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UMC - Rotary - Troubleshooting Guide

Service Home UMC - Rotary - Troubleshooting Guide
Recently Updated Last updated: 04/04/2023

UMC - Rotary - Troubleshooting Guide


UMC - Rotary - Troubleshooting Guide

- Jump to Cause - Back to Top

10.6 UMC ROTARY - TROUBLESHOOTING

Introduction

  1. Solenoid valve connector
  2. Solenoid valve
  3. Air tube
  4. Pneumatic piston
  5. Brake booster
  6. Piston
  7. Return springs
  8. Hydraulic line
  9. Hydraulic pressure switch
  10. Hydraulic fluid reservoir
  11. Switch for the reservoir fluid

Symptom Table

Symptom Possible Cause Corrective Action
Alarm 6.108 or 7.108 B or C AXIS SERVO OVERLOAD The feeds and speeds are too high for the work. Decrease the feeds and speeds.
The cutting tool is not sharp or is damaged. Install a new tool or a new tool insert.
There is a mechanical blockage in the axis of travel. Make sure the axis has a clear path of travel.
There is an internal mechanical obstruction in the rotary unit. Test the rotary unit.
The brake solenoid for the rotary unit has an electrical fault. Troubleshoot the brake solenoid.
The servo amplifier has a problem Troubleshoot the servo amplifier.
Alarm 6.103, 7.103 B or C AXIS SERVO ERROR TOO LARGE The connection to the encoder or power is faulty. Check the encoder and power cable connections to the motor.
The input shaft on the Cycloidal unit is loose

Check for lateral and vertical movement of the input shaft. 

Verify the Lock Nut on input shaft has not came loose. 

See Input Shaft section.

Collant contamination under the platter causing Moly grease to harden.

See Coolant Contamination section

HSG-A 06/28/2023

Verify C axis Platter seal is not damaged. Refer to AD0597
The machined part has inaccurate features The feeds and speeds are too high for the work. Decrease the feeds and speeds.  Refer to the UMC - Applications - Troubleshooting Guide.

Alarm 6.423 or 7.423 B or C AXIS SECONDARY ENCODER POSITION MISMATCH

Alarm 6.9944 or 7.9944 B or C AXIS SECONDARY ENCODER Z FAULT

Alarm 6.9945 or 7.9945 B or C AXIS SECONDARY ENCODER Z CHANNEL MISSING

Alarm 6.9946 or 7.9946 B or C AXIS SECONDARY ENCODER CABLE FAULT

 

The rotary scale or scale cable is faulty. Check the rotary scale cable.
The rotary scale encoder is not grounded correcty.

See UMC B and C Axis Rotary Scale Encoder section.

HSG-A 02/03/2023

Alarm 6.994 or 7.994 AMPLIFIER OVERLOAD Brake ring is damaged or leaking due being over pressurized Replace the brake ring or add brake regulator service kit - AD0601

Alarm 6.9948 or 7.9948 B or C AXIS SECONDARY ENCODER SERIAL FAULT

Alarm 6.9918 or 7.9918  B or C AXIS SERIAL ENCODER INTERNAL DATA ERROR

Alarm  6.9922 or 7.9922  B or C AXIS MOTION CHANNEL FAULT DETECTED

Alarm  6.9923 or 7.9923  B or C AXIS SOFTWARE DETECTED ENCODER FAULT

Alarm  6.9930 or 7.9930 B or C AXIS SERIAL ENCODER POOR COMMUNICATION

Alarm  6.9959 or 7.9959  B or C AXIS SERIAL ENCODER DISCONNECT

Alarm  6.9949 or 7.9949 B or C AXIS SOFTWARE DETECTED SECONDARY ENCODER FAULT

Alarm 6.9950 or 7.9950B or C AXIS SOFTWARE DETECTED SECONDARY ENCODER FAULT

Alarm 6.9951 or 7.9951 B or C AXIS SECONDARY ENCODER SERIAL COMMUNICATION FAULT

Alarm  6.9960 or 7.9960  B or C AXIS SECONDARY SERIAL ENCODER CABLE FAULT

 

The software is outdated.

Alarm is obsolete 

New alarm for encoder faults updated in software. Update to latest version 100.21.000.1130 or Higher;

Added Alarms 9719 and 9720 for Encoder Fault Detection on Mocon Primary and Secondary Axis.

Alarm 4011, 6.4011, 7.4011 ROTARY BRAKE ENGAGEMENT FAILURE Pressure switch failure. Check the pressure switch.
Faulty solenoid. Check the solenoid.
Refer to the Solenoid Troubleshooting Guide.
Air in the brake. Bleed the brake.
Damaged brake booster seals. Use the bleed tool kit to check for pressure.
Air cylinder is seized. Repair the cylinder shaft.
Brake ring is damaged or leaking due being over pressurized Replace the brake ring or add brake regulator service kit - AD0601
Backlash. Poor surface finish. Air in the brake. Bleed the brake.
Faulty solenoid. Test the solenoid.
Damaged brake booster seals. Use the bleed tool kit to check for pressure.
Alarm 4003 or 6.4003 Rotary Brake Release Failure Air cylinder does not have the return line installed Install air line, refer to Rotary - Hydraulic Brake Booster Retract Air Line - Installation.
Pressure switch failure. Check the pressure switch.
Alarm 6.4004 or 7.4004 AXIS MOTION OCCURRED WHILE THE ROTARY BRAKE WAS ENGAGED Coolant contamination under the platter causing Moly grease to harden.

See Coolant Contamination section
There is hydrualic oil leaking from below the platter. The rotary brake seal may be damaged.

Verify incoming air pressure to the machine, if higher then 105 psi / 6.8 bars add the appropriate Service Kit. Refer to the Rotary Brake Service Kits below.

Brake continues to leak after service kit is installed Refer to the Rotary Brake Ring replacement below.  

Alarm 6.9719, 7.9719  B or C AXIS PRIMARY ENCODER SERIAL FAULT

Alarm Subcode (0x1) Encoder Data Fault = (Alarm 9918 SERIAL ENCODER INTERNAL DATA ERROR)

Encoder signals are affected by noise from high power cables.

(Faulty servo motor encoder.)

Refer to Serial Data Communication Faults / Electrical Noise section below.

(Check the servo motor for coolant contamination.)

Alarm  6.9719, 7.9719   B or C AXIS PRIMARY ENCODER SERIAL FAULT

Alarm Subcode (0x2) Encoder Internal Axis Fault 1 = (Alarm 9922 MOTION CHANNEL FAULT DETECTED)

(The motion channel has reported an internal fault of a type that is not recognized by the control)  Cycle power to the machine, If the issue persists, take an error report (Shift F3) and email to Haas Service

Alarm 6.9719, 7.9719  B or C AXIS PRIMARY ENCODER SERIAL FAULT

Alarm Subcode (0x3) Encoder Internal Axis Fault 2 = (Alarm 9923 SOFTWARE DETECTED ENCODER FAULT)

 (Software has report an internal fault of a type that is not recognized by the control.)

 Cycle powe to the machine. If the issue persists, take an error report (Shift F3) and email to Haas Service

Alarm  6.9719, 7.9719   B or C AXIS PRIMARY ENCODER SERIAL FAULT

Alarm Subcode (0x4) Encoder CRC Fault = (Alarm 9930 SERIAL ENCODER POOR COMMUNICATION)

 (Encoder signals are affected by noise from high power cables.)

 (Refer to Serial Data Communication Faults / Electrical Noise section below.)

Alarm  6.9719, 7.9719   B or C AXIS PRIMARY ENCODER SERIAL FAULT

Alarm Subcode (0x5) Encoder Cable Fault = (Alarm 9959 SERIAL ENCODER DISCONNECT)

 (Cables are not connected correctly or encoder is faulty.)

 (Inspect the cables and connectors. Refer to the Main Processor/Encoder Cable section below.)

Alarm  6.9720, 7.9720  B or C AXIS SECONDARY ENCODER SERIAL FAULT.

Alarm Subcode (0x1) Encoder Data Fault  = (Alarm 9948 SECONDARY ENCODER INTERNAL DATA ERROR)

Scale signals are affected by noise from high power cables.

(Faulty Linear Scale, Configuration File issue; incorrect motor type or incorrect Scale type.)

Refer to Serial Data Communication Faults / Electrical Noise section below.

(Check Scale Encoder for coolant contamination.)

Alarm  6.9720, 7.9720 B or C AXIS SECONDARY ENCODER SERIAL FAULT

Alarm Subcode (0x2) Encoder Internal Axis Fault 1 = (Alarm 9949 SOFTWARE DETECTED SECONDARY ENCODER FAULT)

(The motion channel has reported an internal fault of a type that is not recognized by the control)

 Cycle power to the machine. If the issue persist, take an error report (Shift F3) and email Haas Service

Alarm 6.9720, 7.9720 B or C AXIS SECONDARY ENCODER SERIAL FAULT

Alarm Subcode (0x3) Encoder Internal Axis Fault 2 = (Alarm 9950 SOFTWARE DETECTED SECONDARY ENCODER FAULT)

 (Software has report an internal fault of a type that is not recognized by the control.)

 

Cycle power to the machine. If the issue persist, take an error report (Shift F3) and email to Haas Service

Alarm 6.9720, 7.9720 B or C AXIS SECONDARY ENCODER SERIAL FAULT

Alarm Subcode (0x4) Encoder CRC Fault = (Alarm 9951 SECONDARY ENCODER SERIAL COMMUNICATION FAULT)

(Liner Scale signals are affected by noise from high power cables.)

(Refer to Serial Data Communication Faults / Electrical Noise section below.)

Alarm  6.9720, 7.9720 B or C AXIS SECONDARY ENCODER SERIAL FAULT

Alarm Subcode (0x5) Encoder Cable Fault = (Alarm 9960 SECONDARY SERIAL ENCODER CABLE FAULT)

(Cables are not connected correctly or Linear scale is faulty.)

(Inspect the cables and connectors. Refer to the Main Processor/Encoder Cable section below.)

UMC-350HD Machines built before 6/14/2023

Tools 1.25 inches or longer do not reach the OTS Probe.

Longer tools will need to update the probe mount. Refer to the UMC-350HD Probe Mount Retro Fit procedure to determine if the machine has the old probe mount and retrofit the new one if needed.
Machines with software 100.23.000.1200 having issues applying User Rotaries. Software is outdated. Upgrade to software version 100.24.000.1002 or later.

Air In The Brake

Corrective Action:

If air gets into the brake system, the brake does not generate the correct pressure. You must bleed the brake system to remove the air. Use bleed tool T-0062A for EC1600, T-0062 for UMC.

Machines made before November, 2016 may need to reconfigure the reservoir feed hose. Refer to EC-1600, UMC-750 - Hydraulic Brake Booster - Replacement for more information.

Refer to:

  • UMC series machine: UMC - B-Axis and C-Axis Rotary Brakes - Bleed Instructions
  • EC-1600 machine: EC-1600 - Rotary Brake - Bleed Instructions

Program

Possible Cause: The feeds and speeds are too high for the work.

Corrective Action:

Decrease the feeds and speeds of the active program to decrease the machine load.

Tooling

Possible Cause: The cutting tool is not sharp or is damaged.

Corrective Action:

Examine the cutting tool for damage. Install a new tool or a new tool insert if the cutting tool is damaged or is not sharp.

Servo Amplifier

Possible Cause: The servo amplifier has a problem.

Corrective Action:

For servo amplifier troubleshooting instructions, refer to Servo Amplifier - Troubleshooting Guide.

Electrical Short

Possible Cause: There is a short to ground in the axis motor cable.

Corrective Action:

Inspect the rotary cables for wear or damage, refer to electrical diagram below.

UMC B and C Axis Rotary Scale Encoder

Inspect the B or C-axis ground cable that is attached to the encoder mount plate.  Make sure is fasten to the encoder mount plate.  Verify the other end of the cable is connected to chassis.

If the machine does not have a ground cable installed. Verify the encoder mount has [1] 8-32 UNC location for the ground screw. 

Install the following  :

33-8001  GND to SP Encoder 16FT (C axis)

33-6055 GND to SP Encoder 13FT (B axis)

If needed;

20-7278A - MNT NCE/HOME SW B AXIS UMC

20-7279A - MNT NCE/HOME SW C AXIS UMC

 

Note: Do not loosen the read head screws, doing this will require the machine to be lazer compensated. 

 

Input Shaft

Corrective Action:

Tighten the lock nut with the spanner wrench until the marks lined up

Pressure Switch

Corrective Action:

The machine monitors a pressure switch to ensure the brake is holding pressure when activated. Do these steps to test the pressure switch.

  • Zero return all axes. Push [EMERGENCY STOP].
  • Disconnect the sensor cable from the B-Axis booster unit.
  • Connect the leads from a digital multimeter to the sensor contacts [1].
  • Release the [EMERGENCY STOP].
  • Manually activate the solenoid to unclamp the brake.
  • The multimeter shows OL (open) when the brake is clamped, and 0.1 to 0.4 Ohms when it is unclamped.
  • If there is air in the brake system, the brake does not generate enough pressure to activate the switch. Properly bleed the brake before you replace the switch.

Solenoid

Corrective Action:

Use code M11 and M13 to clamp and unclamp the axis brake. Check for 120 VAC at the solenoid.

If the voltage is present refer to: Solenoid Troubleshooting Guide.

If the voltage is not present refer to:

  • I/O PCB - NGC - Troubleshooting Guide

Booster

Corrective Action:

Use the brake bleed kit (Haas P/N T-0062A for EC-1600, T-0062 for UMC) to check the system pressure. If you cannot build pressure, 400-425 psi (27.6 - 29.3 bar), or, if the pressure drops, the booster may have damaged seals. If the oil level in the reservoir consistently drops, the brake is leaking internally. Refer to UMC-750 - B- and C-Axis Brake Booster - Replacement for more information.

Air Cylinder

Corrective Action:

Remove the air cylinder from the brake booster body.

Push the air cylinder piston shaft [1] into the retracted position. Remove the rear air fitting.

Use a small diameter rod (.375” (10 mm) or smaller) [2] to push the piston assembly to the extended position.

Use a stone to remove any burrs or high spots on the shaft.

Use your hand to move the shaft back and forth. It should move freely.

Rotary Brake Kits

Rotary Brake Service Kits
Part Number Description
93-3510 (2X) BRAKE REGULATOR RETROFIT KIT UMC AD0601
93-3511 (1x) BRAKE REGULATOR RETROFIT KIT EC-1600 AD0604
93-3512 (1X) BRAKE REGULATOR RETROFIT KIT VMT AD0605
Rotary Brake Assembly Kits
Part Number Description
93-3108 14.39 OD ROTARY BRAKE ASSEMBLY KIT
93-3111  18.39 OD ROTARY BRAKE ASSEMBLY KIT

Serial Data Communication Faults / Electrical Noise

Sigma-5 servo motors, non-contact encoders output serial data signal to the control. If the serial data signal is missing or becomes unreliable the control will generate a serial data communication error. Electrical noise can cause the serial data signal from the encoder to become unreliable and cause false alarms. Follow the troubleshooting guide below to help eliminate the noise in the system.

  1. Incorrect machine grounding. Make sure the ground wire size is correct. Also the ground wire should run all the way back to the electrical panel.
  2. Noise from other equipment. Make sure the machine does not share it's electrical service with another machine.
  3. Loose encoder data connectors at PCB or at the motor encoder, can cause the serial data to become unreliable. Refer to the Main Processor / Encoder Cable section.
  4. Loose ground or high voltage power connectors will induce noise into the system.
    • electrical cabinet check for loose connection at all the ground and high voltage power terminals (vector drive, wye-delta contactors, transformer..etc).
    • pendant check for loose terminal connectors.
    • spindle head check for loose ground and motor power terminals.
  5. The ferrite filters suppress high frequency noise produced by the amplifiers and vector drive, when servos are on. Make sure they are installed in:
    • Encoder data cables. Make sure there is a ferrite filter P/N 64 1252 installed in all the encoder data cables.
    • Axis motor power cables. Make sure there is a ferrite filter P/N 64-1252 installed in X, Y, Z axis motor power cables [1].
    • Spindle motor cables. Make sure there is a ferrite filter installed in the motor output of the vector drive.

      For a 40HP vector with 6 wire leads [1] use ferrite P/N 64-1254.

      For a 40HP vector with 3 wire leads [2] use ferrite P/N 64-1252.

      For a 20HP vector drive with 6 or 3 wire leads [3, 4] use ferrite P/N 64-1252.

  6. Cable routing. Make sure that the encoder cable is separated from high power spindle/axis/pump cables.

Maincon PCB / Encoder Cable

Corrective Action:

Examine the connector [1] on the Maincon. Make sure it is not damaged.

Examine the cable. Look for signs of damage or stiffness. The connector [4] has two housings [2,3] for the cable pins.

If the pins have been pushed into the motor, you must replace the motor and cable together.

Make sure the cable is firmly connected at both ends. Reseat both connections. Make sure the cable is installed in the correct connector at the Maincon or MOCON PCB.

Coolant Contamination

Possible Cause:

 Coolant intrusion under the platter, contaminating the Moly grease. Causing grease to harden or rust the surface of the brake.

Corrective Action:

Determine if the platter can be cleaned or must be replaced

  • Clean the platter and brake surface and inspect for damage
  • Refer to AD0667 for removal and replacment of the platter. 

Platter Service Kits

93-3783 B PLATTER W/PLUG SVC KIT UMC-750/1000

93-3784 B PLATTER W/PLUG SVC KIT UMC-500

 

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