Service Home How To Procedures Rotary Cable Management Kit - Installation - AD0530
Last updated: 01/06/2023

Rotary Cable Management Kit - Installation

AD0530

Rotary Cable Management Kit - Installation - AD0530

Introduction

1

This procedure will cover installing the rotary cable management kit, formerly the rotary retract kit. This kit keeps the conduit from rubbing on the way covers while jogging the mill.

Rotaries built after February 2022 that include rotary cable support either as a standard feature or an additional option will be shipped with the new style of cable management. 

Required Materials: 

  • Part number: ROTARY-CBL-SUPPORT.

Follow the link if you are looking for the ROTARY INSTALLATION PROCEDURE.

Follow this link if you are looking for the ROTARY TROUBLESHOOTING PROCEDURE.

WIPS Alarms:

  • Alarm 1101 PROBE STARTUP FAILURE 
  • Alarm 1092 UNEXPECTED SURFACE FOUND

If, after installing a rotary, you start getting either of the above alarms, the rotary, the retract kit, or the rotary cables may be the cause. These items may break the line of sight between the probe and the OMI or the Tool Setter and the OMI. 

To solve this problem, either move the cable retention kit so that the cables and spring don’t break the line sight or move the OMI to a location where the cables and spring will not be in the way. 

Installation

1

After the rotary is placed in the machine and secured to the table, have the machine zero return to home. 

Remove the zip ties and any other packaging on the rotary cables. 

Undo the two screws [1] holding the top part of the bracket [2]. Put the top part of the bracket to the side and route the rotary cables through the hole. Do not pull the cable tight, and be sure that the section of the cable in the enclosure has some slack. 

Note: The images in this procedure use the newest bracket. Machines from March 2022 and later will be compatible with this bracket. Older machines will need a different bracket with a different bolt pattern. 

 Warning: The next few steps may require getting fully in the machine. Be sure to take the proper lock-out tag-out precautions any time someone is in a machine. 

2

Place all the cables in the Rotary Cable support. This will require a 5/32 Allen wrench. The ribs in the clamp [1] are meant to fit into the ribs of the cable sleeve. This prevents the clamp from sliding up and down the rotary cable. 

Place the magnet and spring in such a way that there is some but very little slack in the cable. This extra slack will ensure that when the machine zero returns, it won’t pull on the cable or damage it. 

The large holes [2] are for the power cables. The medium side [3] holes below the large holes are for the scale cables. The smallest holes [4] are for the airlines.   

With the machine still in the front left and the retention spring installed, adjust the cable in, or out of the machine so there is a little slack between the clamp and the routing hole in the enclosure. 

3

Once the cable support assembly has been installed, move the X & Y axis to max travel in the negative and positive directions following the image.

Ensure the Mill table can jog in all directions without the support spring and rotary cables getting in the way or getting damaged. 

Below are descriptions of how the cable should be routed in the machine. 

Note: In the images below, the magnet is shown as being placed on the back panel of the mill's enclosure. It can also be placed on the top panel of the enclosure. 

Warning: The Rotary cables should not be dragged through chips as this will damage the cable. 

Once you have verified that the cables will move safely, reinstall the top part of the cable bracket removed in step 1.  

4

Front Left

When the table is in the front left, the cables should be set up so that there is some tension and no slack between the cable clamp and the rotary, and there is some slack between the cable clamp and the cable routing hole in the enclosure. 

Since the home position is slightly more forward and to the left than the machine's zero position, the additional slack is necessary to pull on or damage the cable while zero returning the machine. 

 Note: It is best to keep the spring’s extension as small as possible. The more extended a spring is, the greater force it applies to the cable. This can be adjusted by loosening the clamp and moving it back several ribs on the cable sleeve or moving the magnet. 

5

Back Left

When the table is in the back left of the machine, there will still be no slack on the cable between the cable clamp and the rotary. The cable should be slightly drooping on the clamp's other side. 

6

Back Right

In the back right corner, only the weight of the cables will be pulling on the spring. 

It is best if the cable stays higher than the table, as this reduces the chance of the cable getting crushed. 

If you expect a large volume of chips in the machine, pay close attention if the cable will be dragging on chips. Regularly dragging on chips will eventually damage the cable and fail. 

7

Front Right

This corner is similar to the back right corner, but there is a bit less slack in the cable. 

8

Work Area

Test the mill’s movement in the expected work area as a final check. Since this is where the machine will be most of the time, it is best to verify that the cables are in a good position. 

If you intend to use WIPS for work probing, place a part on the rotary and probe it. If alarms 1101 or 1092 are generated, the cables, spring, or rotary may be getting in the way. 

Moving the retract kit magnet may move the cables and spring out of the way. If the rotary is in the way, moving the OMI or using a longer stylus may fix the issue.