080

Navigate to SYSTEM > PMC > PMC SIGNAL TRACE and monitor ATC ready signal addresses (typically G54.0-G54.7 range). Check for ATC-READY, MAGAZINE-IN-POSITION, ARM-AT-ORIGIN signals while cycling through manual ATC operations.

Perform manual ATC origin return using the machine MPG panel or MDI mode. Execute M06 or manufacturer-specific origin return M-code (often M60 or custom macro) to index the tool changer to home position.

Ensure no tool is in the spindle or ATC gripper before performing origin return to prevent collisions.

Check ATC position detection switches using DIAGNOSIS screen > #700-#799 (machine builder specific diagnostic addresses). Verify dog cams or proximity sensors for arm rotation, magazine index, and vertical position are functioning and adjusted correctly.

Verify parameters related to ATC reference position: Check Parameter 6000-series (machine builder ATC parameters). Confirm reference position data has not been lost due to battery failure or encoder issues.

Access PMC ladder diagram: SYSTEM > PMC > PMC LADDER DISPLAY. Search for coil output signal *ATCRDY or equivalent (address varies by machine builder, typically R address). Trace back through logic to identify which contact is open/preventing ready signal.

Check PMC input signals: SYSTEM > PMC > PMC I/O SCREEN > INPUT (X addresses). Verify all safety interlocks: door closed (X____), air pressure switch (X____), hydraulic pressure (X____), tool unclamped sensor (X____) are showing correct states (typically X=1 for ready condition).

Monitor PMC keep relays and timers: SYSTEM > PMC > PMC SIGNAL TRACE > K-RELAYS. Check for stuck timers (T addresses) or sequence step failures (K addresses) that may hold the ATC in not-ready state even after physical conditions are met.

Review machine pneumatic/hydraulic pressure at source. Verify air pressure at 5-6 bar minimum at regulator and check hydraulic unit pressure gauge. Low pressure commonly prevents ATC ready signal even if pressure switch shows marginal ON state.

Do not bypass pressure switches or safety interlocks as this creates unsafe tool change conditions and potential spindle damage.

Physically inspect all ATC limit switches and proximity sensors for mechanical damage, contamination by coolant/chips, or loose mounting. Check sensor LED indicators (if equipped) while manually rotating ATC through positions.

Set machine to EMERGENCY STOP and enable AXIS LOCK before manually rotating ATC components to prevent unexpected motion.

Test individual sensor inputs using multimeter or SYSTEM > PMC > I/O DIAGNOSIS screen. Trigger each sensor manually and observe corresponding X-address input change. For inductive proximity sensors, verify 10-30VDC supply voltage at sensor connector.

Check sensor wiring continuity from machine terminal block back to PMC I/O modules. Reference machine electrical schematic to identify correct X-address terminal assignments. Look for damaged cables in cable carriers that flex during ATC rotation.

If sensors are confirmed functional but ATC still not ready, verify dog cam positioning and sensor gap clearance (typically 1-3mm for inductive sensors). Adjust sensor mounting or dog position per machine manufacturer specifications and re-test ATC cycle.