power voltage is below Check to see if the voltage is
Momentary
70V. rated, or if the voltage suddenly
blackout/Insuffi
drops when surrounding
cient voltage
machines are activated.
U9 2 Unable to ① Error in communicating Check to make sure that the
transfer to with wireless system. wireless system and the
separate communication line are well
system connected. (Only applicable to
(Problem in cases in which the wireless
transferring system does not respond to the
between Slave main system.)
system and
Master system)
UH 2 System Channel ① Error in the parameter Replace the Control Engine
Problem recorded in the Control P
(EEPROM Board.
Problem)
UJ 1/2 ① Connection Protector is Verify the information detected
activated (In the case of by the Protector.
OP2 Activated uniform, it may be
connected upon
shipment).
193
HP5100 HP51MTE87
Alarm Alarm
Code Level
1E - Above the ① he temperature being Check the Warning setting.
permitted watched has exceeded
temperature the preset permitted
range range.(Not a problem
Warning 1 with the oil cone.)
~
5E - Above the
permitted
temperature
range
194
HP5100 HP51MTE87
2052 Filter Change Alarm For TSC Unit
Alarm indicating that the high-pressure coolant equipment(TSC) Filter is

Status
clogged and needs to be replaced
① The high-pressure coolant equipment(TSC) Filter is clogged.

Cause ② Fault in the Filter clog detection sensor or parts related to the
connection cable to the electrical cabinet terminal block.
① Replace with a new Filter.
Solution ②Divide into areas - Filter Unit, from the Filter Unit to the electrical
cabinet terminal block, and Input Module - and check for problems.

Signal Address I/O
Symbol (Pin) Tube
TSC Filter or X3.3
-SP16 Input Module Slot 07 XJ411 (11) M222
Pressure Check CPOC.M
Filter Change Alarm

of TSC Unit
Filter Abnormal
Status Check-Time

A6.3 2052 Filter Change Alarm of TSC Unit
F0.6 SA Servo Ready
K4.4 KFILT Filter Status Check Not Used
K9.2 KHTSC High Pressure (TSC) Coolant Used
K12.7 KCO&MD Coolant Dual and Middle TSC
R436.2 TMB67 Filter Abnormal Status Check-Time
X3.3 CPOC.M TSC Filter or Pressure Check
195
HP5100 HP51MTE87
2060 Spindle Tool CL/UNCL Overtime Alarm
The Spindle Tool Unclamp Cylinder Location Detection Switch has been
Status
set differently from the command signal for more than ten seconds.
① Faulty adjustment of the location detection Switch

Cause
② Problems with cables or related parts
Solution Adjust the Switch, reading the detection Lamp on the proximity switch
attached to the back of the Spindle Tool Unclamp motion Cylinder.
② Problems with cables or parts
Check (in order) the Proximity Switch, From the Proximity Switch to
the Spindle Head terminal box, cables from the Spindle Head Terminal
box to the electrical cabinet, and the Input Module. Make any
necessary repairs or replacements.

Cable,
ECBLS0170F - BKS B20-1-03 Balluff
Proximity/Switch
Switch, Proximity/PNP ESWPX0265F -SX11/12 BES516-325-E5-C-S4 Balluff

Signal Address I/O
Symbol (Pin) Tube
TCL.M 08
-SX12 XJ412 (76) VPF2
Unclamp TUCL.M 08
Distributed I/O
Spindle Tool Y39.6 -KAR11 Module (B) XC57B(A23) KAR11
Unclamp STUN.R -YV11 Mini Relay (DC KAR11(11) YV11
24V)
Spindle Spindle Tool

Tool Clamp
Unclamp
0.8~1.2mm
Proximity Dog
Switch
196
HP5100 HP51MTE87
Spindle Tool CL/UNCL

Overtime Alarm
Spindle Tool CL/UNCL

Check Time

A1.6 2015 Spindle Tool Unclamp Alarm
A7.3 2060 Spindle Tool Cl/Uncl Overtime Alarm
F0.6 SA Servo Ready
R626.5 TMB30 Spindle Clamp/Unclamp Check Time
X6.4 TCL.M Spindle Tool Clamp
X6.5 TUCL.M Spindle Tool Unclamp
Y39.6 STUN.R Spindle Tool Unclamp
197
HP5100 HP51MTE87
2063 ATC Arm Pin Alarm
The Tool Change command (M06) has been given without the ATC Arm
Status Pin being released, or the ATC Arm Pin Location Detection Sensor has
been set differently from the command signal for more than 3 seconds.
① The ATC Arm Pin is locked.
Cause ② Faulty adjustment of the ATC Arm Pin position detection Reed Switch
③ Fault in the ATC Arm Pin position detection Reed Switch or in related
parts
① Manually operate the ATC or command "M235”(ATC Arm Pin Release)
Solution in MDI mode.
② Loosen the Reed Switch Holder security Screw and move it towards the
Shaft. Find and secure in the location in which the Sensor's LED lights
up.
③ Check (in order) the Reed Switch, connection cable, and I/O board.
Connector Numbering
(Pin) Tube
ATC Arm Pin Locking -SD55 XJ414 (11) SD55
ATAL.M 06
ATC Arm Pin Release -SD56 XJ414 (43) SD56
ATAR.M 06
ATC Arm Pin Locking -YV55 YV55
ATAL.R 01 (04)
ATC Arm
Pin Locking
ATC Arm
Pin Release
198
HP5100 HP51MTE87
ATC Arm Pin Alarm
ATC Arm Pin Alarm

Check Time

A7.6 2063 ATC Arm Pin Alarm
F0.6 SA Servo Ready
K61.1 KATCSV ATC Used Servo
R443.1 TMB122 ATC Arm Pin Alarm Check Time
R721.0 MANM06 Manual 1 Cycle ATC Start
X15.3 ATAL.M ATC Pin Locking
X15.5 ATAR.M ATC Pin Release
Y0.2 ATAL.R ATC Pin Locking
Y12.6 TST.R ATC Servo Start
199
HP5100 HP51MTE87
2064 Waiting Tool Pot Spindle/Magazine Side Alarm
The Waiting Port Location Detection Switch has been set differently from
Status
the command signal for more than 15 seconds.

Cause
Solution Manually activate the Waiting Port and adjust the Location Detection
Switch.
Check (in order) the Limit Switch, from the Limit Switch to the Tool
Magazine terminal box, cables from the Tool Magazine terminal box to
the electrical cabinet, and the Input Module. Make any necessary
repairs or replacements.

Signal Address I/O
Symbol (Pin) Tube
Waiting Pot Spindle X7.0 Input Module
-SX5A XJ412 (12) SX5A
Side WPSS.M Slot 08
Waiting Pot Magazine X7.1 Input Module
-SX5B XJ412 (28) SX5B
Side WPMS.M Slot 08
Distributed I/O
Waiting Pot Spindle Y39.4 -KAR53 Module (B) XCE57B(A22) KAR53
Side WPSS.R -YV53 Mini Relay KAR53(09) YV53
(DC 24V)
Distributed I/O
Waiting Pot Magazine Y39.5 -KAR54 Module (B) XCE57B(B22) KAR54
Side WPMS.R -YV54 Mini Relay KAR54(10) YV54
(DC 24V)
200
HP5100 HP51MTE87
Waiting Pot Tool Waiting

Magazine Side Magazine Pot
Pocket Detect Spindle
Waiting Tool POT

SPD/MAG Side Alarm
Waiting Tool POT

Check Time
201
HP5100 HP51MTE87

A7.7 2064 Waiting Tool Pot SPD/MAG Side AL
F0.6 SA ATC Not Used
K6.0 KMATRX Matrix Tool Magazine is Used
R627.1 TMB34 Waiting Tool Pot Check Time
R2410.7 2081F
R4005.0 TMB34A Waiting Tool Pot Check Time
X7.0 WPSS.M Waiting Pot Spindle Side
X7.1 ATAL.M Waiting Pot Magazine Side
Y39.4 WPSS.R Waiting Pot Spindle Side
Y39.5 WPMS.R Waiting Pot Magazine Side
202
HP5100 HP51MTE87
2065 Changer Arm Position Check Alarm
When the ATC Arm was in its Home Position, there was no Servo Home
Status
Position signal from the Home Position Detection Switch or the Servo Motor
① Faulty adjustment of the ATC Home Position Check Detection Switch or
Cause faulty parts
② Faulty adjustment of the Servo Motor or Drive, or faulty parts.
① Confirm and insepct the following signal from the ATC changer home
Solution location.
☞ ATC Changer Initial Position
Address X7.6 X8.7 X8.6 X8.5
Status 1 1 0 0
② Refer to “Canceling the AL2065”below.

Signal Address I/O
Symbol (Pin) Tube
ATC Servo Home X7.6 Input Module
-A81 XJ412 (10) THOMEI
Position MCAH.M Slot 08
Tool Clamp X8.5 Input Module
SX51 XJ412 (38) SX51
Command CLMD.M Slot 08
Tool Unclamp X8.6 Input Module
-SX52 XJ410 (22) SX52
Command ULMD.M Slot 08
ATC Home Position X8.7 Input Module
-SX53 XJ412 (37) SX53
Check CAHP.M Slot 08
(Reference) Canceling the AL2065 (Verifying the Arm Home Position)

1) Meaning of the Alarm : The alarm becomes activated when there is a change in t
he Main Changer Arm Home Position due to the Servo System or from other causes.
That is, the case where there is a difference between the reference point (X7.6)
memorized in the servo system and the reference point that recognizes
proximity switches (X8.7) by the present arm position.
2) Objective of the Alarm: The alarm aims to increase the stability of the Servo
Mechanisms (e.g. Clamping/Unclamping), which must work based on the Arm's
actual location, by maintaining the same Arm position setting regardless of
continuous tool exchanges.
3) Troubleshooting the Alarm
☞ Checking for Problems with the Changer Arm Home Position Detection Proximity
S/W
After checking for problems with switch looseness/ Dog looseness/
contamination/firing range, proceed normally.
203
HP5100 HP51MTE87
☞In case of alarm, when the changer arm home dog is deflected or even if the
position is normal, observe inside the Cam to see if the Turret Can Follower
Bearing is positioned on the Cam's Center area. Since this area is very small, it is
convenient to use a mirror and worklight.
Is the Cam Follower

Bearing in the middle of
the central area?
Central
Mirror Area
A≒B
☞After verifying the Cam Follower Bearing location, use those observations to
cancel the #2065 Alarm by Origin Initialization from the Servo Drive..
Cam
Case S/W & Dog align Solution
Follower
Normal Faulty Reorder the Switch, secure, and Initialize
A Normal Normal Initialize
Faulty Normal Realign the Changer Arm using Inching,
B
Faulty Faulty reorder the Switch, and Initialize
204
HP5100 HP51MTE87
(1) Case “A”
① Press the "MODE" Key once on the Servo Drive start

screen [r 0000]
② Press the "DOWN" Key once on the

[rd-oFF] screen
③ Press the "SET" Key for five seconds on the

[Or9.S--] screen. The letters will blink, then complete
Servo Origin Initialization.
④ Power Off → On
⑤ Move back to Maintenance Mode. Execute the

205
HP5100 HP51MTE87
(2) Case “B”

① Press the MODE Key once and the "DOWN" Key
four times on the Servo Drive start screen[r 0000] to
display the [JOG run]. Press the "SET" Key once to
display the [Jr.0000].
② Appropriately use the "UP/DOWN" Key (which

drives the Arm 20rpm every time it is pressed) to
position the Cam Follower Bearing in the center of the
middle section. If necessary, reorder the S/W and press
the "Set" Key once to exit to the [JOG run] screen.
③ Press the "UP" key three times on the [JOG run] screen.
④ Press the "SET" Key for five seconds on the

[Or9.S--] screen. The letters on the screen will blink,
and then complete the Servo Origin Initialization.
⑤ Power Off → On
⑥ Move back to Maintenance Mode. Execute the

206
HP5100 HP51MTE87
2073 Pallet or Table CL/UNCL Switch Alarm
The Pallet or Table Location Detection Switch doest not correspond to the
Status
command signal.
① Faulty adjustment of the location detection switch
Cause ② The Table Angle Index Use Curvic Coupling is not in its correct position
but has been pushed up.
③ Faulty Cables or Parts
① Faulty adjustment of the location detection switch
Solution Adjust the Switch, reading the detection switch on the proximity switch
attached to the back of the Spindle Tool Unclamp Activation Use Cylinder.
② Refer to“Setting the Table Reference Point”to reset the B Axis refrence
point.
③ Faulty Cables or Parts
Check (in order) the proximity switch, from the proximity switch to the
Spindle Head terminal box, cables from the Spindle Head terminal box to
the electrical cabinet, and the Input Module.

Signal Address I/O
Symbol (Pin) Tube
X10.0
Pallet Clamp -SP61 Input Module Slot 09 XJ413 (16) SP61
PCL.M
X10.1
Table Clamp -SL62 Input Module Slot 09 XJ413 (32) SL62
TACL.M
Pallet X10.2
-SP63 Input Module Slot 09 XJ413 (48) SP63
Unclamp(Rotary) PUCL.M
X10.3
Table Unclamp -SL64 Input Module Slot 09 XJ413 (15) SP64
TAUL.M
Output Module Slot
Y7.2 -KAR62 XJ400 (44) KAR62
Pallet Unclamp 03
PUCL.R -YV62 KAR62(11) YV62
Mini Relay (DC 24V)
Distributed I/O
Y39.7 -KAR61 XCE57B(B23) KAR11
Table Unclamp Module (B)
TUCL.R -YV61 KAR11(11) YV11
Mini Relay (DC 24V)
Table
Clamp
Pallet Clamp
Check
Table
Unclamp
207
HP5100 HP51MTE87
(Reference) Adjusting the hydraulic pressure and Switch of the Table and Pallet
1) Pallet Clamp / Unclamp Check
① Pallet Clamp Adjusted Pressure: 35kg/㎤
② Pallet Unclamp Adjusted Pressure: 8kg/㎤
2) Table Clamp / Unclamp Check
① In case of the Table Clamp, change the B Axis reference point about 0.5
degrees to dislocate the Curvic Coupling, clamp, then check the DGN. At this
point, both switches should be in the 'OFF' position.
② When Keep Relay K8.1 is forcibly set while AL2073 is activated, (“0” ->”1”) the
table becomes unclamped.
(Reference) Resetting the B Axis Reference Point
☞ If the B Axis Servo Motor has been disassembled and then reassembled, or the B
Axis stops at a different location after executing CW or CCW, or if the "2073 Pallet or
Table CL/UNCL Switch Alarm”is activated, the B Axis reference point must be reset.
1) Set the B Axis at 0 degrees and unclamp the table.
ex) “MDI” Mode: G90 B0.; M11;
2) Attach the Test Indicator to the Spindle Head and move the X Axis to match the
parallelism of the Edge Locator.
① Set the Mode to“Handle”and set the selection switch to B Axis and select 0.01.
② Slowly rotate the Handle by degrees to set the parallelism between the edge
locator and the X Axis as accurately as possible.
3) When the parallelism is set, set Parameter N1815's #4 Bit (APZ) to “0,”then return it
to "1”and turn off the power.
☞ When the N1815 #4 Bit (APZ) Parameter is changed, "P/S Alarm 000 Must Turn
Off Power” and “P/S Alarm 300 nAxis Need ZRN”are activated.
4) When the power is turned back on, the alarm is canceled and the B Axis position on
the screen changes to "0".
5) Check the accurate clamp position of the table.
① With the B Axis as the standard for 0 degrees, activate from 90 degrees to 0
degrees, and from -90 degrees from 0 degrees. Verify on the angle indicator the
amount that the table moves when the table is clamped (when the teeth of the
curvic coupling fit with each other).
② After unclamping the table, move the B Axis by degrees using the Handle in the
direction that the B Axis moves during clamping after CW or CCW (ex: ±0.03
degrees∼0.05 degrees). Then repeat steps 3) and 4) above.
6) Repeat the above process to make the amount of table movement during clamping
equal on both sides.
☞ The amount of movement is the backlash of the machine itself.
208
HP5100 HP51MTE87
Angle
Pallet or Table
CL/UNCL Switch Alarm
Lub.Pressure Alarm
209
HP5100 HP51MTE87

A9.0 2073 Pallet or Table CL/UNCL Switch Alarm
F0.6 SA Servo Ready
K7.5 K4THA 4th-Axis Not Used
R626.4 TMB29 B-Axis (Table) CL/UNCL Check Time
K8.5 KROTA Rotary Table Used
R600.7 M10 B-Axis (Rotary) Clamp
R601.0 M11 B-Axis (Rotary) Unclamp
R653.0 MEND M-Function End
R752.1 RTCLP B-Axis (Rotary) Clamp
R841.5 BACLPF B-Axis (Table) Clamp Flag
X10.0 PCL.M Pallet Clamp (Index/Rotary)
X10.1 PCL.M Pallet Unclamp (Index/Rotary)
X10.2 PUCL.M Pallet Unclamp
X10.3 TAUL.M Table Unclamp (Rotary Table)
Y39.7 TUCL.R Table Unclamp (Rotary Table)
Y7.2 PUCL.R Pallet Unclamp
210
HP5100 HP51MTE87
2074 ATC Overtime Alarm
For some reason, the tool search (T__ ;) or the tool change
Status
command(M06) was not completed within 45 seconds.
The machine was stopped due to a problem from among the Tool Search
Cause or Tool Change Sequence.
▪ Normally, the particular sequence overtime alarm will activate before
this alarm, indicating the problematic sequence.
Solution Resolve the problem by referring to the corresponding Sequence chart or

Alarm chart.
Connector Numbering
(Pin) Tube
Waiting Pot Spindle X7.0 Input Module Slot
-SX5A XJ412 (12) SX5A
Side WPSS.M 08
Waiting Pot X7.1 Input Module Slot
-SX5B XJ410 (28) SX5B
Magazine Side WPMS.M 08
ATC Arm Pin X15.3 Input Module Slot
-SD55 XJ414 (11) SD55
Locking ATAL.M 10
-SD56 XJ414 (43) SD56
Release ATAR.M 10
ATC Arm Pin Y0.2 Output Module
-A41 T/Block(04) YV55
Locking ATAL.R Slot 01
Y9.0 Output Module
TMG.2 Servo ON -A41 XJ400 (03) SV02
(SV02.R) Slot 03
Tool Mag. S-Motor Y11.0 Output Module
-KA85 XJ401 (12) KA85
Brake Rel. TMBK.R Slot 04
TMG Servo On Y11.5 Output Module
-A41 XJ401 (43) SVON
Table SVON.R Slot 10
211
HP5100 HP51MTE87
1) ATC Main Sequence
Initial Condition Changer Arm

② 2nd Reference Point & M19 X7.0 (SX5A) WPSS.M
③ Pot Spindle Side X7.2 (SD32) WPCL.M Arm
& Clamp Forward
④ Arm Pin Release X15.5(SD56) ATAR.M
Gripping Tool

▪ Output : Y39.6(STUN.R), KAR11-YV11,Distribute I/O B (A23) On
▪ Completion : X6.4(TCL.M), SX11, Input Module Slot8(Pin31) Off
X6.5 (TUCL.M), SX12, Input Module Slot8(Pin47) On Spindle Tool
Arm Pin
Locking
Arm Out
&
▪ Output : Y 0.2(ATAL.R), YV55,Output Module Slot01(Pin04) On
Rotation
▪Completion: X15.3(ATAL.M), SD55, Input Module Slot06(Pin11) On
X15.5 (ATAR.M), SD56, Input Module Slot06(Pin43) Off
Tool Change
Spindle Tool Clamp

Arm In
▪ Output : Y39.6(STUN.R), KAR11-YV11,Distribute I/O B (A23) Off
▪ Completion : X6.4(TCL.M), SX11, Input Module Slot8(Pin31) On
X6.5 (TUCL.M), SX12, Input Module Slot8(Pin47) Off Spindle Tool Clamp
Arm Pin
Release
Arm
▪ Output : Y 0.2(ATAL.R), YV55,Output Module Slot01(Pin04) On Forward
▪Completion :X15.3(ATAL.M), SD55, Input Module Slot06(Pin11) On
X15.5 (ATAR.M),SD56, Input Module Slot06(Pin43) Off

▪ Input Signal : X8.7(CAHP.M), SX53, Input Module Slot8(Pin37) On
212
HP5100 HP51MTE87
ATC Overtime Alarm
ATC Overtime

A9.1 2074 ATC Overtime Alarm
R445.5 TMB142 ATC Overtime In Matrix
R628.1 TMB42 ATC Overtime
R628.1 TMB42 ATC Overtime
R648.6 M250A Door Interlock Bypass On Aux.
R649.6 DCL Operator Door Close Confirm
213
HP5100 HP51MTE87

R702.0 TCCMDA T-code Command Aux.
R749.6 ATCAUT ATC MAG. Auto Mode
R2410.7 2081F
Y9.0 SVO2.R TMG. 2 Servo On
Y11.0 TMBK.R Tool Mag. S-motor Brake Rel.
Y11.5 SVON.R TMG Servo On Table
214
HP5100 HP51MTE87
2075 ATC Magazine Rotation Over Time Alarm
The tool magazine rotation was not completed within 50 seconds of the
Status command signal(TMG Servo On: Y11.5 or TMG2 Servo On:Y9.0) being sent
out, either manually or automatically.
Cause Fault in the Tool Magazine Driving Servo Motor or Servo Drive
Refer to the Servo Motor or Servo Drive maintenance guide to make

Solution necessary repairs or replacements.
☞ Refer to the appendix (Repairing Servo Driver Alarms)

Signal Address I/O
Symbol (Pin) Tube
Y9.0 Output Module
TMG.2 Servo ON -A41 XJ400 (03) SV02
(SV02.R) Slot 03
Tmg.2 Servo Motor Y9.7 Output Module

-KA185 XJ400 (33) KA185
Break Rel. TMB2.R Slot 03
Tool Mag. S-Motor Y11.0 Output Module
-KA85 XJ401 (12) KA85
Brake Rel. TMBK.R Slot 04
TMG Servo On Y11.5 Output Module
-A41 XJ401 (43) SVON
Table SVON.R Slot 10
ATC Magazine Rot.

Overtime Alarm
ATC Magazine Rot.

Overtime Check
215
HP5100 HP51MTE87

A9.2 2075 ATC Magazine Rot. Overtime Alam
K7.6 KAPC ATC Not Used
R445.6 TMB143 Man. ATC Mag. Rot. Overtime Check
R628.2 TMB43 ATC Magazine Rot. Overtime Check
Y9.0 SVO2.R TMG2 Servo On Table
Y9.7 TMB2.R TMG2 Servo Motor Brake Release
Y11.0 TMBK.R TMG Servo Motor Brake Release
216
HP5100 HP51MTE87
HP50/63 ATC SERVO DRIVE Adjust/Operation/PARAMETERS

AH5P,AH6P 1. PARAMETER SETTING METHOD
NO. REMARK
41POT 61POT 1) Press "MODE" on SERVO DRIVE.
00 0 0 MOTOR POWER CAPACITY 2) Change to parameter fixing mode as the following display.
01 0 0 MOTOR RUNNING DIRECTION 0.0.0 0 0 0
02 0 0 RESERVE PARAMETER
03 1 1 FIX-DIRECTION, JOG FUNCTION SELECTION The first two segments are the parameter NO.
04 0 0 RESERVE PARAMETER The last four segments are the setting value.
05 41 41 ATC 41 TOOLS POT 3) Search parameter NO. to be changed by pressing "UP" or "DOWN".
61 61 ATC 61 TOOLS POT 4) Press "SET" after searching parameter NO. to be changed.
06 GEAR RATIO - MOTOR SIDE 5) The dot below the first two segments will disappear.
106 106 AH5P/AH6P 6) Press "UP" or "DOWN" to adjust 4 segments to value to be set.
7) Press "SET" after completion of adjusting.
07 GEAR RATIO - MACHINE SIDE 8) The dot will appear below the first two segments.
9 9 AH5P/AH6P 9) The data will be stored.
10) Some parameters will display the former data after setting.
MODE ▲▼ rd.oFF origin mode
▲▼ Or 9.5 "SET" 7 sec push
08 * * TOOL POT NUMBER OF HOME 11) The parameters will display the stored data after power on/off.
09 0 0 RESERVE PARAMETER 2. INITIAL TOOL NO. SET OR MANUAL HOME SETTING METHOD
10 256 256 POSITION LOOP PROPORTIONAL GAIN 1) Normally clamp the Tool No. to any position.
11 250 250 SPEED LOOP PROPORTIONAL GAIN 2) Set current position NO. to parameter NO.8
12 1 1 SPEED LOOP INTEGRAL GAIN 3) The display will turn to the former setting value after setting.
13 10 5 BRAKE OFF DELAY TIME (When power is turned off and then turned on again, it will display
14 2 1 BRAKE OFF CONTROL DELAY TIME the stored data)
15 10 5 BRAKE ON DELAY TIME 4) Press "MODE" and change the display of the servo ON/OFF mode.
16 0 0 MONITOR OFFSET VOLTAGE rd-oFF Jog Operation Ready Condi.
MODE
17 0 0 MONITOR SELECTION
18 200 200 POSITIONING COMPLETE RANGE ▲▼ jog.run Jog Operation Mode Change
19 6000 6000 REMAINING PULSE ALLOWANCE
SET jr.0000 Jog Operation Mode
20 0 0 POSITION LOOP FEED-FORWARD GAIN
21 0 0 FEED-FORWARD FILTER TIME CONSTANT ▲ jr.0.1.0.0 Jog MAG. CCW Rotation
22 250 250 POSITIVE TORQUE LIMIT 1
23 250 250 NEGATIVE TORQUE LIMIT 1 ▼ jr.0.-1.0.0 Jog MAG. CW Rotation
24 100 100 POSITIVE TORQUE LIMIT 2 jog.run Jog Operation Mode Return
SET
25 100 100 NEGATIVE TORQUE LIMIT 2
26 2050 2050 SPEED LIMIT MODE rd-oFF ORIGIN Mode
▲▼ Or 9.5 "SET" 7 Sec Push

27 80 100 JOG SPEED AT SET HOME
28 2000 2000 TOOL MAGAZINE INDEX SPEED
29 200 200 ACCLERATION TIME 5) Press "SET" for 7 seconds and display will set parameter
30 200 200 DECELERATION TIME automatically and the turn back the display to zero-point setting
mode.
31 3000 3000 SPEED MONITOR OUTPUT VOLTAGE 6) Turn the power OFF and the ON again and the setting of the zero
32 1500 1500 TORQUE MONITOR OUTPUT VOLTAGE point is now completed.
33 6 6 INITIAL STATUS DISPLAY 3. NOTE
34 AUTO SET ENCODER COORDINATES COMPENSATION (LOW) 1) Don't change parameters during indexing.
35 AUTO SET ENCODER COORDINATES COMPENSATION (UP) 2) Adjusted parameters operated as the following.
36 AUTO SET SET VALUE OF MACHINE ZERO-POINT (LOW) ① Parameter NO.00~09
37 AUTO SET SET VALUE OF MACHINE ZERO-POINT (UP) : Adjusted parameters are only valid when power is off → on.
38 750 750 CURRENT LOOP PROPORTIONAL GAIN You can adjust the parameters under the servo is off
39 510 510 CURRENT LOOP INTEGRAL GAIN ② Parameter NO.10~18
40 2048 2048 ENCODER PULSE PER ONE ROTATION : You can adjust the parameters under the servo is off or on.
41 AUTO SET FEEDBACK PULSE(LOWER) ③ Parameter NO.19~33
42 AUTO SET FEEDBACK PULSE(UPPER) : You can adjust the parameters under the servo is off.
43 AUTO SET ACCELERATION RATE OF REMAINING VALUE ④ Parameter NO.34~45
44 AUTO SET DECELERATION RATE OF REMAINING VALUE : These parameters will be set automatically by home setting.
45 AUTO SET RESERVE PARAMETER Do not change these parameters.
3) Do not turn the power while mounting or dismounting the
operator panel of turret servo drive.
VERSION DATE REVISED CONTENT

1.1 010504
DAEWOO HEAVY INDUSTRIES LTD.
217
HP5100 HP51MTE87
2077 Waiting Pot & Spindle Tool No. Zero
Status All of the Tool Data in the Waiting Pot and Spindle are set to "0".
① The Waiting Pot was emptied due to command T00; sent out from a
Cause Program.
② The Spindle Tool was emptied due to command M06 T00; sent out
from a Program.
③ The data in the D452 (Waiting Tool No.) or D450(Spindle Tool No.) has
been erased.
① Search for another tool.
Solution ☞ Just in case, make sure to check that there are no tools in the Waiting
Pot.
(It must be empty.)
② Change another tool.
☞ Just in case, make sure to check that there are no tools in the Spindle.
(It must be empty.)
③ Enter“SYSTEM” → “PMC” → “DATA” → “G DATA” and input the D452
(Waiting Tool No.) D450 (Spindle Tool No.) data, after checking the
actual tool numbers.
Wait.Pot & Spdl Tool

Data Zero

R711.0 WSZERO Wait.& Spdl Pot Zero
R710.4 STZERO Spindle Tool No.Zero
A9.4 2077 Wait.Pot & Spdl Tool Data Zero
218
HP5100 HP51MTE87
(Reference) Verifying the Spindle or Waiting Pot Tool Numbers

1) From the Main Control panel, press the "SYSTEM" Key from the right side of the CRT.
▪ The following appears in the Soft Key space below the CRT.
2) Press the〔PMC〕Soft Key.
3) Press the〔PMCPRM〕Soft key.
〔TIMER〕〔COUNTR〕〔KEEPRL〕〔DATA〕〔SETING〕
4) Press the〔DATA〕Soft Key.
〔G.DATA〕〔G.CONT〕〔NO.SRH〕〔〕〔INIT〕
5) Press the〔G.DATA〕Soft Key.
▪ The following appears in the Soft Key space below the CRT, and the DATA screen
appears.
〔C.DATA〕〔G-SRCH〕〔SEARCH〕
6) The following Tool Data appears when the Page Down button is pressed once from
the control board.
No Address Data
0000 D0450 3 → Spindle Tool No.
0001 D0452 5 → Waiting Tool No.
0002 D0454
0003 D0456
0004 D0458
The data shown in #D0450 is the Spindle Tool No., and the data shown in #D0452 is
the Waiting Pot Tool No.
219
HP5100 HP51MTE87
2078 ATC OP Manual Mode
The selection switches in the main control board were set to EDIT,
Status
MEMORY, TAPE, or MDI Mode while the Manual/Auto Selection Toggle
Switch in the ATC Manual control board was set to "Manual."
Solution Set the Manual/Auto Selection Toggle Switch in the ATC Manual control
board to “AUTO”.

Signal Address I/O
Symbol (Pin) Tube
ATC Main Mode X15.6 Input Module
-SA81 XJ414 (10) SA81
Select TSMD.M Slot 10
ATC Manual Control Board
ATC OP Manual Mode
220
HP5100 HP51MTE87

A14.5 2118 Machine Maintenance Mode
K6.0 KMATRX Matrix Tool Magazine is Used
R1484.0 RT_MANMD ATC Manual Mode From Executer
X15.6 TSMD.M ATC Manual Mode Select
221
HP5100 HP51MTE87
2080 ATC or APC Interlock Alarm
Either the ATC or the APC is not set to its initial position in Auto Mode
Status
(Edit, Memory, Tape, MDI Mode).
① ATC : Faulty adjustment of the ATC Home Position Check Proximity
Cause Switch, or faulty parts
Faulty Home Position signal due to disorder in the ATC Servo Motor or
Drive
② APC : Faulty adjustment of the APC Up/Down Check Proximity Switch,
or faulty parts
Faulty adjustment of the Pallet No. Check Proximity Switch or faulty parts
① (Reference) Refer to Below
Solution ② Find the faulty signal from the PMC DGN or the Ladder and reset the
faulty Switch, or replace the faulty part.
Address X7.6 X7.2 X7.1 X7.0 X8.7
Status 1 1 0 1 1
Address K61.1 X7.6 X7.3 X7.1 X8.7
Status 1 1 1 1 1
☞ APC Initial setting
0 1
Status 1 0 1 1 1 0 1
1 0
Connector Numbering
(Pin) Tube
ATC Servo Home X7.6
Position MCAH.M
Tool Clamp X8.5
Command CLMD.M
Tool Unclamp X8.6
Command ULMD.M
Check CAHP.M
APC Up Check X11.6
(OFF) APUP.M
APC Down Check X11.7
(ON) APDP.M
Pallet No.1
X11.1
Detection -SX75 Input Module Slot 09 XJ413 (28) SX75
PN01.M
(ON/OFF)
Pallet No.2
X11.2
PN02.M
(OFF/ON)
222
HP5100 HP51MTE87
(Reference) Adjusting the ATC / APC Confirmation Switch

1) ATC Home Position Check
ATC Home
Position Check
2) Pallet No 1 Detection / No 2 Detection, APC Up / Down Check
APC UP Check Pallet No.1

SX81 SX75
APC Down
Check
SX82 Pallet
No.2
SX76
2~2.5mm
Proximity
Switch Dog
(Reference) DGN(Diagnostic) Check Process

1) Finding the DGN
① From the Main Operation Panel, press the "SYSTEM" Key from the right side
of the CRT.
② Press the 〔PMC〕Soft Key.
223
HP5100 HP51MTE87
③ press the〔PMCDGN〕Soft Key.
〔TITLE〕〔STATUS〕〔ALARM〕〔TRACE〕
④ Press the〔STATUS〕Soft Key.
〔NO.SRH〕〔〕〔〕〔〕〔〕
⑤ Input the DGN number being searched. Ex) When searching for X4.1: “X”, “4”, “.”, “1”,
⑥ Press the〔NO.SRH〕Soft Key.
▪ A Diagnostic screen appears with the number being searched.
2) Reading the DGN
Ex) X 003 00110010
Of Address X3, Bit 1, 4, 5 are On, and Bit 0, 2, 3, 6, 7 are Off.
Shown 0 0 1 1 0 0 1 0
as
Bit No. Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
ATC or APC
Switch Alarm
ATC Interlock
224
HP5100 HP51MTE87
APC Interlock

A9.7 2080 ATC or APC Switch Alarm
K61.0 KATCIV ATC Used Inverter
K61.1 KATCSV ATC Used Servo
R534.3 MDI MDI Mode
R718.7 ATCINT ATC Interlock
R769.7 APCINT APC Interlock
X7.6 THOMEI.M ATC Servo Home or Man. Home Pos.
X8.5 CLMD.M Tool Clamp Command
X8.6 ULMD.M Tool Unclamp Command
X8.7 CAHP.M ATC Home Position Check
R628.7 TMB48 Pallet Unclamp Interlock Time
R756.0 AHPOS1 APC Changer Position (CW)
R756.1 AHPOS2 APC Changer Position (CCW)
X11.6 APUP.M APC Up Check
X11.7 APDN.M APC Down Check
225
HP5100 HP51MTE87
2081 ATC Magazine Guard Door Open
Status The ATC Magazine Guard Door is open.
① ATC Magazine Guard Door is open, or the Door Open Detection Safety
Cause
Switch is improperly adjusted.
① Close the ATC Magazine Guard Door.
Solution ② Differentiate and check the Safety Switch and cables from the Switch
to the electrical cabinet. Make any necessary repairs or replacements.
Connector Numbering
(Pin) Tube
Tool Magazine Door X8.2 Input Module
-S85 XJ412 (39) S85
Interlock MDIT.M Slot 08
Tool Magazine Door X10.6 Input Module
-S85A XJ413 (30) S85A
Interlock MDI2.M Slot 09
Safety Switch
226
HP5100 HP51MTE87
ATC Magazine
Guard Door Open
Tool Mag. Door Interlock Check

Tool Mag. Door
Interlock Check

A10.0 2081 ATC Magazine Guard Door Open
F212.6 AL81-FM Door Open Alarm Of Matrix MAG.
K8.3 KDCLAR Alarm Reset By Door Close
K9.6 KMDINI Tool MAG.Door Interlock Not Use
R635.6 MAN Manual Mode
R717.7 MDIT Tool Magazine Door Open
R719.2 MATCST Manual ATC Start
R719.3 MATSTF Man ATC Start Flag
R436.4 TMB69 Tool Mag. Door Interlock Check
227
HP5100 HP51MTE87
2084 APC Set-Up Station Door Open
Status The APC Set-Up Station Door is Open.
The APC Set-Up Station Door is Open, or the Door Open Detection Safety
Cause
Switch or related parts are faulty.
① Close the APC Door.
Solution ② Differentiate and Check the Door Open Detection Safety Switch, cables
from the Safety Switch to the electrical cabinet, and the Input Module.
Connector Numbering
(Pin) Tube
X5.4 Input Module
Set Up Door Interlock -S91 XJ411 (19) S91
SUIT.M Slot 07
X17.5 Input Module
Set Up Door Interlock 2 -S91A XJ414 (34) S91A
SUIT.M Slot 10
228
HP5100 HP51MTE87
2085 APC Set-Up Location S/W Unpush
When the M60(Pallet Change) or M61(APC 1 Load), M62(APC 2 Load)

Status commands were given, the Set-Up Switch in the APC Manual Control
board was not pressed.
After setting the workpiece on the Table, the Set-Up Switch was not
Cause
pressed.
① After setting the workpiece on the Pallet, close the Splash Door and
Solution press the Set-Up Push Button on the APC Manual Control board.
☞ The yellow light comes in on the Set-up Switch Lamp.
② Check the switches related to Set-up. Differentiate and check the
switch, cables from the switch to the electrical cabinet, and the Input
Module in the problematic area. Make any necessary repairs or
replacements.
Connector Numbering
(Pin) Tube
Set Up(APC), X16.6 Input Module Slot
-SB93 XJ414 (22) SB93
Set-up Mode2(PMG) SETU.M 10
Set-Up Switch
APC Manual control board
229
HP5100 HP51MTE87
APC Set-up,location
S/W Unpush

A10.4 2085 APC Set-up,location S/W Unpush
R607.1 M60 APC Macro Call
R755.7 SETUP Set Up
R759.0 APCMST APC Macro Start
230
HP5100 HP51MTE87
2086 APC OP Manual Mode
The Moode selection switches in the main operation panel were set to
Status EDIT, MEMORY, TAPE, or MDI Mode while the Manual/Auto Selection
Toggle Switch in the ATC Manual control board was set to "Manual."
① Set the Manual/Auto Selection Toggle Switch in the ATC Manual control
Solution board to “AUTO”.
② Differentiate and check the Manual / Auto Selection Toggle switch,
cables from the switch to the electrical cabinet, and the Input Module.
Connector Numbering
(Pin) Tube
APC Manual Mode X16.7 Input Module Slot
- SA91 XJ414 (37) SA91
Selection PMMD.M 10
Manual/Auto
Selection
Toggle Switch
Toggle Switch
APC Manual Control board
231
HP5100 HP51MTE87
APC Op Manual Mode
APC Manual Mode

A10.5 2086 APC Op Manual Mode
A22.1 2178 Commanded Pallet Can Not Find
A22.2 2179 Commanded Pallet Is On The Table
R1050.0 PMGOFF Pallet Magazine Off Mode
R1053.0 PMGOFF Pallet Magazine Off Mode
R1054.0 SETOFF Set-up Off Mode
R1420.7 PMGSEL Pmg Operation Selected
R1420.7 PCHOFF Pallet Change Off Mode Pmg
R1484.7 PMMD.MR APC Manual Mode
X16.7 PMMD.M APC Man Mode,set-up Mode3(PMG)
X41.5 PAUT.M Pmg Auto Mode Selection
232
HP5100 HP51MTE87
2090 Table Or Pallet Clamp Alarm
Status The Pallet or Table Clamp Switch cannot be detected
① Faulty adjustment of the Table Clamp Detection Limit Switch or

Cause disorder in related parts
② Lowered oil pressure or disorder in the Pallet Clamp Check Pressure
Switch or related parts
Solution Refer below “Table & Pallet Clamp Check”
Conector Numbering
(Pin) Tube
Pallet Clamp -SP61 XJ413 (16) SP61
PCL.M 09
Table Clamp -SL62 XJ413 (32) SL62
TACL.M 09
Table Unclamp -SL64 XJ413 (15) SP64
TAUL.M 09
Output Module Slot
Y7.2 -KAR62 03 XJ400 (44) KAR62
Pallet Unclamp
PUCL.R -YV62 Mini Relay KAR62(11) YV62
(DC 24V)
Distributed I/O
Y39.7 -KAR61 Module(B) XCE57B(B23) KAR61
Table Unclamp
TUCL.R -YV61 Mini Relay KAR11(11) YV61
(DC 24V)
Table
Clamp
Pallet Clamp
Check
Table
Unclamp
(Reference) Table & Pallet Clamp Check

1) Faulty adjustment of the Table Clamp Detection Limit Switch or disorder in related
parts
Separate the Z-Axis Sliding cover near the Column, then manually press the Table
233
HP5100 HP51MTE87
Clamp use Micro Switch to check the DGN. If there is no problem, adjust using the
Micro Switch security Bolt or Switch Bracket security Bolt. If the DGN does not operate,
differentiate and check the Micro Switch, cables from the Switch to the Table terminal
box, cables from the terminal box to the electrical cabinet, and the Input Module. Make
any necessary repairs or replacements.
2) Lowered oil pressure, disorder in the Pallet Clamp Check Pressure Switch or related
parts
▪ Lowered oil pressure : The oil pressure in the Pallet Unclamp use oil pressure Line has
fallen below 8kg/㎠.
☞ Pallet Clamp Check(x10.0) : 35kg/㎠ /Pallet Unclamp Check(x10.2) : 8kg/㎠
3) Faulty Pallet Unclamp use Solenoid Valve prevents normal oil pressure supply
If the block in the oil pressure supply is judged to be caused by damage to a Spring inside
the Pallet Unclamp use Solenoid Valve or a jam in the Spool, use a small screwdriver or
wrench to push the spool to check the problem. When the faulty part is found, repair or
replace with a new part.
▪ If there are no problems with the Pallet Unclamp Check Pressure Switch or related parts,
differentiate and check the Press. Switch, the cables from the Switch to the electrical
cabinet, and the Input Module. Make any necessary repairs or replacements.
Table Or Pallet Clamp

Alarm
B-axis Or Pallet
Unclamp Inter
234
HP5100 HP51MTE87
Table(B-axis) Clamp
Alarm D-time

A11.1 2090 Table Or Pallet Clamp Alarm
F0.4 SPL Feed Hold
F0.5 STL Cycle Start
R607.5 M64 Pallet Load Macro Call
R628.3 TMB44 Table(B-axis) Clamp Alarm D-time
R628.3 TMB44 Table(B-axis) Clamp Alarm D-ti
R752.4 TMBINT Table/Pallet Unclamp Interlock
R752.6 TMBINT1 Table Unclamp Interlock
R752.7 PALINT B-axis or Pallet Unclamp Inter
R759.0 APCMST APC Macro Start
X10.0 PCL.M Pallet Clamp(Index/Rotary)
235
HP5100 HP51MTE87
2094 Chip or Screw Conveyor Alarm
Status Faulty Chip Conveyor or Screw Conveyor
The protective brake has been stopped or rotation is blocked due to over
Cause
current.
(1) In the case of the Chip Conveyor
Solution ① Check the status of the -QM1 brake inside the Control Box attached
within the main body of the Chip Conveyor.
☞ if the -QM1 is stopped, inspect the three-phase cables first.
② If -TM1 or -TM2 is activated, the rotation confirm signal (-SX1) sent
after the motor command signal is not being detected. The chain
connected to the motor and the -SX1 switch must all be checked.
(2) In the case of the Screw Conveyor
① Check to see if the -QM62/63 inside the electrical cabinet is stopped.
② Check for disconnection of the three-phase main cable, magnet (-
KM62/63), and motor.
Connector Numbering
(Pin) Tube
Screw Conveyor X2.4 -QM63~
Input Module Slot 07 XJ411 (37) SCOL
Overload SCOL.M -QM62
Chip Conveyor X3.6
-M61 Input Module Slot 07 XJ411 (10) M241
Alarm CCFT.M
☞ QM62,63 Setting Overload 치: 3.0 A

Breaker, Circuit ENFBX0257R QM62,63 3RV1011-1EA10(2.8-4A) Siemens
Breaker, Auxillary ENFBX0290R QM62,63 3RV1901-1F(2NO) Siemens
Chip or Screw
Conveyor Alarm

K9.1 KCHIP Chip Conveyor is Used
X2.4 SCOL.M Screw Conveyor Overload
X3.6 CCFT.M Chip Conveyor Alarm
236
HP5100 HP51MTE87
Inout
Inout Module(AID32E) : Slot77
Module(AID32E) :Slot
X2.4(SCOL.M)
X2.4 (SCOL.M)
1515
SCOL
-QM63
SCOLA
-QM62
1L+
Screw
ScrewConveyor Overload
Coveyor Overload
237
HP5100 HP51MTE87
2107 Operator’s Door Open
Status The Door near the operator is open.
① The Door near the operator is open.

Cause ② Faulty Adjustment of the Door Open Detection Safety Switch or fault in
related parts
① Close the door near the operator.
Solution ② Differentiate and check the Safety Switch, the cables from the switch
to the ATC terminal box, and the cables from the ATC terminal box to
the electrical cabinet. Make any necessary repairs or replacements.
Connector Numbering
(Pin) Tube
Operator’s Safety X5.3 Input Module Slot
-KA02 XJ411 (02) S13
door Interlock OSDI.M 07
X32.5 Distributed I/O
Cycle Start -SB12 XC56A(B04) SB12
ST.M Module A
ATC Servo or
Inverter Alarm

A12.3 2100 Machine In Service Mode
A13.2 2107 Operator’s Door Open Alarm
X5.3 OSDI.M Operator’s Safety door Interlock
X32.5 ST.M Cycle Start
Safety
Switch
238
HP5100 HP51MTE87
2118 Operator’s Door Open Alarm
① Keep Relay is selected.

Status
② Maintenance Mode is commanded.
Cause Maintence Mode is selected.
① If Keep Relay K5.7 had been intentionally selected, return to the

Solution original setting after the intended process is complete.
② If M239 had been commanded, cancel by commanding M240.
Machine Maintenance Mode
Operating Maintence for ATC/APC
Maintenance Mode for ATC/APC

F0.6 SA Servo Ready
K5.7 KMAINT Operating Maintence For ATC/APC
R409.3 M239 ATC/APC Maintenance Mode On
239
HP5100 HP51MTE87

R409.4 M240 ATC/APC Maintenance Mode Off
R458.0 M239-M Maintenance Mode For ATC/APC
R643.3 MDI MDI Mode
R761.0 M62CD M62cd
240
HP5100 HP51MTE87
2120 Y-Z Interference Zone Alarm
Status The Axis has entered reciprocal interference area.
Cause ① The Y Axis and/or Z Axis has entered into reciprocal interference area.
① Transfer the axis in the opposite direction which it entered ,to transfer
Solution it out of reciprocal interference area.
② Check the program to see if there are problems with the stroke.
③ If Keep Relay K8.4 is set to “1,”the command is nullified.
Connector Numbering
(Pin) Tube
Tool Length X17.0
Sensor Up TLUP.M
Tool Length X17.1
Sensor Down TLDN.M
Tool Length Y1.7 T/Block
-YV67 Output Module Slot 01 YV67
Sensor Up TLUP.R (20)
Y-Z Interference Zone Alarm
Y-Z Interference Zone
241
HP5100 HP51MTE87

A14.7 2120 Y-Z Interference Zone Alarm
K0.7 KTLENG Moving Type Tool Meas.Is Used
K8.4 KMCIFZ Machine Interference Zone
R642.5 YAZONE Y axis Interference Zone
R642.6 ZAZONE Z axis Interference Zone
R642.7 YZZONE Y-Z Interference Zone
R692.2 SEON Work Measure Sensor On
X17.0 TLUP.M Tool Length Sensor Up
X17.1 TLDN.M Tool Length Sensor Down
Y1.7 TLUP.R Tool Length Sensor Up
242
HP5100 HP51MTE87
2126 APC Up / Down Alarm
A completion signal was not received within ten seconds after the APC
Status
Up or Down command is sent out, the APC Up Check and Down Check
signals were turned on or off simultaneously and sustained for over ten
seconds.
① Faulty adjustment of the detection switch
Cause ② Problems with the detection Switch, activation Solenoid Valve,
connecting cables, or related parts
① Faulty adjustment of the switch
Solution Check the location of the proximity switch and dog attached to the top
of the APC Up/Down use Hyd. Cylinder, and in the case of a problem
with adjustment, loosen the proximity switch security nut and adjust
the switch.
② Problems with the detection Switch, activation Solenoid Valve,
connecting cables, or related parts
Differentiate and check the proximity switch, cables from the switch to
the APC terminal box, cables from the terminal box to electrical cabinet,
and the Input Module. Make any necessary repairs or replacements.
Also differentiate and check the activation Solenoid Valve, cables from
the Valve to the APC terminal box, cables from the terminal box to the
electrical cabinet, and Output Module. Make any necessary repairs or
replacements.
☞ APC Initial Condition
0 1
Status 1 0 1 1 1 0 1
1 0
Connector Numbering
(Pin) Tube
APC Up Check -SX81 XJ413 (10) SX81
APUP.M 09
APC Down Check -SX82 XJ413 (42) SX82
APDP.M 09
Distributed I/O
Y39.2 -KAR75 XCE57B(A21) KAR75
APC Changer Up Module (B)
APUP.R -YV75 KAR75(11) YV75
Mini Relay (DC 24V)
Distributed I/O
APC Changer Y39.3 -KAR76 XCE57B(B21) KAR76
Module (B)
Down APDN.R -YV76 KAR76(11) YV76
Mini Relay (DC 24V)
243
HP5100 HP51MTE87
APC UP Check Pallet No.1
APC Down Check
Pallet No.2
APC CCW APC CW
APC Up
APC Up
244
HP5100 HP51MTE87
APC Up/Down Alarm
APC Up / Down
Check Time

A15.5 2126 APC Up/Down Alarm
R627.7 TMB40 APC Up/Down Check Time
R763.4 MAPCSP Manual APC Stop
R1056.2 MCHASP Manual Pallet Changer Stop
R1420.7 MPFSEL PMG Operation Selected
X11.7 APDN.M APC Down Check
Y39.2 APUP.R APC Changer Up
Y39.3 APDN.R APC Changer Down
245
HP5100 HP51MTE87
2127 APC Changer 180CW/CCW Alarm
The APC Changer CW or CCW command was not completed within 15

Status
seconds, or the CW and CCW detection signals were detected
simultaneously.
Cause ② Problems with the detection Switch, activation Solenoid Valve,
connection cables or related parts
Solution ① Faulty adjustment of the Switch

Check the location of the proximity switch and dog attached to the top
of the APC. In the case of a problem with adjustment, loosen the
proximity switch security nut and adjust the switch.
☞ Adjustment of the distacne between the proximity Switch and Dog:
2∼2.5mm
② Troubled in the detection Switch, activation Solenoid Valve, connection
cables or related parts
③ APC Initial Condition
Address X11.7 X11.6 X11.2 X11.1
1 0
Status 1 0
0 1
Connector Numbering
(Pin) Tube
Pallet No.1
Detection -SX75 XJ413 (28) SX75
PN01.M 09
(On/Off)
Pallet No.2
Detection SX76 XJ413 (44) SX76
PN02.M 09
(Off/On)
APC Up Check X11.6 Input Module Slot
-SX81 XJ413 (10) SX81
(Off) APUP.M 09
Distributed I/O
Pallet Changer Y39.0 -KAR73 XCE57B(A20) KAR73
Module B
CW. Rotation PCW.R -YV73 KAR73(09) YV73
Mini Relay (DC 24V)
Distributed I/O
Pallet Changer Y39.1 -KAR74 XCE57B(B20) KAR74
Module B
CCW. Rotation PCCW.R -YV74 KAR74(10) YV74
Mini Relay (DC 24V)
Distributed I/O
Y39.2 -KAR75 XCE57B(A21) KAR75
APC Changer Up Module B
APUP.R -YV75 KAR75(11) YV75
Mini Relay (DC 24V)
246
HP5100 HP51MTE87
Pallet
No.1
APC UP Check
APC Down Check Pallet

No.2
APC CCW APC CW
APC Up
APC Up
APC Changer
CW/CCW Alarm
247
HP5100 HP51MTE87
APC 180CW/
180CCW Check

A10.3 2084 APC Set-up Station Door Open
A15.6 2127 APC Changer CW/CCW Alarm
R430.7 TM32 APC Auto Door Close Check Time
R452.0 TMB193 Setup Supplier Door Close C-tm
R627.6 TMB39 APC 180cw/180ccw Check
R756.0 AHPOS1 APC Changer POS.(Cw)
R756.1 AHPOS2 APC Changer POS.(CCw)
R763.4 MAPCSP Man APC Stop
R1056.2 MCHASP Man Pallet Changer Stop
Y39.0 PCW.R Pallet Changer CW.Rotation
Y39.1 PCCW.R Pallet Changer CCW.Rotation
Y39.2 APUP.R APC Changer Up
248
HP5100 HP51MTE87
2154 Waiting Pot Clamp Alarm
The ATC Waiting Pot Clamp command was not completed within 5
Status seconds, the Waiting Pot Clamp and Unclamp signals were detected
simultaneously, or both were not detected for over five seconds.
① Faulty adjustment of the detection Reed Switch
Cause
②Problemswith the detection Switch,activation Solenoid Valve,
① Faulty adjustment of the Switch

Solution
Check the functioning of the Reed Switch attached to the Tool
Magazine Waiting Pot Clamp Air Cylinder. In the case of a problem
with adjustment, loosen the Switch Bracket security Bolt and move
them along the cylindrical length direction, adjusting the switch while
reading the Red Lamp.
② Problems with the detection Reed Switch, activity Solenoid Valve,
Differentiate and check the Reed Switch, cables from the Switch to
the electrical cabinet, and the Input Module. Make any necessary
repairs or replacements. Also differentiate and check the Air Solenoid
Valve, cables from the Valve to the electrical cabinet, and the Output
Module. Make any necessary repairs or replacements.
Waiting Pot
Unclamp Check
Waiting Pot
Clamp Check
Pot Clamp ATC Door Close
ATC Arm Pin

Locking
249
HP5100 HP51MTE87

Signal Address I/O
Symbol (Pin) Tube
Waiting Pot Clamp X7.2 Input Module Slot
-SD32 XJ412 (44) SD32
Check SD32.M 08
Waiting PoUnclamp X7.3 Input Module Slot
-SD33 XJ412 (11) SD33
Check SD32.M 08
Y3.0 Output Module Slot
Waiting Pot Clamp -YV37 T/Block(12) YV37
WPCL.R 02
Waiting Pot
Clamp Alarm
Waiting Pot
Clamp Check Time

A19.1 2154 Waiting Pot Clamp Alarm
F0.6 SA Servo Ready
R435.4 TMB61 Waiting Pot Clamp Check Time
R4005.1 TMB61A Waiting Pot Clamp Check Time
X7.2 WPCL.M Waiting Pot Clamp Check
X7.3 WPUL.M Waiting Pot Unclamp Check
Y3.0 WPCL.R Waiting Pot Clamp
250
HP5100 HP51MTE87
2155 Tool Magazine Pot Detect Switch Alarm
The given command cannot be completed in the current ATC Waiting Pot
Status location.
① When the Pot is at the Magazine Side: the Waiting Pot Magazine Side
command was given.
② When the Pot is at the Spindle Side: the Waiting Pot Spindle Side
command was given.
① Wrong command
Cause
② Faulty Adjustment of the detection Switch
③ Problems with the detection Switch, connection cables or related parts
① Check the Waiting Pot position(Tool Search presence) and give the
Solution appropriate command.
② Faulty adjustment of the Switch
Check the location of the proximity switch and dog attached to the
Tool Magazine. In the case of a problem with adjustment, loosen the
proximity switch security Bolt and adjust the Switch.
☞ Adjusted distance: 2∼2.5mm
③ Problems with the detection Switch, connection cables or related parts
the electrical cabinet, and the Input Model. Make any necessary
repairs or replacements.

Switch, Proximity / BES M18MI-PSC50B-
ESWPX0268F - Balluff
PNP S05G
Cable, Proximity
ECBLS0171F -SX36 BKS B20-1-05 Balluff
Switch
Connector Numbering
(Pin) Tube
Tool Magazine X7.7
Pocket Detect TPDT.M
Tmg.2 Servo On -A41 XJ400 (03) SV02
(SV02.R) 03
Tmg Servo On Y11.5 Output Module Slot
-A41 XJ401 (43) SVON
Table SVON.R 10
251
HP5100 HP51MTE87
Waiting Pot Tool Magazine

Magazine Side Pocket Detect
Tool Magazine Pot

Detect SW Alarm
Alarm 2155 Aux.

A19.2 2155 Tool Mag. Pot Detect SW Alarm
K6.0 KMTRX Matrix Tool Magazine Is Used
K10.1 KWPDTC Waiting Pot Detect Keep
R438.3 TMB84 Alarm 2155 Aux.
R627.3 TMB36 T-Code Command Delay Time
R703.0 RAYCS1 Re-Chan.ATC Step1(Pot Unclamp)
252
HP5100 HP51MTE87

R704.6 ATCS7 Do.7(Changer Home Check
R713.3 TP.X=Y Tool Pot X=Y
R724.2 MWPSS Man Waiting Pot Spindle Side
R724.3 MWPMX Man Waiting Pot Mag. Side
X7.7 TPDT.M Tool Magazine Pocket Detect
Y9.0 SVO2.R TMG.2 Servo On
253
HP5100 HP51MTE87
2158 Waiting Pot Spindle/Magazine Side Command Alarm
Waiting Pot Location Detection Switch or the Waiting Tool Pot Presence
Status
Detection Switch has spent over five seconds in a different status from
the command signal.

Cause
② Problems with the cables or parts

Solution
Check the location of the proximity switch and dog attached to the
APC. In the case of a problem with adjustment, loosen the proximity
switch security Bolt and adjust the Switch.
② Problems with the detection Switch, motion Solenoid Valve, connection
the TMG terminal box, from the terminal box to the electrical cabinet,
and the Input Module. Make any necessary repairs or replacements.

ESWPX0268F -SX5A/5B Balluff
PNP S05G
Cable, Proximity
ECBLS0171F - BKS B20-1-05 Balluff
Switch
Connector Numbering
Symbol Address Symbol I/O
(Pin) Tube

Side WPSS.M
Waiting Pot X7.1
Tool Magazine X7.7
Pocket Detect TPDT.M
254
HP5100 HP51MTE87
Waiting Pot Waiting

Magazine Tool
Pot
Side Magazine
Spindle
Pocket
255
HP5100 HP51MTE87
2160 APC Pallet Check Switch Alarm
More than 15 seconds have passed with both the APC Pallet No.1 and 2
Status
Detection switches on or off.

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

Solution
Check the location of the APC Pallet No. Check use proximity Switch
and Dog. In the case of a problem with adjustment, loosen the proximity
switch security Bolt and adjust the Switch. (Adjusted distance :
2∼2.5mm)
② Problems with the detection Switch, connection cables or related parts
the electrical cabinet, and the Input Module. Make any necessary repairs
or replacements.
Product Product # Symbol Model Maker

ESWPX0268F - Balluff
PNP S05G
Cable, Proximity
ECBLS0171F -SX75/76 BKS B20-1-05 Balluff
Switch
Connector Numbering
(Pin) Tube
Pallet No.1
X11.1
PN01.M
(On/Off)
Pallet No.2
X11.2
PN02.M
(Off/On)
256
HP5100 HP51MTE87
Pallet No.1
APC UP Check
Check
Pallet No.2
Check
APC Down Check
APC Pallet Check

Switch Alarm
APC Pallet No.

Check Time

A15.6 2127 Pallet Changer CW/CCW Alarm
A19.7 2160 APC Pallet Check Switch Alarm
K25.0 KAPSET ATC Rotation Keep
R436.0 TMB65 APC Pallet No. Check Time
X11.1 PNO1.M Pallet No.1 Detection
X11.2 PNO2.M Pallet No.2 Detection
257
HP5100 HP51MTE87
2163 ATC Door Open/Close Alarm
The ATC Door Open/Close command was not completed within 5

Status seconds, the Door Open and Close signals were detected simultaneously,
or five seconds passed without either signal being detected.
① Faulty adjustment of the ATC Door Close Check Reed Switch
Cause
② Problems with the ATC Door Close detection Switch or related parts
① Loosen the Reed Switch Holder security Screw and move it towards
Solution the Shaft to secure the place where the Sensor LED lights up.
② Check the Reed Switch, Connection cables, and I/O board in order.
Connector Numbering
(Pin) Tube
X8.0
ATC Door Open -SD51 Input Module Slot 08 XJ412 (07) SD51
ATDO.M
X8.1
ATC Door Close -SD52 Input Module Slot 08 XJ412 (24) SD52
ATDC.M
Reed
Switch
Holder
Reed
Switch ATC Door
Holder Close Check ATC Door
Open Check
258
HP5100 HP51MTE87
ATC Door
Open/Close Alarm
ATC Door
OP/CL Check Time

A20.2 2163 ATC Door Open/Close Alarm
F0.6 SA Servo Ready
R627.5 TMB38 ATC Door Open/Close Check Time
X8.0 ATDO.M ATC Door Open
X8.1 ATDC.M ATC Door Close
Y4.4 ATDO.R ATC Door Open
Y4.5 ATDC.R ATC Door Close
259
HP5100 HP51MTE87
2200 T-code Or M06 Commanded Status
Status Manual Operation was activated during a ATC Tool Change Cycle.
Manual operation was attempted before the ATC Tool Change Cycle was
Cause
completed.
Cancel the alarm using the alarm reset button, and proceed with manual
Solution
operation after the ATC Tool Change Cycle is complete.
Connector Numbering
(Pin) Tube
ATC Manual Start -SB81 XJ414 (27) SB81
TSST.M 10
ATC Manual Mode X15.6 Input Module Slot
-SA81 XJ414 (10) SA81
Select TSMD.M 10
T-code Or M06 Commanded

Status

A24.7 2200 T-code Or M06 Commanded Status
R702.3 TPSCMD Tool Pot Search Command
R719.6 ATCMMD ATC Main Op Manual Mode
R4010.4 RTCMDF Re-change T-code Command Flag
260
HP5100 HP51MTE87
2215 VPF Off Of Tool Magazine
After the Magazine rotation command, the Magazine Pot location signal
Status was not confirmed.
① The magazine did not rotate after the command.

Cause
② Problems with the magazine stop position signal(VPF)
① Check the Magazine command number and the actual number.

Solution
② Check the VPF signal.
☞ During the magazine rotation, it turns on/off at every port, and
turns on if it stops at the correct position.
③ If there is no VPF signal, check the connection of the cables from the
servo amp to the Input Module.
Connector Numbering
(Pin) Tube
X6.7
TMG Servo Verify -A41 Input Module Slot 08 XJ412 (46) VPF
VPF.M
Tmg Servo On Y11.5
-A41 Output Module Slot 10 XJ401 (43) SVON
Table SVON.R
Mag.2 Servo X100.7
-A41 Input Module Slot 06 XJ410 (46) VPF2
Verify VPF2.M
Y10.7
Tmg. Servo Start -A85 Output Module Slot 04 XJ401 (46) ST
SVST.R
Tmg Servo on Y11.5
-A41 Output Module Slot 10 XJ401 (43) SVON
Table SVON.R
VPF Off Of Tool Magazine
261
HP5100 HP51MTE87
Check VPF1
VPF Check Time
Check VPF2

A26.6 2215 VPF Off Of Tool Magazine
F0.6 SA Servo Ready
R443.6 TMB127 VPF Check Time
R836.2 VPF1C Check Vpf1
X6.7 VPF.M TMG Servo Verify
Y10.7 SVST.R TMG. Servo Start
F0.6 SA Servo Ready
R443.6 TMB127 VPF Check Time
R701.3 KDMAG Dual Mag.(100,120tools) Keep
R836.1 VPF2C Check VPF2
R836.2 VPF1C Check VPF1
X100.7 VPF2.M Mag.2 Servo Verify
Y13.7 ST2.R TMG. 2 Servo Motor Start
Y9.0 SVO2.R TMG. 2 Servo On
262
HP5100 HP51MTE87
Appendix 1) X-Y Signal Address

Connector Numbering
(Pin) Tube
Hydraulic Motor X2.1 QM31~ Input Module Slot
XJ411 (32) HOL
Overload HOL.M -QM36 07
Coolant & Lub. X2.2 -QM10~ Input Module Slot
XJ410 (48) MOL
Motor Overload MOL.M -QM185 07
Screw Conveyor X2.4 -QM63~ Input Module Slot
XJ411 (37) SCOL
Overload SCOL.M -QM62 07
Oil Cooling Alarm -OCFT XJ411 (47) OCFT
OCFT.M 07
Hyd. Pressure X3.0 Input Module Slot
-SP01 XJ411 (12) SP01
Check (Main) HPRS.M 07
Air Pressure Check -SP12 XJ410 (28) SP12
EPRS.M 07
TSC Filter Or X3.3 Input Module Slot
-SP16 XJ411 (11) M222
Pressure Check CPOC.M 07
Chip Conveyor X3.6 Input Module Slot
-M61 XJ411 (10) M241
Alarm CCFT.M 07
Oil Cooling X4.0 Input Module Slot
-M73 XJ411 (07) OCFT1
Alarm(Special) SOCF.M 07
Lub. Level Low -SV51 XJ411 (03) SV51
LUB.M 07
Lub. Pressure X5.1 Input Module Slot
-SP51 XJ411 (20) SP51
Check LPRS.M 07
Lub. Manual Start -M51 XJ411 (35) SB51
LMS.M 07
Operator’s Safety X5.3 Input Module Slot
-KA02 XJ411 (02) S13
Door Interlock OSDI.M 07
Set Up Door X5.4 Input Module Slot
S91 XJ411 (19) S91
Interlock SUIT.M 07
TCL.M 08
-SX12 XJ411 (47) SX12
Unclamp TUCL.M 08
TMG Servo Verify -A41 XJ412 (46) VPF
VPF.M 08
Waiting Pot Spindle X7.0 Input Module Slot
-SX5A XJ412 (12) SX5A
Side WPSS.M 08
-SX5B XJ412 (28) SX5B
Magazine Side WPMS.M 08
263
HP5100 HP51MTE87
Connector Numbering
(Pin) Tube
Waiting Pot Clamp X7.2 Input Module Slot
-SD32 XJ412 (44) SD32
Check SD32.M 08
-SD33 XJ412 (11) SD33
Unclamp Check SD32.M 08
ATC Servo Home X7.6 Input Module Slot
-A81 XJ412 (10) THOMEI
Position MCAH.M 08
Tool Magazine X7.7 Input Module Slot
-SX36 XJ412 (42) SX36
Pocket Detect TPDT.M 08
ATC Door Open -SD51 XJ412 (07) SD51
ATDO.M 08
ATC Door Close -SD52 XJ412 (24) SD52
ATDC.M 08
Tool Magazine Door X8.2 Input Module Slot
-S85 XJ412 (39) S85
Interlock MDIT.M 08
Tool Clamp X8.5 Input Module Slot
SX51 XJ412 (38) SX51
Command CLMD.M 08
Tool Unclamp X8.6 Input Module Slot
-SX52 XJ410 (22) SX52
Command ULMD.M 08
ATC Home Position X8.7 Input Module Slot
-SX53 XJ412 (37) SX53
Check CAHP.M 08
ATC Home Position X8.7 Input Module Slot
-SX53 XJ412 (37) SX53
Check CAHP.M 08
ATC Servo Or X9.6 QM31~ Input Module Slot
XJ412 (01) TALM
Inverter Alarm TALM.M -QM36 08
Pallet Clamp
(Index/Rotary) -SP61 XJ413 (16) SP61
PCL.M 09
(On)
Table Clamp
(Index/Rotary) -SL62 XJ413 (32) SL62
TACL.M 09
(On)
Pallet X10.2 Input Module Slot
-SP63 XJ413 (48) SP63
Unclamp(Rotary) PUCL.M 09
Table Unclamp
(Index/Rotary) -SL64 XJ413 (15) SP64
TAUL.M 09
(Off)
Table Unclamp -SL64 XJ413 (15) SP64
TAUL.M 09
Tool Magazine Door X10.6 Input Module Slot
-S85A XJ413 (30) S85A
Interlock MDI2.M 09
264
HP5100 HP51MTE87
Connector Numbering
(Pin) Tube
X11.0
Pallet Rot. Lock Input Module Slot
PLOC.M -SX89 XJ413 (12) SX89
(Setup S-D.O.) 09
(SSDC.M)
Pallet No.1
Detection -SX75 XJ413 (28) SX75
PN01.M 09
(On/Off)
Pallet No.2
Detection SX76 XJ413 (44) SX76
PN02.M 09
(Off/On)
APC Up Check X11.6 Input Module Slot
-SX81 XJ413 (10) SX81
(Off) APUP.M 09
APC Down Check X11.7 Input Module Slot
-SX82 XJ413 (42) SX82
(On) APDP.M 09
-SD55 XJ414 (11) SD55
Locking ATAL.M 06
ATC Manual Start -SB81 XJ414 (27) SB81
TSST.M 10
-SD56 XJ414 (43) XJ414 (43)
Release ATAR.M 06
ATC Manual Mode X15.6 Input Module Slot
-SA81 XJ414 (10) SA81
Select TSMD.M 10
Set Up(APC) -SB93 XJ414 (22) SB93
SETU.M 10
APC Manual Mode X16.7 Input Module Slot
-SA91 XJ414 (37) SA91
Selection PMMD.M 10
Tool Length Sensor X17.0 Input Module Slot
-SD61 XJ414 (03) SD61
Up TLUP.M 10
Tool Length Sensor X17.1 Input Module Slot
-SD62 XJ414 (20) SD62
Down TLDN.M 10
Set Up Door X17.5 Input Module Slot
-S91A XJ414 (34) S91A
Interlock 2 SUIT.M 10
X32.4 Distributed I/O XC56A
Machine Ready -SB11 SB11
MRD.M Module A (A04)
X32.5 Distributed I/O XC56A
Cycle Start -SB12 SB12
ST.M Module A (B04)
Mag.2 Servo Verify -A41 XJ410 (46) VPF2
VPF2.M 06
ATC Door Open -YV51 YV51
ATDO.R 01 (02)
265
HP5100 HP51MTE87
Connector Numbering
(Pin) Tube
ATC Door Close -YV52 YV52
ATDC.R 01 (03)
ATC Arm Pin Y0.2 Output Module Slot T/Block
-YV55 YV55
Locking ATAL.R 01 (04)
Pallet Air For Table -YV63 YV63
PAIR.R 01 (18)
Tool Length Sensor Y1.7 Output Module Slot T/Block
-YV67 YV67
Up TLUP.R 01 (20)
Lubrication For Y2.4 Output Module Slot
-QM51 T/Block(07) KM51A
Guide Way LUBM.R 02
Waiting Pot Clamp -YV37 T/Block(12) YV37
WPCL.R 02
Output Module Slot
Y7.2 -KAR62 03 XJ400 (44) KAR62
Pallet Unclamp
PUCL.R -YV62 Mini Relay KAR62(11) YV62
(DC 24V)
Tmg.2 Servo On -A41 XJ400 (03) SV02
(SV02.R) 03
Tmg.2 Servo Motor Y9.7 Output Module Slot
-KA185 XJ400 (33) KA185
Break Release TMB2.R 03
Tmg. Servo Start -A85 XJ401 (46) ST
SVST.R 04
Tool Mag. S-Motor Y11.0 Output Module Slot
-KA85 XJ401 (12) KA85
Brake Rel. TMBK.R 04
ATC Servo Start -A81 XJ401 (22) TST
TST.R 04
Tmg Servo On Y11.5 Output Module Slot
-A41 XJ401 (43) SVON
Table SVON.R 10
Tmg.2 Servo Motor Y13.7 Output Module Slot
-A41 XJ401 (33) ST2
Star ST2.R 04
X-Axis Ref. Point Y33.0 Distributed I/O XC56A
-HL21 HL21
Return XZL.L Module A (A20)
Y-Axis Ref. Point Y33.1 Distributed I/O XC56A
-HL22 HL22
Return YZL.L Module A (A20)
Z-Axis Ref. Point Y33.2 Distributed I/O XC56A
-HL23 HL23
Return ZZL.L Module A (A20)
Hydraulic 1,2,3 Y38.4 Distributed I/O XCE57B
-KA31 KA31
Motor Run HYDM.R Module B (A18)
Pallet Changer Y39.0 -KAR73 Distributed I/O XCE57B KAR73
266
HP5100 HP51MTE87
Connector Numbering
(Pin) Tube
CW. Rotation PCW.R -YV73 Module B (A20) YV73
Mini Relay KAR73(09)
(DC 24V)
Distributed I/O
XCE57B
Pallet Changer Y39.1 -KAR74 Module B KAR74
(B20)
CCW. Rotation PCCW.R -YV74 Mini Relay YV74
KAR74(10)
(DC 24V)
Distributed I/O
XCE57B
Y39.2 -KAR75 Module B KAR75
APC Changer Up (A21)
APUP.R -YV75 Mini Relay YV75
KAR75(11)
(DC 24V)
Distributed I/O
XCE57B
APC Changer Down (B21)
APDN.R -YV76 Mini Relay YV76
KAR76(11)
(DC 24V)
Distributed I/O
XCE57B
Waiting Pot Spindle Y39.4 -KAR53 Module B KAR53
(A22)
Side WPSS.R -YV53 Mini Relay YV53
KAR53(09)
(DC 24V)
Distributed I/O
XCE57B
Waiting Pot Y39.5 -KAR54 Module B KAR54
(B22)
Magazine Side WPMS.R -YV54 Mini Relay YV54
KAR54(10)
(DC 24V)
Distributed I/O
XCE57B
Spindle Tool Y39.6 -KAR11 Module B KAR11
(A23)
Unclamp STUN.R -YV11 Mini Relay YV11
KAR11(11)
(DC 24V)
Distributed I/O
XCE57B
Table Unclamp (B23)
TUCL.R -YV61 Mini Relay YV11
KAR11(11)
(DC 24V)
267
HP5100 HP51MTE87
Appendix 2) M-CODE LIST

M-CODE DESCRIPTION M-CODE DESCRIPTION
M00 PROGRAM STOP M25 CHIP CONVEYOR STOP

ATC SPEED LOW
M01 OPTIONAL STOP M27
(WHEN USE INVERTER)
ATC SPEED HIGH
M02 PROGRAM END M28
(WHEN USE INVERTER)
SPINDLE FORWARD (CW)
M03 M29 RIGID TAPPING MODE ON
ROTATION
SPINDLE REVERSE(CCW) PROGRAM END (RESET &
M04 M30
ROTATION REWIND)
SPINDLE ROTATION
M05
STOP
M06 ATC MACRO CALL
THROUGH THE SPINDLE TOOL DATA
M07 M33
COOLANT ON COMPARE(TN=STN) ON
TOOL DATA
M08 FLOOD COOLANT ON M34
COMPARE(TN=STN) OFF
M09 COOLANT OFF
RESERVED FOR “MACHINE
M10 4TH-AXIS CLAMP M36
LOCK EFFECTIVE”
RESERVED FOR “MACHINE
M11 4TH-AXIS UNCLAMP M37
LOCK INEFFECTIVE”
M12 SHOWER COOLANT ON M38 5TH-AXIS CLAMP
INTERMITTENT COOLANT
M13 M39 5TH-AXIS UNCLAMP
ON
M14 COLLET AIR BLOW ON M40 6TH-AXIS CLAMP
M15 COLLET AIR BLOW OFF M41 6TH-AXIS UNCLAMP

TOOL MEASURE AIR BLOW
M16
ON
M17 AIR GUN ON
TOOL MEASURE AIR BLOW THROUGH THE SPINDLE
M18 M44
OFF AIR BLOWER ON
THROUGH THE SPINDLE
M19 SPINDLE ORIENTATION M45
AIR BLOWER OFF
M20 RESERVED FOR “LADDER & M46 MACHINE FLUSHING
268
HP5100 HP51MTE87
ROBOT” COOLANT ON
RESERVED FOR
M21 “OPTIONAL BLOCK SKIP
VALID”
RESERVED FOR
M22 “OPTIONAL BLOCK SKIP M48 OVERRIDE INVALID
CANCEL”
M49 OVERRIDE VALID
M24 CHIP CONVEYOR START

APC/SPLASH GUARD
M50 M78 PALLET CLAMP
DOOR OPEN 2
APC/SPLASH GUARD
M51 M79 PALLET UNCLAMP
DOOR CLOSE 2
APC/SPLASH GUARD
M52 M80 MIRROR IMAGE OFF
DOOR OPEN
APC/SPLASH GUARD
M53 M81 MIRROR IMAGE X-AXIS
DOOR CLOSE
M54 PART COUNT M82 MIRROR IMAGE Y-AXIS
REPEAT PROGRAM AFTER
M55 M83 MIRROR IMAGE Z-AXIS
M02/M30
AXIS MOVING VALID
M84
WHEN SPDL STOP
AXIS MOVING INVALID
M85
WHEN SPDL STOP
M86 TOOL PRECHECK ON
M87 TOOL PRECHECK OFF

PALLET RETRACT
M60 PALLET CHANGE M88
FUNCTION ON
PALLET RETRACT
M61 APC 1 LOAD MACRO CALL M89
FUNCTION OFF
M62 APC 2 LOAD MACRO CALL
PALLET UNLOAD MACRO
M63 M91 EXTERNAL M-CODE M91
CALL
M64 PALLET LOAD MACRO CALL M92 EXTERNAL M-CODE M92
M65 AUTO POWER OFF ENABLE M93 EXTERNAL M-CODE M93
269
HP5100 HP51MTE87
ATC & APC CHANGE

M66 M94 EXTERNAL M-CODE M94
SIMULTANEOUSLY
CUSTOM MACRO
M68 SPINDLE TOOL CLAMP M96
INTERRUPTION ENABLE
CUSTOM MACRO
M69 SPINDLE TOOL UNCLAMP M97
INTERRUPTION DISABLE
PALLET MAGAZINE INDEX
M70 M98 SUB PROGRAM CALL
MACRO CALL
APC 1 UNLOAD CALL/PMG
M71 M99 SUB PROGRAM END
INDEX 2
APC 2 UNLOAD CALL/PMG
M72 M100 WARMING UP STOP
INDEX 3
WORK/TOOL
WARMING UP
M73 MEASUREMENT SENSOR M101
START(UNDER 7 DAYS)
OFF
WORK MEASUREMENT WARMING UP START(OVER
M74 M102
SENSOR ON 7 DAYS)
WORK MEASUREMENT
M75
SENSOR OFF
TOOL MEASUREMENT
M76
SENSOR ON
TOOL MEASUREMENT
M77
SENSOR OFF
PALLET DATA INPUT
M106 TOOL FROM PALLET ON M146
ENABLE 2
PALLET DATA INPUT
M107 TOOL FROM PALLET OFF M147
DISABLE 2
PALLET DATA INPUT
M148
ENABLE 3
PALLET DATA INPUT
M149
DISABLE 3
M110 BASE COOLANT ON
M111 BASE COOLANT OFF
M155 EXTERNAL M-CODE M155
270
HP5100 HP51MTE87

ATC START FLAG ON
M117 TOOL LIFE COUNT RESET M159
(DUAL ROTARY TABLE)
TOOL SKIP IN TOOL LIFE ATC START FLAG OFF
M118 M160
MANAGEMENT (DUAL ROTARY TABLE)
SPINDLE MULTI
M119
ORIENTATION
TOOL BREAKAGE DETECT

M170
MACRO CALL
M132 OIL MIST COLLECT ON
M133 OIL MIST COLLECT OFF M176 FIXTURE CLAMP
M134 OIL MIST CLEAR ON M177 FIXTURE UNCLAMP
M135 OIL MIST CLEAR OFF M178 FIXTURE 2 CLAMP

COOLANT CHIP AIR BLOW
M136 M179 FIXTURE 2 UNCLAMP
ON
COOLANT CHIP AIR BLOW
M137 M180 FIXTURE 3 CLAMP
OFF
APC PAN COOLANT
M138 M181 FIXTURE 3 UNCLAMP
RECOVERY ON
APC PAN COOLANT
M139 M182 FIXTURE 4 CLAMP
RECOVERY OFF
M183 FIXTURE 4 UNCLAMP
M184 MIRROR IMAGE 4TH AXIS
M185 MIRROR IMAGE 5TH AXIS
PALLET DATA INPUT

M144 M186 MIRROR IMAGE 6TH AXIS
ENABLE 1
PALLET DATA INPUT
M145
DISABLE 1
M188 W-AXIS CLAMP M224 TABLE LOCATE
M189 W-AXIS UNCLAMP M225 TABLE UNLOCATE
271
HP5100 HP51MTE87
M226 PALLET LOCATE

POWER MATE-E REF.
M191 M227 PALLET UNLOCATE
RETURN
TOOL BREAKAGE SENSOR
M192 M228 Y-AXIS CLMAP
CHECK
TOOL BREAKAGE CHECK
M193 M229 Y-AXIS UNCLAMP
START
TOOL BREAKAGE CHECK
M194
(POWER MATE-E)
ATC CHANGE START FLAG
M231
MODE
ATC WAIT POT UP/MAG.
M196 IN-POSITION CHECK ON M232
HOME POS
ATC WAIT POT
M197 IN-POSITION CHECK OFF M233
DOWN/MAG. CHANG POS
M234 ATC ARM PIN LOCKING
M235 ATC ARM PIN RELEASE
M200 TOOL LOAD MONITOR OFF M236 ATC NEXT TOOL INDEX
ATC MOTOR BRAKE
M201 TOOL LOAD MONITOR ON M237
RELEASE ON
ATC MOTOR BRAKE
M238
RELEASE OFF
ATC/APC MAINTENANCE
M239
MODE ON
ATC/APC MAINTENANCE
M240
MODE OFF
ATC ARM 1 CYCLE MODE
M210 APC UP M241
ON
M211 APC DOWN M242 ATC ＋ STEP MODE ON
M212 APC ROTATION (CW) M243 ATC － STEP MODE ON
M213 APC ROTATION (CCW) M244 ATC ＋/－ STEP MODE ON

APC MANUAL UP/DOWN ATC WAITING POT
M214 M245
MODE ON MAG/SPINDLE SIDE
APC MANUAL CW/CCW
M215 M246 ATC WAITING POT CLAMP
MODE ON
272
HP5100 HP51MTE87
ATC WAITING POT

M247
UNCLAMP
ATC WAITING POT
M248
SPINDLE SIDE
PRE-SPINDLE ATC WAITING POT
M219 M249
ORIENTATION MAGAZINE SIDE
MACHINE SERVICE MODE
M250
ON
MACHINE SERVICE MODE
M251
OFF
M222 ATC DOOR OPEN
M223 ATC DOOR CLOSE
KEEP MAGAZINE ROTATE

M253
BY T－CODE
RELEASE MAGAZINE
M254
ROTATE BY T－CODE
SPINDLE TOOL NUMBER
M255
SET
M256 NEXT TOOL NUMBER SET
KEEP RELAY SET FOR
M257
ATC/APC
REMOVE ATTACHMENT
M260
SPINDLE ORIGINAL
M261 MAX SPINDLE SPEED 1
273
HP5100 HP51MTE87
Appendix 3) Maintenance method of Spindle Amp Alarms
ALARM NO. DESCRIPTION REMEDY

Check And Correct The Peripheral
01 Motor Overheated Temperature And Load Status.
If The Cooling Fan Stops, Replace It.
Check And Correct The Cutting Conditions To
Decrease The Load.
02 Speed Deviation Excessive Correct Parameter No.4082
N4082(Spindle Motor Speed Moderation)
Verification
Replace The SPM Unit.
Replace the Spindle Amp
03 Fuse Blow Of DC Link
Check The Motor Insulation Status.
Replace The Interface Cable.
Check The State Of The Input Power Supply
04 Power Phase Missing
To The PSM.
Check And Correct The Parameter.
07 Excessive Speed
Replace The Feedback Cable.
Improve The Heat Sink Cooling Capacity.
09 Main Circuit Overload If The Cooling Fan Stops, Replace The SPM
Unit.
Check The Selected PSM.
Check The Input Power Voltage And Change
11 Excess Voltage In DC Link In Power During Motor Deceleration.
If The Voltage Exceeds 253 VAC (For The 200-
V System)Or 530 VAC (For The 400-V
System), check the Power Supply Impedance.
Check The Motor Insulation Status.
12 Excess Current In DC Link Check The Spindle Parameters.
Replace The SPM Unit.
Check to see if the PMC alarm has been
Problems with main axis activated, and recheck the input/output status
15 conversion/output through the ladder.
conversion Replace The Switching MC Magnet
(KM20/KM21)
16 Ram Error Replace The SPM Control Printed Circuit Board.
18 Rom Sum Check Error Replace The SPM Control Printer Circuit Board.
Excessive U Phase Current
19 Replace The SPM Unit.
Offset
274
HP5100 HP51MTE87

Excessive V Phase Current
Offset
Position Sensor Polarity Check And Correct The Parameters.
21
Setting Error (PRM N4000#0,N4001#4)
Place The CNC-To-Spindle Cable Away From
The Power Cable.
(Problems caused by noise)
Abnormal Serial Data Separate the spindle signal cables from other
24
Transmission power cables, or attach protective equipment
such as a ferrite core.
Replace The Cable.
Position Coder Signal Replace The Cable.
Disconnection
27 Readjust the abnormal BZ sensor and sensor
interval
29 Short Time Overload Check And Correct The Load Status.

Excess Input Circuit Check the power supply to the power supply
30
Current module
Check And Correct The Load Status.
Disconnection of the
31 speed detection signal and Replace The Motor Sensor Cable(JY2 Or JY5)
motor binding status Problems with the spindle motor feedback
cable
SLC Sli Internal Ram
Abnormal
32 Abnormal serial data Replace The SPM Control Printer Circuit Board.
transfer use LSI internal
RAM
Check And Correct The Power Supply Voltage.
Insufficient DC Link Insufficient DC Link capacity
33 (Problem with the power supply unit)
Charging
Replace The PSM Unit.
Correct A Parameter Value According To The
Manual.
Abnormal Parameter
34 If The Parameter Number Is Unknown,
Setting
Connect The Spindle Check Board,
And Check The Indicated Parameter.
Check The Value According To The Parameter
35 Excessive Gear Ratio Data
Manual.
Error Counter Overflow Check Whether The Position Gain Value Is Too
36
Large, And Correct The Value.
37 Speed Detecting Unit Correct The Value According To The Parameter
275
HP5100 HP51MTE87

Error Setting Manual.
Erroneous Detection Of Check And Correct The Parameter
The Position Coder Replace The Cable.
41 One Revolution Signal Abnormal position coder cable
Re-Adjust The BZ Sensor Signal.
Abnormal BZ Sensor signal or sensor interval
Replace The Cable.
Nondetection Of
Abnormal position coder cable
42 The Position Coder
One Revolution Signal Re-Adjust The BZ Sensor Signal.
abnormal BZ Sensor signal or sensor interval
Differential Speed Position Replace The Cable.
43
Coder Disconnection Abnormal position coder cable
Check And Correct The Parameter.
Erroneous Detection Of Replace The Cable.
46 One Revolution Signal Abnormal position coder cable
On Threading
Abnormal BZ Sensor Signal or sensor interval
Replace The Cable.
Abnormal position coder cable
Abnormal Position Coder Abnormal BZ Sensor Signal or sensor interval
47
Signal Correct The Cable Layout (Vicinity Of The
Power Line). Make sure that the cables do not
cross, and add protective equipment such as
ferrite cores.
Check Whether The Calculated Differential
Excessive Differential
Speed Value Exceeds The Maximum Motor
49 Speed
Speed.
Conversion Value
N3772 (setting maximum speed-G96)
Excessive Speed
Command Check Whether The Calculated Speed Value
50
Value During Spindle Exceeds The Maximum Motor Speed.
Synchronization
Check and Correct The Power Supply Voltage.
51 DC Link Under Voltage Replace The MC.
MC (KM20/KM21) Magnet connection status
Replace The SPM Control Printed Circuited
Board.
52 ITP Signal Error
Replace The Spindle Interface Printed Circuit
Board In The CNC. (JA41)
276
HP5100 HP51MTE87

Board.
53 ITP Signal Error
Replace The Spindle Interface Printed Circuit
Board In The CNC. (JA41)
54 Overload Current Review The Load Status.
Replace The Magnetic Contactor.
Power Line State Signal Check And Correct The Sequence and
55
Error abnormal Magnet Connection Status
(KM20/KM21)
Internal Cooling Fan
Stopped
Decrease The Acceleration/Deceleration Duty.
Check the belt tension (belt method). Lower
the deceleration setting. (N4082)
Check the Peripheral Temperature and the
Excessive Deceleration of
57 condition of all cooling equipment.
Power
If The Cooling Fan Stops, Replace The Cooling
Fan.
If The Resistance Is Abnormal, Replace The
Resistor.
Convert Main Circuit Check The PSM Cooling Status.

58
Overload Replace The SPM Unit.
Converter Cooling Fan
Stopped
Replace The Cable.
Inter-Spindle-Amplifier
66 Check And Correct The Connection of the
Communication Error
signal cable.
Check And Correct The Connection of the
feedback cable.
Motor Sensor
73 Check The Shield Processing.
Disconnection
Check And Correct The Connection.
Adjust The motor Sensor location and interval.
74 CPU Test Alarm
Board.
75 CRC Test Alarm
Board.
79 Initial Test Alarm
Board.
81 Motor Sensor One-
Check And Correct The Parameter. N4016#6 /
277
HP5100 HP51MTE87

N4017#2
Rotation Check And Correct The Connection of the
Signal Detection Error feedback cable.
Adjust The motor Sensor location and interval.
Motor Sensor One- Check And Correct The Connection of the

82 Rotation feedback cable.
Signal Undetected Adjust The motor Sensor location and interval.
83 Motor Sensor Signal Error Check the location and intervals of the motor
sensor
Check The Shield Processing.
Check And Correct The Connection of the
Spindle Sensor feedback cable.
84
Disconnection Check And Correct The spindle-related
Parameter.
Adjust The motor Sensor (position coder)
location and interval.
Spindle Sensor Check And Correct The Parameter.

85 One-Rotation Replace The Feedback Cable.
Signal Detection Error
Adjust The Sensor.
Check the connection status of the feedback
Spindle Sensor
cable.
86 One-Rotation
Signal Undetected Adjust The Sensor.
Adjusting the motor sensor (position coder)
location and interval
The One-Rotation Signal Of The Spindle
Spindle Sensor Signal Sensor
87
Error Is Not Generated. check the electric conection
and adjust the sensor locations and intervals.
88 Cooling Fan Stopped Replace The SPM External Cooling Fan.
If This Alarm Is Issued When The Spindle
Program Rom Error
Amplifier Power Is Switched On.
A0 (The Control
-.Wrong Software Specification.
A1 Programming Is Not
-.Defective Printed Circuited Board.
A2 Running)
Replace The SPM Or SPM Control Circuited
Board.
278
HP5100 HP51MTE87

If The Alarm Is Issued When The Motor Is
Active.
Check The Grounding Wire.
If The Spindle Sensor Signal Wire Is Bundled
Together With Any Motor Power Line,
Separate
Them and add protective equipment such as
ferrite cores.
Replace The Communication Cable
Communication Error
Between Amplifier And Module.
Between Amplifier
b0 Abnormal Spindle Amp or NC Board
Modules
Replace The SPM Or PSM Control Printed
Circuited Board.
Low Converter Control
b1 Power Supply Voltage Replace The PSM Control Printed Circuit Board.
(PSM Alarm Indication:6)
Excessive Converter Check The Regenerative Resistance.
b2 Regenerative Power Check The Motor Selection.
(PSM Alarm Indication:8) Replace The PSM.
Stopped Cooling Fan Of
b3 The Converter Radiator Replace The Cooling Fan.
(PSM Alarm Indication: A)
Replace The Communication Cable
Between CNC And SPM. Abnormal spindle
amp or NC Board.
C0
Abnormal Data Replace The SPM Control Printed Circuited
C1
Transmission Board.
C2
Replace The CPM Side Spindle Interface
Printed Circuit Board. Abnormal NC Unit
(JA41, unit where serial signals are input)
279
HP5100 HP51MTE87
Appendix 4) ATC Main Changer Sequence Table
Initial Condition Changer Arm Home

② 2nd Reference Point & M19
③ Pot Spindle Side X7.0 (SX5A) WPSS.M Arm
& Clamp X7.2 (SD32) WPCL.M Forward
④ Arm Pin Release X15.5 (SD56) ATAR.M
Gripping Tool

Output : Y39.6(STUN.R), KAR11-YV11,Distribute I/O B (A23) On
Completion : X6.4(TCL.M), SX11, Input Module Slot8(Pin31) Off
X6.5(TUCL.M), SX12, Input Module Slot8(Pin47) On Spindle Tool Unclamp
Arm Pin Locking
Arm Out
&
Output : Y 0.2(ATAL.R), YV55,Output Module Slot01(Pin04) On
Rotation
Completion: X15.3(ATAL.M), SD55, Input Module Slot06(Pin11) On
Tool Change
Spindle Tool Clamp

Arm In
Output : Y39.6(STUN.R), KAR11-YV11,Distribute I/O B (A23) Off
Completion : X6.4(TCL.M), SX11, Input Module Slot8(Pin31) On
X6.5(TUCL.M), SX12, Input Module Slot8(Pin47) Off Spindle Tool Clamp
Arm Pin Release

Arm
Output : Y 0.2(ATAL.R), YV55,Output Module Slot01(Pin04) On Forward
Completion : X15.3(ATAL.M), SD55, Input Module Slot06(Pin11) On

Input Signal : X8.7(CAHP.M), SX53, Input Module Slot8(Pin37) On
280
HP5100 HP51MTE87
Appendix 5) Pallet Change Sequence Chart
START (M60 Command)
▶ Y,Z-Axis Return to the 2nd reference point

① Y,Z-Axis 2nd Ref. Position Program : G00 G91 G30 Y0. Z0.;
Y,Z-Axis 2nd ▶ X,Y,Z-Axis Return to the 2nd reference point

Ref. POS.？ No Program : G00 G91 G30 Y0. Z0.;
Yes
▶ B-Axis Return to the reference point
② B-Axis Ref. Position
Program : G00 G91 G28 B0.;
▶ B-Axis Return to the reference point

B-Axis Ref. Program : G00 G91 G28 B0.;
Position.？ No
★ 2042 M61/M62 Command Illegal POS.
Yes activated
X10.0 PCL.M -SP61 On X10.1 TACL.M -SL62 On
X11.1 PNO1.M -SX75, X11.2 PNO2.M -SX76 On/Off
APC Initial
X11.6 APUP.M -SX81 On X11.7 APDN.M -SX82 Off
Position？ No
X12.1 ACUP.M -SX81 Off
Yes
Pushed Set- ★ 2085 APC Set-Up Location S/W Unpush

Up Button？ No Activated
Confirm Signal : X16.6 SETU.M -SB93 On
Yes
Output Signal : Y7.2 PUCL.R -KAR62/-YV62 On
③ Pallet Unclamp Completion Signal: X10.0 PCL.M -SP61 Off
Pallet ★ 2073 Table or Pallet CL/UNCL Switch Alarm

Unclamp No Activated
Confirm Signal: X10.0 PCL.M -SP61 Off
？
Yes
Output Signal: Y39.2 APUP.R -KAR75/-YV75
④ APC Up Completion Signal : X11.6 ACUP.M -SX81
★ 2126 APC Up/Down Alarm Activated

APC Up O.K？
No Confirm Signal: X11.6 ACUP.M -SX81 On
Yes
281
HP5100 HP51MTE87
Pallet 1 Position？ GO TO 1
No
Yes
⑤ APC Arm 180 CW Rotation Output Signal : Y39.0 PCW.R -KAR73/-YV73
APC Arm 180 CW Rot. ★ 2127 APC Changer 180CW/180CCW Alarm Occurrence
End？ No ON
Checking Signal : X11.2 PNO2.M -SX76
Yes
2
APC Down Output Signal : Y39.3 APDN.R -KAR76/-YV76

⑥
Completion Signal : X11.7 APDN.M -SX82
APC Down O.K？ ★ 2126 APC Up/Down Alarm Occurrence

No Checking Signal : X11.7 APDN.M -SX82
Yes
Pallet Clamp Output Signal : Y7.2 PUCL.R -KAR62/-YV62
⑦
Completion Signal : X10.0 PCL.M -SP61
Pallet Clamp O.K？ ★ 2073 Table or Pallet CL/UNCL Switch Alarm Occurrence
No Checking Signal : X10.0 PCL.M -SP61 ON
Yes
End
Checking Signal : 1 POS. X11.1 PNO1.M -SX75 OFF

Pallet 2 Position？
2 POS. X11.2 PNO2.M -SX76 ON
Yes
APC Arm 180 CCW Rotation Output Signal : Y39.1 PCCW.R -KAR74/-YV74
⑧
APC Arm 180 CCW Rot. ★ 2127 APC Changer 180CW/180CCW Alarm Occurrence
End？ No Checking Signal : X11.1 PNO1.M -SX75
Yes
2
282
HP5100 HP51MTE87
Appendix 6) Recovering ATC Breakage
If the Changer Arm stopped in the middle of Tool Change(M06), you must
manually return the Changer Arm to its home position. Because the necessary
measures differ with each situation, you must accurately find the cause of the
problem and take appropriate measures.
☞ Since this is done with tools attached to the Changer Arm, be careful not to drop the
tools. Just in case tools fall, set up a wooden pallet to protect tools or the machine cover
below the ATC.
(1) Changer Arm stop during Spindle Tool Clamp Status

The Changer Arm stopped between the Home Position and the Spindle.
(2) Changer Arm stop during Spindle Tool Unclamp Status

The Changer Arm stopped after falling out from the Spindle and rotating 180˚
before inserting the tool into the Spindle.
(3) Arm Jam during Unclamping or directly following Clamping

The Changer Arm stopped while stuck in the Spindle.
(4) Alarm 2065 (“Changer Arm Position Check Alarm”) activated despite
having returned the Changer Arm to Home Position
The Changer Arm has been returned to Home Position, but for some reason this
position does not match the Servo reference point or the ATC machine reference
point set in the Cam bundle.
(1) Recovery Process when the Changer Arm has stopped during
Spindle Tool Clamp Status
1) In Emergency Stop status, or in Power Off

status, remove the cause and turn the
machine on, press Machine Ready.
283
HP5100 HP51MTE87
2) Select "JOG" mode from the main operation

panel.
3) Press the "CUSTOM" NC Function Key.

The“CUSTOM WINDOW”screen appears.
4) Press the "PMC-SW”soft key. The ATC, APC

Manual screen appears.
5) When the ATC, APC Manual screen appears,

press the “ATC-ON”soft key to select the ATC.
The ATC Manual Mode changes from
“DISABLE”to “ON”.
6) Move the cursor keys to choose "ATC ARM

REVERESE STEP,”and repeatedly press the main
operation panel's cycle start button repeatedly
to move the Changer Arm to Home Poistion.
284
HP5100 HP51MTE87
7) Repeatedly press the main operation panel's

Cycle Start button to move the Changer Arm to
Home position, where it no longer moves. (If
the Changer Arm stops moving, it has been
returned to Home Position.)
※ If the Changer Arm jams after replacing
tools and Spindle Tool Clamping, select
"ATC ARM FORWARD STEP”to manually
send it to other sections.
Verification: D450 = D452 in PMC G.DATA
Mode
8) Move the cursor Key to select“ATC ARM 1

CYCLE,”and press the main operation panel's
Cycle Start button. The Changer Arm will
execute Tool Change once, and the inner Cam
and Changer Arm will be reordered.
9) At completion, press the “OFF”soft key. The

ATC Manual Mode will change from “ON” to
“DISABLE.”
10) Press (in order)“SYSTEM” => PMC => PMC DATA => G.DATA, confirm the tool
numbers of the Spindle and Standby Port from D450, D452, and reset.
D450 : Spindle tool number
D452 : Waiting pot tool number
11) When each axis is returned to its reference point, the ATC breakage recovery is
complete.
285
HP5100 HP51MTE87
Appendix 7) Maintenance method of Servo driver Alarm

① UV (Under Voltage) Alarm : Voltage shortage Alarm in Main circuit direct
current voltage.
Dirve
LED
Contents Inside DC link voltage become below the designated value.
▪ Check input voltage whether it is within 200V ~ 220V. And reset it if it
has a problem.
Measure the voltage

between 2 terminals
among L1, L2, and L3
Measure
▪ Check the connections of Motor power cable. Replace it if it has a

problem
▪ Change the drive if the same alarm occurs when the turret servo drive
was turned off and on even after the above measures were taken.
Note) Turret Servo Drive Alarm is aimed to protect Servo drive, motor, Turret Unit.
So if you power Off and then on to cancel the alarm, drive and motor itself
has no problem so it doesn’t have to be replaced.
286
HP5100 HP51MTE87
② OV (Over Voltage) Alarm : Overvoltage alarm in Main circuit direct current

voltage.
Drive LED
Contents Inside DC link voltage become below the designated value.
▪ Check input voltage whether it is within 200V ~ 220V. And reset it if it
has a problem.
Measure the voltage

between 2 terminals
among L1, L2, and L3
▪ Disassemble the drive, detach connector connected in PAB, check

whether the regenerative resistance is 26Ω. And then replace it if it
has a problem.
Measure
Power Board (PAB)
Regenerative
resistor
Connector for
regenerative
resistor
▪ Check Motor power cable connections and then replace it if it has a

problem.
▪ Change the drive if the same alarm occurs when the turret servo drive
was turned off and on even after the above measures were taken.
.
287
HP5100 HP51MTE87
③ OH (Over Heat) Alarm : Overheat alarm.
Drive
LED
Contents IPM become overheat.
▪ When the alarm shows, Power off the turret servo drive to cool down
Method the Servo drive.After power on,if the same alarm shows, then IPM is
defective. Replace the drive.
Enclosed) Turret Servo Drive Alarm is aimed to protect Servo drive, motor, Turret
Unit. So if you power Off and then on to cancel the alarm, the drive or motor
are not included in the replacement
④ OC (Over Current) Alarm : Over current alarm.
Drive
LED
Contents Over current flow in motor.
▪ Check whether acceleration and retardation parameter No. 29, No. 30
setting is low.
Measure
▪ After checking disconnections of motor power cable, replace the cable if
it has a problem
288
HP5100 HP51MTE87
⑤ CA Alarm : Encoder-related alarm, the method will be different according to

11Bit old drive or 17Bit new drive
Drive
LED
11 Bit ▪ A,B,Z error among encoder signal.

Contents
▪ Power input into the Turret Servo drive before encoder
17 Bit
initialization.
▪ Detach from Servo drive and reset it due to Encoder data
receiving cable connection error.
▪ Check the disconnection of encoder data receiving cable, and
replace it if it has a problem.
Encoder data
receiving cable
11 bit
Measure
▪ See the Motor encoder connector Short and then replace the motor
if it has a problem.
Motor encoder
connector
▪ After power off turret servo drive, 5 seconds later after motor
encoder initialization finished, turn on turret servo drive and
then the alarm will be released.
17 bit
▪ Turret Servo drvie from DVSD-TT-14A to DVSD-TT-14A-04 will
be applied. After DVSD-TT-14A-05 version, CA alarm is
deleted
289
HP5100 HP51MTE87
⑥ CO Alarm : Applied after 17Bit Turret servo drive DVSD-TT-14A-05 version.

Encoder signal abnormal related alarm.
Drive
LED
Alarm Encoder signal error.
▪ Detach from Servo drive and reset it due to Encoder data receiving
cable connection error.
▪ Check the disconnection of encoder data receiving cable, and replace it
Encoder data
receiving cable
Measure
▪ See the Motor encoder connector Short and then replace the motor if it has a
problem.
Motor encoder
connector
.
290
HP5100 HP51MTE87
⑦ OS (Over Speed) Alarm : Overspeed alarm.
Drive
LED
Contents Motor speed exceed the maximum speed
▪ Detach from Servo drive and reset it due to Encoder data receiving
cable connection error.
Encoder data
Receiving cable
Measure
▪ Check the disconnection of encoder data receiving cable, and replace it

▪ Check the disconnection of motor power cable, and replace it if it has a
problem.
▪ Check the Motor encoder connector Short and then replace the motor if it has
a problem.
Motor encoder
connector
.
291
HP5100 HP51MTE87
⑧ OL (Over Load) Alarm : Overload alarm
Drive
LED
▪ Turret servo motor overload continue more than the regulated time.
▪ Overload detection time
Contents 250% ~ : 1sec, 220% ~ : 24sec, 200% ~ : 48sec
180% ~ : 96sec, 160% ~ : 192sec, 150% ~ : 384sec
140% ~ : 769sec, 130% ~ : 1536sec
▪ Set turret to Unclamp in Keep Relay, check whether the turret rotate
smoothly, Check the rotation while increasing parameter No.10, No.11
by 10.and do the proper action if it does not move well.
▪ Check the parameter setting.

(Enclosed) If after 11Bit AS Turret servo driveDASD-CT15SPXC-05 version
and after 17Bit new turret servo drive DVSD-TT-14A-04 version, No. 4
parameter value is 2048. And if you change the value, then the
overload alarm will show.
Measure
▪ It happens when the tool load is high for the turret or it has a mechanical
problem. So check the rotation of turret through adding 10 in parameter
No.10, No.11. Do proper action if problem found..
▪ Check Relay and do the proper action.
▪ Motor power cable or encoder data receiving cable could have a problem.
So pull them out of turret servo drive and assemble it again.
Encoder data
Receiving cable
Motor power
cable
292
HP5100 HP51MTE87
▪ Check the disconnection of motor power cable or encoder receiving cable.

Replace it if it has a problem.
▪ Perform above, turn the turret servo drive ‘Off’ and then ‘On’. If alarm
continues, replace the drive.
⑨ SE Alarm : Double Interrut Alarm.
Drive
LED
Contents CPU calculation or turret servo drive inside MCB trouble.
▪ Initialize turret servo drive parameter and reset the parameter
Measure ▪ Perform above, turn the turret servo drive ‘Off’ and then ‘On’. If alarm
continues, replace the drive.
⑩ PE (Parameter Error) Alarm : Parameter abnormal alarm.
Drive
LED
Turret servo drive parameter saved value is not within the regulated
Contents
range.
▪ Initialize turret servo drive parameter and position compensation value
and reset the parameter and reference point
Measure
▪ Perform above, turn the turret servo drive ‘Off’ and then ‘On’. If alarm
continues, replace the drive..
.
293
HP5100 HP51MTE87
⑪ RP (Residue Pulse) Alarm(ALP-rP) : Position deviation excess alarm.
Drive
LED
Contents Rest pulse exceed the regulated value fixed in the parameter no.19
▪ Check whether parameter No.19 setting is low.
▪ Encoder data receiving cable could be error, so detach from turret servo
drive and then re assemble it.
Encoder data
receiving cable
Measure
▪ Check the disconnection of motor encoder cable, and replace it if it has

a problem.
▪ Check the disconnection of motor encoder connector, and replace it if it
has a problem.
Motor encoder
connector
.
294
HP5100 HP51MTE87
⑫ EN (Battery) Alarm : Encoder backup battery abnormal alarm.

▪ If Turret servo drive and motor are united when machine power has not been
provided, use battery’s power.
▪ Battery life(The largest consumption current 150㎂)
In 25℃, 1.44 year ~ 1.5 year
In 75℃, 0.89 year ~ 0.96 year
Drive
LED
Contents Encoder backup battery discharged or pulled out.
▪ Replace the encoder backup battery inside the turret servo drive.
Encoder backup
battery
Measure
▪ Disassemble Turret servo drive and check the connector’s status.

Replace it if it has a problem
Encoder backup
Battery connector
Main Control Board (MCB)
295
HMC 고장진단 및 처치 HP51MTK87
Revision Record
HMC Maintenance HP5100 (HP51MTK87)
Version Date Contents Writer
Mr.Jeong Sam
01 2008.05 1st edition
Young
Mr.Lee Dae
02 2008. 07 1st revised
Seop
03
04
05
06
07
08
09
10
127

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Machine Tools

Appendix1 X-Y Signal Address 263

2001 OP Emg. Stop PB or LS Off

Part Name Part Number Symbol Model Maker

ddress Symbol Coil Comment

2002 Main Spindle Servo Alarm

Status The Alarm shows on the Main Spindle Drive Unit

① Main Spindle Drive Unit troubled

Address Symbol Coil Comment

2003 Circuit Protector Trip

Status Circuit Protect has been activated in the electrical cabinet.

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

Part Name Part Number Symbol Model Maker

Address Symbol Coil Comment

TR IP -Q F23 A C 100V C ontrol

-Q F14 T ranse Form er P ower TR IP E

T R IP A -Q F81 A TC M otor B rak e

-Q F21 D C 24V C ontrol TR IP D TR IP F

T R IP C -Q F28 S olenoid D C P ower S ource

-Q F22 T ool M agazine M otor B rake TR IP H

2004 Hyd. Pump Motor Overload

Status Overcurrent detected in the Hyd. Pump Motor.

① Burnout of the Hyd. Pump Motor or power Cable

Tool Connector Numbering

Hydraulic Motor X2.1

Hyd. Pump Motor

Address Symbol Coil Comment

-Q M 31 H yd. P um p M otor(M ain)

-Q M 36 F ixture Hyd. P um p M otor

2005 Hyd. Pressure Down Alarm

Tool Connector Numbering

Aux. Hyd. Pressure

Address Symbol Coil Comment

Address Symbol Coil Comment

2009 ATC Servo or Inverter Alarm

① Servo Motor Inverter troubled

Tool Connector Numbering

Address Symbol Coil Comment

2010 Spindle Tool Unclamp Cmd. Fault

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

ATC SERVO HP51

note *1) ( ) used HSK Tool

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

Tool Connector Numbering

Spindle Tool Unclamp

Address Symbol Coil Comment

2015 Spindle Tool Unclamp Alarm

Product Product # Symbol Model Label

Tool Connector Numbering

Spindle Spindle Tool

Proximity Switch Dog

Address Symbol Coil Comment

2020 Coolant & Lub. Pump Overload

Status Overcurrent detected in the coolant or lubricant Pump Motor.

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

Product Product # Symbol Model Label

Tool Connector Numbering

Coolant & Lub. Pump

Address Symbol Coil Comment