This section outlines the process for powering up and the zero return process on the DC-Series machines.

If all the axes have a zero position set, you can move the X, Y, and Z axes to their home position. On the Haas control pendent, use the following command to bring of the zero return page shown in the image:

[Z]+[zero return]+[single].

Inside the window you can set the zero for each axis independently by highlighting the axis and pressing [F2] [1].

Warning: Pressing [F2] with the Z-axis highlighted will set the zero position at the current position. 

To move an axis to the current zero position, press [F3] [5] to send the axis home at the selected rapid.

You can also unzero an axis by highlighting the axis and pressing [UNDO] [2].

Note: The [UNDO] option is only visible with a service key.

The green check mark [3] in the Zero Return Status window indicates that the axis has been zeroed. A yellow caution icon [4] indicates that the axis is not zeroed.

This section shows how to load tools into the carousel and operate tool changes. To load tools in the spindle they first must be loaded into the tool carousel.

Both DC-1 and DC-2 machines can be purchased as 30 taper or 40 taper machines. The tool changers vary slightly between the 30 and 40 taper versions.

To load tools, Press P{pocket_number}  to select what tool pocket you want to load the tool into. Then press [ATC FWD] on the control pendant to have the tool carousel change pocket positions. 

Tools can only be loaded into the side pocket as shown in the image [1]. Calling the P command in a program will bring the specified pocket to the side. 

Example: Calling P6, then ATC FWD will bring pocket 6 to the side as shown in the image.

When loading tools into the side pocket, make sure the tools are oriented with the cutout [1] facing the front of the tool carousel. This orientation allows the tool to be loaded correctly into the spindle

NOTE: The correct tool orientation is shown in image [2]

Tools can only be loaded into the right side pocket [1]. This pocket has room to slide tools into position. Once you orient the tool, lock it into the pocket by pulling it towards the front door

Make sure the spindle is in its orient position. This is where the spindle dog is closest to the front of the machine and the spindle dogs are parallel to the Y-axis.

To do this, press [Current Commands] and go to the Devices tab and then the Mechanisms window [1].

Type "Main Spindle" and then press [F1] [2] to search for the Main Spindle Orient device.

Press [F2] [3] to move the spindle to it's orient position.

When you first press [Recovery] you can choose [A] for automatic recovery, or [Z] for zero axes [1]. This section will show navigating the zero axes option.

The zero axes option allows to you to change the the zero position for the TT-axis and the Z-axis.

Note: You don't change any offset values in this process, it allows to select a new zero position using the existing offset values.

After pressing [Z] to change the zero position for either the TT-axis or Z-axis, you will see the screen shown in the image.

Note: When you press [Z] there will be no motion from any of the axes, this button does not move either of the axes to their current zero position.

Answer the question [Y] [1] or [N] [2] depending on if there are any tools present in the carousel or the spindle.

Note: You can also exit the Zero Axes section by pressing [E] [3] if you think it isn't needed to change the zero, or if you want to change back to Automatic Recovery.

If you answered [Y] to there being tools in the carousel or spindle, then you will be asked whether the Z-axis is above the tool unclamp position.

The tool unclamp position is above the Z-axis zero position and is essentially where the spindle dogs [1] are about to make contact the slot in the tool pocket [2]. 

Note: If there is a tool clamped in the spindle then your Z-axis is below the tool unclamp position. You cannot have a tool in the spindle and be above the tool unclamp.

Answer the question [Y] [3] or [N] [4] depending on your Z-axis position.

Only if Z-axis is at or above unclamp position:

If you were above the unclamp position and answered [Y] then you will have to jog the Z-axis up high enough so that the spindle clears the pullstuds [1] of the tools in other pockets.

Once the Z-axis is high enough press [C] to continue to the next step of setting the zero positions.

Only if Z-axis is below unclamp position:

If you were below the unclamp position and answered [N] then you will have to jog the Z-axis down from the zero position at least 6.5" so that the spindle head clears the pull studs of the tools in other pockets.

Note: The zero position is roughly above where the arrow on the left [1] is aligned with the arrow on the right [2].

Once the Z-axis is low enough press [C] to continue to the next step of setting the zero positions.

Important: If the TT-axis zero position does not need to be reset, and you just want to skip to setting the Z-axis zero position, press [C] to continue to the next page. Skip to Step 7 in this section for setting Z-axis Zero position.

Once the Z-axis is in a safe position, (either high enough or low enough to allow for carousel rotation) you can jog the carousel (TT-axis).

Press [Insert] [4] to switch to the carousel axis.

Use the left [2] and right [3] arrow keys on the control so that you can bump jog the carousel to the correct position.

Once the carousel looks to be in the correct spot where the bottom of the pocket in line with the spindle is parallel with the table, press [F2] [1] to go back to the zero return menu.

Press [F3] [5] to set the zero position for the TT-axis.

Important: When you press [F3] you should expect to see the carousel rotate clockwise slightly (1-2 degrees) and then rotate back counterclockwise about the same amount.

After you press [F3] to set the zero position, the Tool changer Status should say Pocket 1 [1].

Note: It may say a different pocket than pocket 1. It's important that the pocket number [1] matches the tool number [2].

The current position for the TT axis is now the zero position.  Press [C] [3] to continue to setting the Z-axis zero position.

Press [F2] to toggle to the jog window [3].

Jog the Z-axis so that the arrow decals are aligned.

You can also align the arrows so that the arrow on the spindle head [1] is an 1/8"-1/4" above the arrow on the back enclosure [2].

Once the Z-axis is in position, toggle out of the jog window and then press [F3] [4] to set the Z-axis zero position.

Note: When [F3] is pressed, you should expect to see the Z-axis drop down slightly, and then move back up.

If the Z-axis behaved as expected press [C] [5] to continue.

Both axes should now be at their correct zero position.

The correct zero position for the carousel is where the bottom of the tool pocket in line with the spindle is sitting parallel to the table.

Note: If you wanted to check if it were parallel, use an indicator to check from position [1] to [2] on the face of the pocket. The two positions should be within 0.0005" of each other when jogging along the X-axis.

The correct zero position for the Z-axis is where the arrow on the spindle head is about a 1/2" above the arrow on the enclosure as shown in the image.

Press the [Recover] button on the Haas Control to enter Tool Changer Recovery.

The Tool Changer Status window [1] shows the current condition of the Z-axis and Tool Carousel.

In this scenario, the status window has:

• Carousel - Off Position [2]
• Z-axis -  Home Position [3]
• Tool Changer - Tool 1 [4]

Press [A] [5] for Automatic Recovery.

The next window will ask if you have any tool in the spindle or in the carousel. 

Important: Selecting No [N] [2] at this point will result in the machine doing an automatic tool change to recover. This may result in a dropped tool or a crash if there are tools in the spindle or carousel. Only select [N] if you want the machine to automatically do a tool change.

Answer the question either pressing Yes [Y] [1] or No [N] [2].

Follow the instructions on the screen.

The Z-axis needs to be at least 6.5" (165mm) [1] below the Z-axis zero position which is where the arrows on the right side of the spindle head and enclosure are aligned.

Note: If the Z-axis isn't moved down, then tool holders will hit the spindle head when the carousel is rotated. This could damage the pocket fingers holding the tools.

To jog the Z-axis make sure to press [Handle Jog] and then select the Z-axis. Jog it down so that the carousel can be rotated without risk of collision. 

The image shows a safe position for the Z-axis to start jogging the TT-axis.

Press [C] [2] to Continue to the next step once the Z-axis is jogged down.

Next the tool carousel (TT-axis) needs to be jogged so that the pocket that shows in the Tool changer Status window [1] for the Tool Changer - {Tool}.

In the image shown, the Tool Changer is showing Tool 1 [2] so that means that pocket 1 needs to be used to align with the spindle. If it showed Tool 7, then you would use pocket 7 to align with the spindle.

To jog the carousel you can press [TT]+[Handle Jog] or use the arrow keys to rotate the carousel.

Note: If there is a tool in the pocket that needs to be aligned with the spindle, remove the tool from the pocket.

Jog the TT-axis until the Tool Changer Status [1] reads:

• Carousel - At Pocket [3]

Press [C] to continue only when it reads "At Pocket". If it reads "Pocket #" or "Moving" then the carousel needs to still be jogged.

In this scenario the Tool Changer Recovery Page will look like the image. The Tool Changer Status window [1] will show:

• Carousel - No Zero [2]
• Z-axis - Home Position
• Tool Changer - Tool 1

Press [A] [3] to enter Automatic Recovery and then follow the remaining steps in this section.

Note: Make sure to read the warnings on the Recovery pages. Take precautions to protect against dropping tools if you aren't familiar with the process.

Important: If you have tools in the spindle or the carousel, do these steps before continuing with the on-screen instructions. If there are no tools, skip to step 6 below and follow the instructions on the recovery page.

There are images showing the different positions that the Z-axis might be at and the correct position to jog the Z-axis in each scenario.

Note: To jog the Z-axis on this screen you can press [Handle Jog] and then select the Z-axis.

When Recovery asks you "Is Z-axis above tool unclamp position?", the unclamp position is shown in the image.

The unclamp position is when the spindle dog [1] is sitting in the tool pocket slot [2]. If you are at or above that position you should answer [Y] [3]. If you are below that position then you should answer [N] [4].

Tool in Spindle/Carousel and Z-axis is below Tool Unclamp Position [1]

• Jog the Z-axis down 6.5" (165mm) below the Z-axis zero position [2]. The zero position is roughly where the decals on the spindle head and the back enclosure are aligned.
• To get a tool out of the spindle, align an empty pocket with the spindle and slowly jog the Z-axis up. You have to jog the Z-axis above the zero position until the tool pocket fingers grab the tool from the spindle and the drawbar is released.
• Remove the tool from the pocket once it is out of the spindle.
• Align pocket 1 with the spindle and press Continue [C] and follow the next steps.

Tools in Spindle/Carousel and Z-axis is at or above Tool Unclamp Position [5]

• Jog the Z-axis up close to the top of travel which is about 4" (95mm) above the Z-axis zero position. The zero is roughly where the arrow decals [1] and [2] shown in the image would be aligned.
• Note: The Z-axis is jogged up so that the pullstuds of the tools [3] do not hit the spindle head [4] when the carousel is rotated.
• Jog the carousel (TT-axis) so that pocket 1 is aligned with the spindle. Make sure that pocket 1 is empty.
• If there is a tool in the spindle place something underneath the spindle to catch the tool just in case it is dropped.
• Slowly jog the Z-axis down to it's zero position. Go slow since to get to the Z-axis zero the tool will be transfered from the spindle to the tool pocket.
• Remove the tool from pocket 1 if there was one transferred from the spindle.
• Jog the Z-axis down to the zero position until the Z-axis status says "OK" and that Pocket 1 is aligned with the spindle. Then press [C] to continue with the recovery.

There are no tools in the spindle or the carousel

• Jog the Z-axis to about 6.5" (165mm) below the Z-axis zero position. The zero position is roughly where the arrow decals [1] and [2] are aligned as shown in the image. Jog 6.5" below that position.
• Jog the carousel (TT-axis) so that pocket 1 is aligned with the spindle. Make sure pocket 1 is empty.
• Check that the Tool Changer Status window reads Ok and then press [C] to continue through recovery.

Verify that pocket 1 is aligned with the spindle at this point.

Also, the tool pocket will be aligned properly if it is completely flat withe the X-axis travel. To check this, use and indicator and sweep across the face of the tool pocket. 

The pocket when indicating from the right side [1] to the left side [2] should be within 0.0005". Jog the carousel as needed to be within this tolerance.

Once you have pocket 1 aligned to with the spindle, press [Zero Return] to exit jog mode. Then press [F3] [3] to zero the TT-axis at the current position. 

Check to see that the Tool Changer Status now says:

• Carousel - At Pocket [4]
• Z-axis - OK [5]
• Tool Changer - Tool 1 [6]

Press [C] [7] to Continue with recovery.

After you press Continue [C] the Tool Changer Recovery window will ask if you want to verify with a tool change at 25%.

Before doing the test tool change, check the following things:

1. Is the spindle is in it's orient position? It should have the spindle dogs in line with the Y-axis.
2. Does the carousel pocket look like it is aligned with the spindle?

If everything looks aligned, then you can run a tool change at 25%. If you want to run a tool change at 5% press [E] to Exit recovery and then change the rapid to 5%.

In this scenario the Tool Changer Recovery Page will look like the image. The Tool Changer Status window [1] will show:

• Carousel - At Pocket
• Z-axis - No Zero [2]
• Tool Changer - Tool 1

Press [A] [3] to enter Automatic Recovery and then follow the remaining steps in this section.

Note: Make sure to read the warnings on the Recovery pages. Take precautions to protect against dropping tools if you aren't familiar with the process.

The Z-axis needs to be jogged to it's zero position. The zero position is roughly where the red arrow decal on the spindle head [1] and the arrow decal on the rear enclosure panel [2] are aligned to each other.

Press [Z] + [Handle Jog] to jog the Z-axis. 

Note: You can also press [F2] [3] to switch back and forth from the jogging window.

Once you have the arrow decals aligned as best as possible, press [F3] [4] to set the Z-axis zero position at the current location.

The Tool Changer Status window will then show Home Position for the Z-axis. Press [C] [5] to continue to the next step.

After you press Continue [C] the Tool Changer Recovery window will ask if you want to verify with a tool change at 25%.

Before doing the test tool change, check the following things:

1. Is the spindle is in it's orient position? It should have the spindle dogs in line with the Y-axis.
2. Does the carousel pocket look like it is aligned with the spindle?

If everything looks aligned, then you can run a tool change at 25%. If you want to run a tool change at 5% press [E] to Exit recovery and then change the rapid to 5%.

In this scenario the Tool Changer Status window [1] will look like what's shown in the image:

• Carousel - No Zero [2]
• Z-axis -  No Zero [3]
• Tool Changer - Tool 1

Press [A] [4] to enter Automatic Recovery and then follow the remaining steps in this section.

Note: Make sure to read the warnings on the Recovery pages. Take precautions to protect against dropping tools if you aren't familiar with the process.

The next page in recovery will ask if there are any tools present in the spindle or the carousel.

If there are any tools press [Y] [1] for yes. Then continue to Step 3 in these instructions.

If there are no tools in the carousel or spindle, press [N] [2] for no. If you answer no skip to step 6 in these instructions.

Note: It is easier to go through recovery with no tools in the carousel. If there is no tool in the spindle then you can remove the back cover from the tool changer and manually pull all the tools out of the carousel. If there is a tool in the spindle then you must answer Yes.

Only if there is tools in the spindle/carousel

The recovery page will then ask "Is the Z-axis above the tool unclamp position?"

The left image shows what is meant as the tool unclamp position. The Z-axis is above the tool unclamp position when the spindle dog [1] is sitting in the tool pocket slot [2]. Answer [Y] [3] if you are at or above this position, and answer [N] [4] if you are not.

Note: The purpose of this question is to determine if you need to jog the Z-axis up or down to be at a safe location. You need the Z-axis to be at a safe location before you can jog the carousel (TT-axis).

Anything below the position shown is considered below the tool unclamp position.

Answer [Y] [3] if the z-axis is at or above the position shown in the left image. Answer [N] [4] if the Z-axis is at or below the position shown in the right image.

If you answered Yes, continue to step 4. If you answered No, then skip to step 5 in these instructions.

Only if Z-axis is above the tool unclamp position

Since the Z-axis is above the tool unclamp position the safe position to jog the Z-axis is at the top of Z-axis travel. This is about 4" (95mm) above where the arrow decals on the spindle head and sheet metal align.

Important: The safe position is shown in the image. The Z-axis needs to be high enough so that the pull studs of the tool holders [1] will not hit the spindle head [2] when the carousel rotates.

The image shows a position where the Z-axis is too low on the left and the correct position to jog the Z-axis to on the right.

Note: If you were to jog the carousel (TT-axis) with the Z-axis in the position shown in the left image, the tool holder would crash into the spindle as shown.

Once the Z-axis is jogged all the way to the safe position, press [C] on the recovery page and continue to step 6 in this section.

Only if Z-axis is Below Tool Unclamp Postion

Warning: Before jogging the the Z-axis down, make sure the pocket in line with the spindle is empty and that the pocket is roughly aligned. This will prevent the spindle dogs from colliding with the edges of a tool pocket. you can enter [TT]+[Handle Jog] to jog the carousel.

If you answered No to "Is the Z-axis above the tool unclamp position" the Z-axis needs to be jogged down 6.5" (165mm) from the zero position (where the arrow decals are aligned).

Note: 6.5" below the home position is is the safe position where the tool holders cannot hit the spindle head. If the Z-axis is not jogged down far enough there is a risk of collision when the carousel (TT-axis) is jogged.

The image shows the approximate safe position for the Z-axis. Jog down as far as needed to feel confident that the tool holders will not hit the spindle head.

Once the Z-axis is jogged low enough so that the carousel can be jogged without risk of collision, press [C] [2] to continue to the next step.

At this point the Z-axis should be in a "safe position" which depending on the the circumstances is either at the top of Z-axis travel (step 4) or at least 6.5"(165mm) below the Z-axis zero position.

Make sure that pocket 1 is empty. If needed you can jog the the carousel (TT-axis) to the tool loading position to remove the tool and then jog the carousel back so that tool 1 is aligned with the spindle.

Note: If the rear plastic cover of the carousel is removed you can unload tools from any pocket regardless of position.

Once you have pocket 1 roughly aligned, jog the Z-axis back up passed the Z-axis zero position to where the tool pocket is pulled underneath the spindle [3].

Make fine adjustments jogging the carousel so that when you use an indicator on the face of the tool pocket, the left side of the pocket [2] is within 0.0005" of the right side of the pocket [1].

Once the pocket is within 0.0005" press [C] to continue to the next recovery step.

Once Pocket 1 is aligned as mentioned in the previous step, press [Handle Jog] and then press [F3] [1] on the control to set the Carousel zero position.

You can confirm that it was set by looking at the Tool Changer Status window. The window should read:

• Carousel - At Pocket [2]
• Z-Axis - No Zero
• Tool Changer - Tool 1 [3]

Once the Tool Changer Status window matches what is expected, press [C] [4] to continue to zeroing the Z-axis.

Press [F2] [3] to toggle to the jog window.

Press [Z]+[Handle Jog] to jog the Z-axis.

The Z-axis needs to be jogged to it's zero position. The zero position is roughly where the red arrow decal on the spindle head [1] and the arrow decal on the rear enclosure panel [2] are aligned to each other.

Once you have the arrow decals aligned as best as possible, press [Zero Return] to switch out jog mode and press [F3] [4] to set the Z-axis zero position at the current location.

The Tool Changer Status window will then show Home Position [5] for the Z-axis. Press [C] to continue to the next step.

After you press Continue [C] the Tool Changer Recovery window will ask if you want to verify with a tool change at 25%.

Before doing the test tool change, check the following things:

1. Is the spindle is in it's orient position? It should have the spindle dogs in line with the Y-axis.
2. Does the carousel pocket look like it is aligned with the spindle?

If everything looks aligned, then you can run a tool change at 25%. If you want to run a tool change at 5% press [E] to Exit recovery and then change the rapid to 5%.

This section shows how to troubleshoot common issues found with the DC-Series Tool Carousel.

Forcing Recovery WITHOUT a Service Key

You can reset the zero position for the Z-axis and TT-axis directly through the recovery page. 

When you first enter the recovery page you see a screen as shown in the image.

Press [Z] [1] to start the Zero Axes option. This will allow you to start the process of changing the zero position for either axis. Follow the Zero Axes section in the Tool Changer Recovery - 5.3 section in the manual.

Forcing Recovery WITH a Service Key

You can force recovery on the DC-Series machines with a service key by doing the following:

1. Press [Z]+[Zero Return]+[Single] and that will bring up the window shown in the image.
2. Highlight the Z-axis [1] and press [Undo] [2] to unzero the Z-axis.
3. Press [Recover] and try to reset the zero position again.

Note: The yellow caution icon [3] indicates that the axis does not have a zero position set. A green check mark indicates that the axis has a zero position.

When resetting the zero position this time, make sure to jog the Z-axis up so that the arrow on the spindle head is about 1/8-1/4" above the arrow on the enclosure as shown in the image.

Follow the steps in recovery for setting the Z-axis zero position.

Note: You can use either the Zero Axes option or Automatic recovery option. If you use Automatic recovery you do not need to change any alignment using [F4].

DC-1/2 30 Taper Machines:

The DC-1 tool carousel motor is a sigma7 size 04 motor. The pinout for he phases looks different than other axis motors.

This image shows the pins on the motor connector:

1. Gnd
2. Phase A 
3. Phase B 
4. Phase C

NOTE: The Gnd pin [1] should be longer than the other pins as shown in the image.

Check the resistance between the phases. Resistance should be 4.2 Ohms between each phase. 

Refer to the Servo Motor and Axis Cables TSG for more details on checking the motor for shorts.

Turn the spindle so that the spindle dogs are in line with the Y-axis.

Place the mag base on the table and use an indicator to check if the dogs are parallel with the Y-axis.

Indicate from the front dog [1] to the rear dog [2] by jogging the machine in the Y-axis. 

Note: Align the spindle so that the error when sweeping with an indicator is 0.001" or less. 

Once you have the spindle oriented so that there is less than 0.001" error between the dogs and the Y-axis, go to the Factory tab on the Parameters window.

Search for parameter 30.085 [1] which is the Spindle Orientation Offset parameter.

Highlight the parameter as shown in the image.

Press [E-Stop] on the pendant.

Press [S] + [F3] [2] to set the spindle orientation offset to the current position.

The value should populate for the parameter.

Go to Current Commands -> Devices -> Mechanisms [1] and then search for "Main Spindle" [2] and press [F1].

Press [F2] to orient the spindle so the offset position.

Repeat Step 1 and use the indicator to check whether the spindle orientation was set to the correct position. 

If the error between spindle dogs is greater than 0.001" then incrementally change the 30.085 parameter by 0.250 degrees or less until the orient position aligns the dogs within spec of 0.001".

Use the indicator to check whether the spindle orientation was set to the correct position. 

Jog the Y-axis of the machine and check the error between the front spindle dog [1] and the rear dog [2].

If the error between spindle dogs is greater than 0.001" then incrementally change the 30.085 parameter by +/-0.250 degrees or less until the orient position aligns the dogs within spec of 0.001".

Note: If adjusting the parameter by +/-0.250 degrees resulted in the error between spindle dogs changing from positive to negative, use an increment smaller than +/-0.250 degrees when changing the parameter value. For example try adjusting by +/-0.125 degrees instead.

Once you change this parameter repeat this section until the orient position correct.

Before Starting TT-axis Alignment

Remove the front [1] and rear [2] covers of the tool carousel.

The front cover [1] is held in position by metric SHCS accessible from the front of the machine.

Note: When you remove the front cover make sure there is a mark on tool pocket 1 of the carousel. If there is not, mark the carousel [3] so you know how to orient the cover when it is reinstalled.

The rear cover is mounted by metric SHCS and the side windows of the machine may have to be removed to gain access to the screws. 

Remove all tools from the carousel. With the covers off you can remove tools from any pocket.

Warning: If there is a tool stuck in the spindle, it can only be removed by transferring it to the carousel pocket. Don't try and remove the tool from the spindle until you are confident that a pocket is going to grab the tool when the draw bar is released. Place something under the spindle to catch the tool in case it is dropped.

Before Starting TT-axis Alignment

Press [Current Commands] and navigate to the Mechanisms [1] page inside of the Devices window.

Search for Main Spindle [2] and then press [F1] to search for it.

Press [F2] [3] to move the spindle to it's orientation offset based on it's spindle orientation offset parameter (30.085). Refer to the Set Spindle Orientation Offset section for how to set this parameter.

Once all tools are removed from the spindle and carousel start by pressing the [Recover] button on the Haas control to enter into Tool Changer Recovery.

Press [A] [1] for Automatic Recovery.

When asked "Are there any tools present" answer [N] [2] since all tools were removed in the previous step.

Press [Handle Jog] and jog the Z-axis up high enough so that the spindle [1] is above the carousel [2].

At this point the carousel will be pulled fully underneath the spindle as shown in the image. The Z-axis is high enough when the carousel no longer moves as you jog the Z-axis up.

The bottom of the pocket will be flat [3] once the spindle is high enough.

Jog the TT-axis so that pocket 1 is under the spindle is sitting flat parallel to the X-axis of the machine [1].

Put the mag base on the table and bring the indicator up to the pocket under the spindle.

Jog the X-axis so that the indicator moves across the bottom of the pocket from the left side [2] to the right side [3].

If the indicator shows more than 0.0005" difference from the left side of the pocket to the right, then jog the carousel so that the pocket is sitting flat.

Once there is less than 0.0005" difference between the edges of the pocket you can move to the next step.

Jog the table away from the tool carousel so the indicator is clear of the tool carousel press the [Zero Return] button.

Press [F3] [1] to set the initial zero position for the TT-axis. 

When you press [F3] the carousel should rotate clockwise a few degrees. The tool pocket will no longer be sitting parallel with the X-axis. This is expected.

Press [E] [2] twice to exit recovery.

Keep the Carousel in the same position.

Navigate to the Factory tab in the Parameters window.

Search for parameter 9.140 - TT-axis Grid Offset.

Highlight the parameter [1] and press [TT] + [F4] [2] to set the parameter.

Press [Y] to confirm setting the parameter. The value should populate for the parameter.

Note: The carousel should not have been moved from the position it moved to in the previous step.

Go back into recovery and answer the questions until you get to the screen shown in the image.

Press [F2] to switch to jog mode. Jog the TT-axis so that the pocket in line with the spindle is sitting flat. 

Note: You do not need to indicate the pocket at this time to make sure it is within 0.0005" from one side to the other. Jog the TT-axis so that the pocket visually looks flat as shown in the image.

Once the pocket face looks flat, press [F2] [1] to switch back to recover mode and then press [F3] [2] to set the zero position for the TT-axis. 

The carousel will rotate clockwise and then rotate back slightly counterclockwise.

Press [F2] [1] to toggle back to jog mode.

Jog the TT-axis so that the pocket under the spindle is sitting flat.

Use the indicator and sweep from the left side of the pocket [1] to the right side [2].

Jog the TT-axis until the pocket is flat within 0.0005" on the left and right sides.

Once you have the pocket in line with the spindle flat, press [E] twice to exit recovery.

Go to the factory tab in parameters and search for parameter 9.078 - TT-axis Tool Change Offset [3].

Highlight the parameter and then press [TT] + [F2] [4] to set the parameter value. The value should populate for the parameter.

Since you just changed the offset value you need to set the zero position for the TT-axis again.

Press [Recover] to go into recovery. Answer the questions until you get to the page shown in the image to set the carousel zero position.

Visually check that the bottom of pocket 1 looks flat [1].

Note: The carousel should be flat since it is still in the same position as where you set the offset in the previous step. You shouldn't have to jog the carousel.

Press [F3] [2] to set the zero position for the carousel. The carousel will rotate clockwise, but then will rotate back counterclockwise to the position you set as the zero position.

Press [E] [3] twice to exit recovery.

Make sure the spindle is in it's orientation offset position.

To do this, press [Current Commands] and go to the Devices tab and then the Mechanisms window [1].

Type "Main Spindle" and then press [F1] [2] to search for the Main Spindle Orient.

Press [F2] [3] to move the spindle to it's orient position.

Press the [Recover] button to go into recovery.

Press [Z] [1] to go into the Zero Axes page.

Note: Use the Zero Axes option since we are just going to be jogging the Z-axis up and down. If you are not in recovery you cannot jog the Z-axis above it's zero position.

Answer the questions until you get to the Zero Carousel page that is shown in the image.

Press [F2] [2] so that you can jog the Z-axis.

Note: Do not jog the TT-axis, make sure to keep the TT-axis at it's zero position.

Select the Z-axis to jog and continue to the next step.

Start with the Z-axis above the carousel as shown in the left image of the picture.

Jog the Z-axis down and watch to see how the spindle dog [1] engages with the tool pocket [2].

The dog should fit in the slot without contacting the edges of the pocket.

If the spindle dog does hit the edges, either the spindle orient is not parallel with the Y-axis or the TT-axis zero position is not parallel with the X-axis.

Use the indicator to determine if spindle or TT-axis needs to be adjusted. Refer to the sections above for how to adjust the parameters.

Note: While in recovery the spindle may rotate. Watch the first time the dogs meet the tool pocket to see the engagement. If you suspect the spindle dog rotated to self align, exit recovery and re-orient the spindle through Current Commands.

If the spindle dogs engage smoothly with the pocket and don't hit the edges then the TT-axis and spindle are aligned correctly. Press [E] twice to exit recovery.

Continue to setting the Z-axis alignment if needed.

Before Starting Z-axis Alignment

Change Setting 9 - Dimensioning to mm instead of inch.

Remove the front [1] and rear [2] covers of the tool carousel.

Important: Make sure there is no tool in the spindle at this point.

The front cover [1] is held in position by metric SHCS accessible from the front of the machine.

Note: When you remove the front cover make sure there is a mark on tool pocket 1 of the carousel. If there is not, mark the carousel [3] so you know how to orient the cover when it is reinstalled.

The rear cover is mounted by metric SHCS and the side windows of the machine may have to be removed to gain access to the screws. 

Remove all tools from the carousel. With the covers off you can remove tools from any pocket.

Warning: If there is a tool stuck in the spindle, it can only be removed by transferring it to the carousel pocket. Don't try and remove the tool from the spindle until you are confident that a pocket is going to grab the tool when the draw bar is released. Place something under the spindle to catch the tool in case it is dropped.

To start aligning the Z-axis, press the [Recover] button to enter recovery.

Press [A] for Automatic Recovery.

Answer the questions about tools in the carousel. Continue until you get to the window shown in the image.

Press [F2] [1] to switch to jog mode.

Jog the Z-axis so that the arrow decal on the spindle head [2] is aligned with the arrow decal on the back enclosure panel [3].

Once the arrows are aligned, press [F2] [1] to switch out of jog mode. Then press [F3] [4] to set the zero position.

Note: The Z-axis will drop down until it finds the Z-channel signal of the motor. That is expected behavior at this point in the alignment process..

Press [E] [5] twice to exit recovery.

Keep the Z-axis in the same position that it dropped to in the previous step.

Navigate to the Factory tab in the Parameters tab.

Search for parameter 3.140 - Z-axis Grid Offset.

Highlight the parameter [1] and then press [Z] + [F4] [2] to set the grid offset parameter. 

Make sure that the value changes from zero to an actual value.

Once the parameter is set go back into recovery by pressing the [Recover] button.

Once in recovery, press [A] for Automatic recovery and answer the questions about tools in the carousel and continue until you get to the Zero Z-axis page as shown in the image.

Press [F2] [1] to jog the Z-axis up until the arrow decal on the spindle head [2] is lined up with the arrow decal on the back of the enclosure [3].

Once the arrows are lined up, press [F3] [4] to set the zero position.

When you press [F3] the Z-axis will drop as it did the last time, but this time the Z-axis should move back up slightly.

Once the Z-axis moves back up press [E] once to return to the Recovery main menu.

When on the main Recovery menu, press [Z] [1] to start the Zero Axes process. 

Note: This is so that you can jog the Z-axis in the positive direction passed the zero position that was just set in the previous step.

Answer the questions about tools in the carousel until you reach the screen for setting the Z-axis Zero position as shown in the image [2].

Press [F2] when on the page to switch to jog mode. Select the Z-axis for jogging.

Note: Look at the Machine Position for the Z-axis before you start jogging it. The position should be 0.000.

Jog the Z-axis up passed where the arrows align.

Continue jogging until the bottom of the carousel no longer moves backwards to get in line with the spindle [1].

Once the Z-axis is high enough and the carousel no longer moves in or out when jogging, position the indicator so that it is zeroed on the front face [2] of the pocket in line with the spindle.

Note: The indicator will be used to detect when the carousel starts to push forward as the Z-axis is jogged down. The carousel pushing forward is the same point where the draw bar releases the tool in spindle.

Slowly jog the Z-axis down so that the spindle is right above the carousel tool pocket.

Switch to the smallest jogging increments.

Continue jogging the Z-axis down [1] and watch the indicator for when the dial begins to change.

When you see the dial move a few tenths of an inch stop jogging and note the Machine Position [1] for the Z-axis. This indicates that the carousel is beginning to push forward [2].

Note: The machine position is going to be used to calculate the value for parameter 3.367 - Z-axis Zero Return Offset.

The calculation is:

Z-axis Zero Return Offset = 21mm - {Z-axis Machine Position}

For example, parameter 3.367 should be set to 1.733 if the Z-axis Machine Position was 19.267 as shown in the image [3].

Once you have calculated what the Z-axis Zero Return Offset value, press [E] twice to exit Recovery.

Navigate to the Factory tab in the Parameters window.

Search for parameter 3.367 which is the Z-axis Zero Return Offset.

Highlight the parameter [1].

Press [Emergency Stop] and enter the value that was calculated in the previous step.

Once the value populates the Value field [2] release the E-stop and clear the alarms.

Note: For example, in the image the value is set to -12.88mm. This means that the Z-axis Machine Position in the previous step was 33.88mm, since 21mm - 33.88mm results in -12.88mm. Make sure that you did the calculation correct and have the right sign.

Press [Recover] to start recovery.

Press [Z] for the Zero Axes option.

Answer the questions until you get to the window asking to ZERO Z AXIS as shown in the image [1].

Press [F2] [4] to switch to jog mode.

Jog the Z-axis so that the arrow decal on the spindle head [2] is lined up with the arrow decal on the back enclosure [3].

Press [F2]  [4] again to switch out of jog mode when the arrows are aligned.

Press [F3] [5] to set the zero position.

Note: The Z-axis should drop when you press [F3] and then the it will come back up higher than the position where the arrows are aligned. The arrow on the spindle head will be roughly aligned the arrow on the back enclosure panel.