Machine Tools

APC Troubleshooting
(HP 5100)
HP 5100 HP51APCE26

◈ APC Recovery (HP 5100)

▪ If APC stops operation while switching the pallet (M60, M61, M62) for any reason (an interference or
emergency stop of workpiece, fixture or tool, or power failure), you must return APC to the normal
position manually.

1) Solve whatever reason APC stopped, and turn on

the machine (Power On) and enter Machine
Ready.

2) Select the “JOG” mode in the main OP.

3) Turn the mode toggle switch to Manual in the APC

manual OP.

APC manual OP (CE)

4) From the NC function key panel, press the

“CUSTOM” key.
⇒ The “CUSTOM WINDOW” screen appears.

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5) Press the “PMC-SW” soft key.

⇒ The ATC/APC Manual screen appears.

6) When the ATC/APC Manual screen appears, press

“ATC-ON” to select ATC.
⇒ The ATC Manual mode will switch from
“DISABLE” to “ON”.

7) Refer to “Pallet Change Sequence Chart” and

select a necessary measure between ① and ⑤. ON
Then, press the Cycle Start button in the main OP
or press Manual Start in the APC manual OP to
return APC to the initial position step by step. PALLET CLAMP

▪ While APC is working, the Cycle Start button in

the main OP, or the Manual Start button in the
APC manual OP will keep turned on until APC
completes its operation.

☞ If the APC changer won't move as intended, refer to "Sequence conditions for manual step-by-
step operation" mentioned later to find out and solve the cause of problem.
※ If APC stops rotation while rotating CW or CCW, switch K25.0(APC Rotation Keep) from 0 to 1.

8) When the last step of APC manual operation is

completed, press the “OFF” soft key and
complete the operation.
⇒ The ATC Manual mode will switch from “ON”
to “DISABLE”.

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■ Pallet Change (M60) Sequence Chart

Start (M60 Command)

Y,Z-Axis 2nd Ref. Point Command ▶ Return Y and Z axes to their respective 2nd ref.
point
Program : G00 G91 G30 Y0.Z0. ;
Y,Z-Axis 2nd Ref. ▪ Return Y, Z to 2nd Ref. Point
Point ? No Program : G00 G91 G30 Y0.Z0. ;

Yes
▶ Return the B axis to the ref. point
B-Axis Ref. Point Command
Program : G00 G28 B0. ;

B-Axis Ref. ▪ Return the B axis to the ref. point

Point? No Program : G00 G28 B0. ;

Yes
★ AL 2080 “APC OP Manual Mode” occurs
Man APC OP From the APC manual OP, turn the mode switch to
Auto Mode ? No Auto. (X16.7, PMMD.M = 0, SA91)

Yes
★ AL 2042 “M61/M62 Command Illegal Pos.”
APC Initial occurs On
Position ? No On
▪ X10.0(PCL.M) -SP61 Pallet Clamp
▪ X10.1(TACL.M) -SL62 Table Clamp Off/On
Yes
▪ X11.1(PNO1.M) -SX75 Pallet NO1 Detection On/Off
▪ X11.2(PNO2.M) -SX76 Pallet NO2 Detection On
▪ X11.6(APUP.M) -SX81 APC Down Check On
▪ X5.3(OSDI.M) -S13A Operator’s Door Close On

★ AL 2085 “APC Set-Up Location SW Unpush”

Set-Up Switch On ? occurs
No
Press the Set-Up switch on the APC manual OP.On
Yes Check: X16.6, SETU.M, SB93

1 Pallet Unclamp ▪ Output: Y7.2(PUCL.R) –YV62 Pallet Unclamp On

▪ Completed: X10.0(PCL.M) –SP61 Pallet Clamp Off

Pallet Unclamp ★ AL 2072 “B-Axis(Table) Cl/Uncl SW Alarm”

O.K ? No occurs Off
Check: X10.0(PCL.M) –SP61 Pallet Clamp
Yes
2 APC Changer Up ▪ Output: Y39.2(APUP.R) –YV75 APC Changer Up On
▪ Completed: X11.6(APUP.M) –SX83 APC Up Check On

★ AL 2126 “APC Up / Down Alarm” occurs

APC Changer Up
Check: X11.6(APUP.M) –SX81 APC Up Check On
O.K ? No
X11.7(APDN.M) –SX82 APC Down Check Off
Yes
Go To “A”
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 HP 5100 HP51APCE26

Pallet 1 Position ? Go To “1”

No

Yes
3-1 APC 180 CW Rotation ▪ Output: Y39.0(PCW.R) –YV73 APC 180 CW Rot. On
▪ Completed: X11.2(PNO2.M) –SX76 Pallet No2
On
Detection
`★ AL 2127 APC Changer 180 CW/CCW Alarm”
APC 180 CW On
Rotation End O.K ? occurs On
Check: X11.2(PNO2.M)-SX76 Pallet No2 Detection Off
Off
Yes
“2”

4 APC Changer Down ▪ Output: Y39.3(APDN.R) –YV76 APC Changer DownOn

▪ Completed: X11.7(APDN.M) –SX82 APC Down Check
On

★ AL 2126 APC Up/Down Alarm” occurs

APC Down O.K ? Check: X11.7(APDN.M) –SX82 APC Down CheckOn
No
X11.6(APUP.M) –SX81 APC Up Check Off
Yes
5 Pallet Clamp ▪ Output: Y7.2(PUCL.R) –YV62 Pallet Unclamp Off
▪ Completed: X10.0(PCL.M) –SP61 Pallet Clamp On

★ AL 2073 “B-Axis(Table) CL/UNCL SW Alarm”

Pallet Clamp O.K ? occurs
No On
Check: X10.0(PCL.M) –SP61 Pallet Clamp
Yes
Finish

“1”
Go To “A”

Check: X11.1(PNO1.M)-SX76 Pallet No1 Detection Off

Pallet 2 Position ?
No X11.2(PNO2.M)-SX75 Pallet NO2 Detection On

Yes
3-2 APC 180 CCW Rotation ▪ Output: Y39.1(PCCW.R) –YV74 APC 180 CCW Rot.On
▪ Completed: X11.1(PNO1.M) –SX75 Pallet No1
On
Detection
`★ AL 2127 APC Changer 180 CW/CCW Alarm”
APC 180 CCW On
occurs On
Rotation End O.K ?
Check: X11.1(PNO1.M)-SX75 Pallet No1 Detection Off
Off
Yes
Go To “2”
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HP 5100 HP51APCE26

■ Sequence Conditions for Manual Step-by-Step Operation

① Pallet Unclamp (K26.4, M79)

▪ Output Signal: Y7.2(PUL.R) = 1 ▪ Completion Signal: X10.0(PCL.M) = 0
1) From the main OP, turn the mode switch to (“Jog” or “Handle” mode)
2) APC Manual Mode (X16.7 = 1)
3) From the “CUSTOM WINDOW” screen of the main OP, ensure the “APC ON” option
and select “Pallet Unclamp”
4) APC OP Manual Start (X16.4 = 1) or “CYCLE START” (X32.5 = 1)

② APC Changer Up (K25.2)

▪ Output Signal: Y39.2(APUP.R) = 1 ▪ Completion signal: X10.0(APUP.M) = 1
1) Set-Up Door Close (X5.4 = 0)
2) Operator Door Close Confirm (X17.6, X5.3 = 1)
3) Y,Z,B Axis APC Position (Y,Z Axis 2nd Ref, B axis Ref. or K25.0(APC Rotation Keep)
4) APC Down Check (X11.7 = 1)
5) Pallet Unclamp (X10.0 = 0, Y7.2 = 1)
6) From the main OP, turn the mode switch to (“Jog” or “Handle” mode)
7) APC Manual Mode (X16.7 = 1)
8) From the “CUSTOM WINDOW” screen of the main OP, ensure the “APC ON” option
and select “APC Changer Up”
9) APC OP Manual Start (X16.4 = 1) or “CYCLE START” (X32.5 = 1)

③-1 APC 180 CW Rotation (K25.4)

▪ Output Signal: Y39.0(PCW.R) =1 ▪ Completion Signal: X11.2(PNO2.M) = 1
1) Set-Up Door Close (X5.4 = 0)
2) Operator Door Close Confirm (X17.6, X5.3 = 1)
3) APC 180CCW Position(X11.1 = 1, X11.2 = 0 or K25.0 = 1)
4) APC Up Check (X11.6 = 1)
5) From the main OP, turn the mode switch to (“Jog” or “Handle” mode)
6) APC Manual Mode (X16.7 = 1)
7) From the “CUSTOM WINDOW” screen of the main OP, ensure the “APC ON” option
and select “APC 180 CW Rotation”
8) APC OP Manual Start (X16.4 = 1) or “CYCLE START” (X32.5 = 1)

③-2 APC 180 CCW Rotation (K25.5)

▪ Output Signal: Y39.1(PCCW.R) =1 ▪ Completion Signal: X11.1(PNO1.M) = 1
1) Set-Up Door Close (X5.4 = 0)
2) Operator Door Close Confirm (X17.6, X5.3 = 1)
3) APC 180CW Position(X11.1 = 0, X11.2 = 2 or K25.0 = 1)

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4) APC Up Check (X11.6 = 1)

5) From the main OP, turn the mode switch to (“Jog” or “Handle” mode)
6) APC Manual Mode (X16.7 = 1)
7) From the “CUSTOM WINDOW” screen of the main OP, ensure the “APC ON” option
and select “APC 180 CCW Rotation”
8) APC OP Manual Start (X16.4 = 1) or “CYCLE START” (X32.5 = 1)

④ APC Changer Down (K25.3)

▪ Output Signal: Y39.3(APDN.R) = 1 ▪ Completion Signal: X11.7(APDN.M) =1
nd
1) Y,Z,B Axis APC Position (Y,Z Axis 2 Ref, B axis Ref or K25.0(APC Rotation Keep)
2) APC Changer CW or CCW Position(X11.1 = 1 or X11.2 = 1)
3) Pallet Unclamp (X10.0 = 0, Y7.2 = 1)
4) From the main OP, turn the mode switch to (“Jog” or “Handle” mode)
5) APC Manual Mode (X16.7 = 1)
6) From the “CUSTOM WINDOW” screen of the main OP, ensure the “APC ON” option
and select “APC Changer Down”
7) APC OP Manual Start (X16.4 = 1) or “CYCLE START” (X32.5 = 1)

⑤ Pallet Clamp (Keep : K26.4)

▪ Output Signal: Y7.2(PUCL.R) = 0 ▪ Completion Signal: X10.0(PCL.M) =1
1) APC Down Check (X11.7 = 1)
2) From the main OP, turn the mode switch to (“Jog” or “Handle” mode)
3) APC Manual Mode (X16.7 = 1)
4) From the “CUSTOM WINDOW” screen of the main OP, ensure the “APC ON” option
and select “Pallet Clamp”
5) APC OP Manual Start (X16.4 = 1) or “CYCLE START” (X32.5 = 1)

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HP 5100 HP51APCE26

Revision History
APC Troubleshooting HP 5100
Version Year/Month Revision history Created by

01 2012. 06 Created a draft (HP51APCE26) Jung, Sam Young

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