TROUBLESHOOTING (J: APC)

I74859A02E

TROUBLESHOOTING
(J: APC)

<Machine Models>
NH4000
NH5000
NH6300
NH8000

<NC>
MSG-501/2iMB
MSX-501/2iMB

TITLE

TROUBLESHOOTING
(J: APC)
A02E 04.04.08 ISOZAKI
A01E 02.10.14 Y. MORI DRAWING No.
EDITION DATE DRAWN I74859A02E

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Revision Record
Version Person in
Date Change Remark
No. Charge
A01E 02.10.14 Y. MORI New Design
Addition of NH4000,NH6300
A02E 04.04.08 M.ISOZAKI

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J: APC

This section deals with trouble related to the APC. According to the nature of the
trouble encountered, refer to the section indicated below to locate the cause of the
trouble and find the corrective action to be taken.

Classification of Trouble
Item Trouble
J-1 EX0108 (APC is not at the home position)
EX0715 (APC is not at the home position)
EX0727 (APC is not at the home position)
J-2 EX0704 (setup station is not at the home position)
EX0752 (setup station is not at the home position)
J-3 EX0720 (table is not clamped)
J-4 EX0708 (setup station door is open)
EX0751 (setup station door is not closed)
EX0771 (setup station door lock/unlock time-over)
J-5 EX0743 (Z-axis parameter setting error)
J-6
J-7
J-8
J-9
J - 10
J - 11
J - 12
J - 13
J - 14
J - 15
J - 16
J - 17
J - 18
J - 19
J - 20

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J - 1. EX0108 (APC IS NOT AT THE HOME POSITION)

EX0715 (APC IS NOT AT THE HOME POSITION)
EX0727 (APC IS NOT AT THE HOME POSITION)

[ Description of Alarm ]
This alarm occurs if an ATC command (EX0108), an APC command (EX0715) or a
cycle start command (EX0727) is specified although the APC is not at the home
position.

[ Check Items ]
- APC arm lower end position check (X12.4)

[ Check Procedure ]
a-1 Display the APC MANUAL screen and check if the APC is at the home
position.

When the APC is at the home position, the "APC ARM DOWN" and
"A(B or C)-ST, MACHINE SIDE" status items are highlighted.

Is the APC at the home position?

- Yes → To a - 2
- No → To a - 3

a-2 If the APC is at the home position, this alarm does not occur usually.
Check the alarm message once again.
END

a-3 At the APC MANUAL screen, check if the "APC ARM DOWN" status
item is highlighted.

Is the "APC ARM DOWN" status item is highlighted?

- Yes → To a - 5
- No → To a - 4

a-4 After making sure that the Z-axis is the 2nd zero point, select and
execute "APC ARM DOWN" at the APC MANUAL screen.

Did the APC arm move down?

- Yes → To a - 5
- No → To a - 7

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a-5 At the APC MANUAL screen, check if the "APC ARM DOWN" status
item is highlighted.

Is the " APC ARM DOWN " status item is highlighted?

- Yes → To a - 8
- No → To a - 6

a-6 The APC arm lower end position check switch signal may not be ON or
the APC arm upper end position check switch signal may not be OFF.
Check the wiring of the APC arm lower/upper end position check
proximity switch from the electrical control cabinet and also check the
position of the proximity switch.

The APC arm UP/DOWN state can be checked by checking the

addresses indicated below.

Input
Signal Name SQ No. Remark
Signal
APC arm UP X12.3 SQ301
APC arm DOWN X12.4 SP302

END

a-7 If the APC arm does not move down, place the APC in the interlock
canceled state and perform the APC arm moving down operation.

→ To a - 4

a-8 Display the APC MANUAL screen and check if any of A-ST. MACHINE
SIDE, B-ST. MACHINE SIDE and C-ST. MACHINE SIDE (displayed
only for 3-pallet APC specification) is highlighted.

Is any of the messages above highlighted?

- Yes → To a - 2
- No → To a - 9

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a-9 The APC servo axis may not be correctly positioned mechanically.
Check the position data (coordinate value) of the APC servo axis.

At the NC system screen, press the menu selection key [>] several times
until the [PMM] soft-key is displayed. Press the soft-keys [PMM] and
[POS] to call the screen that displays the coordinate value of the power
motion manager (PMM).
Group number of the APC axis is "0".
For details, refer to Z7-1, "CONFIGURATION OF NUMERICALLY
CONTROLLED AXES (SH5000/8000/NH5000)".

PMM Coordinate Value Display Screen

POWER MATE CNC MANAGER

1.GROUP0 / β 2.GROUP1 / β

3.GROUP2 / β

This value indicates

the coordinate value
of the APC axis.

MDI**** **** **** **** **** **** **** **** **** ****

( EXIT ) ( ) ( ) ( ) ( )

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Check if the APC axis coordinate value is within the ranges indicated
below.

- 2-pallet APC specification

A-station: 359.5° - 0.5°
B-station: 179.5° - 180.5°

- 3-pallet APC specification

A-station: 359.5° - 0.5°
B-station: 119.5° - 120.5°
C-station: 239.5° - 240.5°

If the coordinate value is not within the specified range, display the
APC MANUAL screen and turn the APC to position the APC servo axis
at the correct position.

END

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J - 2. EX0704 (SETUP STATION IS NOT AT THE HOME POSITION)

EX0752 (SETUP STATION IS NOT AT THE HOME POSITION)

[ Description of Alarm ]
This alarm occurs if an APC command is executed although the pallet in the setup
station is not at the home position (EX0704).
If the home position check signal of the setup station is turned OFF during the
execution of an APC cycle, this alarm occurs (EX0752).

[ Check Items ]
- Setup station (WSS) home position check 1 (X11.1)
- Setup station (WSS) home position check 2 (X11.2 [3-pallet APC specification])

[ Check Procedure ]
b-1 Display the APC MANUAL screen and check if the setup station is at
the home position.

When the setup station is at the home position, the "WSS HOME POS."
status item is highlighted.

Is the setup station at the home position?

- Yes → To b - 2
- No → To b - 3

b-2 If the setup station is at the home position, this alarm does not occur
usually.
Check the alarm message once again.
END

b-3 Set the setup station pallet in the in-position status and lock the pallet
by stepping on the footswitch. (At two setup stations in the case of
3-pallet APC)
At the APC MANUAL screen, check if the "WSS HOME POS." status
item is highlighted.

Is the "WSS HOME POS." status item highlighted?

- Yes → To b - 2
- No → To b - 4

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b-4 The input signal of the setup station home position switch may not be
turned ON.
Check the wiring of the set-up station home position check proximity
switch from the electrical control cabinet to the proximity switch and
the position of the proximity switch itself.

Whether the setup station is at the home position or not can be checked
by checking the addresses indicated below.

Input
Signal Name SQ No. Remark
Signal
Setup station (WSS) home
X11.1 SQ248
position 1
Setup station (WSS) home
position 2 X11.2 SQ247
(3-pallet APC specification)

END

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J - 3. EX0720 (TABLE IS NOT CLAMPED)

[ Description of Alarm ]
This alarm occurs if an APC command is specified although the table is not
clamped.

[ Check Items ]
- Table lower end position check (X12.5)
- Table upper end position check (X19.5) (1° index specification)
- PC parameter K31.2 (arbitrary index specification)

[ Check Procedure ]
c-1 Check if the B-axis is clamped by checking if the B-axis clamp indicator
on the operation panel is lit or not.

Is the B-axis clamp indicator lit?

- Yes → To c - 2
- No → To c - 3

c-2 If the B-axis is clamped, this alarm does not occur usually.
Check the alarm message once again.
END

c-3 Clamp the B-axis by executing M10.

Before clamping the B-axis, execute B-axis zero return so that APC
operation is enabled.

Is the B-axis clamped successfully?

- Yes → To c - 2
- No → To c - 4

c-4 The table upper end position check signal and/or the table lower end
position check signal may not be input correctly.

Is the B-axis 1° index specification or arbitrary index specification?

- 1° index specification → To c - 5
- Arbitrary index specification → To c - 6

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c-5 The table lower end position check switch signal may not be ON, or the
table upper end position check switch signal may not be OFF.
Check the wiring of these switches from the electrical control cabinet
and also check the position of them.

The table UP/DOWN state can be checked by checking the addresses

indicated below.

Input
Signal Name SQ No. Remark
Signal
Table DOWN X12.5 SQ252
Table UP X19.5 SQ251

END

c-6 Check the PC parameter if "K31.2 = 1".

Also check the wiring of the pressure switch SP7 from the electrical
control cabinet.

END

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J - 4. EX0708 (SETUP STATION DOOR IS OPEN)

EX0751 (SETUP STATION DOOR IS NOT CLOSED)
EX0771 (SETUP STATION DOOR LOCK/UNLOCK TIME-OVER)

[ Description of Alarm ]
EX0708
An APC command was executed although the setup station door was open.
EX0751
The setup station door close check signal was turned OFF during the execution of
an APC cycle.
EX0771
The setup station door lock confirmation signal was not turned ON/OFF within a
preset length of time after the output of the setup station door lock/unlock
command.

[ Check Items ]
Alarms related to the setup station door lock device are summarized below.
Check the wiring of the setup station door lock device.
Signals to be checked

- Setup station door unlock (Y10.1)

- Setup station door close check (X10.0)
- Setup station door lock check (X10.1)

[ Check Procedure ]
d-1 Check if the setup has been completed for the pallet in the setup
station.

Is the indicating lamp in the setup button at the setup station lit?

- Yes → To d - 2
- No → To d - 3

d-2 Cancel the setup completed state by pressing the setup button at the
setup station.
→ To d - 3

d-3 Can the setup station door be opened/closed?

- Yes → To d - 4
- No → To d - 9

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d-4 Close the setup station door.

Is the setup station door close check signal address setting "1"
(X10.0 = 1)?
Check this at the PMCDGN screen.

- Yes → To d - 5
- No → To d - 9

d-5 Set the setup station side pallet in the setup completed state to turn on
the setup lamp.

→ To d - 6

d-6 Is the setup station door locked in the closed position?

- Yes → To d - 7
- No → To d - 9

d-7 Is the setup station door close check signal address setting "1"
(X10.1 = 1)?
Check this at the PMCDGN screen.

- Yes → To d - 8
- No → To d - 9

d-8 Is magnet contactor of KM02 turned ON?

- Yes → To d - 10
- No → To d - 9

d-9 The wiring and/or the door lock device, or the I/O will be faulty.
Check the wiring for the corresponding locations.

END

d - 10 There are no problems with the door lock device related input/output
signals.

END

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J - 5. EX0743 (Z-AXIS PARAMETER SETTING ERROR)

[ Description of Alarm ]
APC is NOT possible unless the Z-axis is at the 2nd zero point. However, since the
2nd zero point may be easily changed by simply changing the setting of the related
NC parameter. To avoid the occurrence of a trouble, the 2nd zero point data is also
set for the PC parameter and APC cycle is disabled with the error message
displayed on the screen if the setting of the NC parameter does not agree with the
setting of the PC parameter. Whether or not this check is executed is set for the
parameter (K8.7 = 0).
This alarm occurs if the setting of the NC parameter does not agree with the setting
of the PC parameter.

[ Check Items ]
- Z-axis 2nd zero return NC parameter (N1241Z)
- Z-axis 2nd zero return PC parameter (D308)

[ Check Procedure ]
e-1 Check the setting of PC parameter K8.7 if the setting is so made to
check the Z-axis 2nd zero point parameter at the execution of APC.

Is "PC parameter K8.7 = 0"?

- Yes → To e - 3
- No → To e - 2

e-2 If the setting for PC parameter K8.7 is NOT "0", this alarm does not
occur.
Check the alarm message once again.

END

e-3 Check the value set for Z-axis NC parameter N1241Z and the value set
for PC parameter D308.

END

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