10.2 UMC ROTARY ENCODER RING - REPLACEMENT

: Warning: Only certified service personnel should perform this procedure. Reorientation of Z-pulse or Trip-Flag will require laser calibration to populate rotary compensation tables with new, correct, values.

Zero-return all Axis.

Handle jog B to +120°.

Press [EMERGENCY STOP].

Remove the C-Axis bottom cover.

Press [SETTING].

Navigate to the Rotaty tab.

Un-Check the 4th Axis.

Press [DIAGNOSTIC].

Navigate to Parameters > Factory.

Set 7.083 C-Axis Linear Scale Enabled to "Scale Disabled".

Power off the machine.

Uninstall the encoder read-head [1] by disconnecting the encoder cable [2] and removing the bolts and washers.

Note the Z-Pulse orientation before removing the encoder ring hub.

Uninstall the encoder ring hub [1] by removing the screws and washers mounting the encoder ring hub to the taper-lock. 

Mount and loosely install the encoder ring hub [1] from the service kit with the provided hardware, SHCS 10-32 X 3/4 (x4) and WASHER #10 FLAT (x4).

Verify the Z-Pulse is in the same location as the ring that was uninstalled. 

 Note: Do not torque mounting screws yet.

Turn on the machine.

Zero return all axis.

 Warning: Do not place the Mag Base anywhere near the Encoder.

Check and document the runout on the OD of the scale encoder ring hub using the upper-most diameter, as shown.

Adjust as necessary. TIR must be 0.0005" or less.

Torque the 4 bolts of the encoder ring hub to 30 in-lbf in the star pattern.

After torquing, double check the runout to verify the ring hub has not shifted.

Clean the back surface of the encoder read-head and the mounting surface.

Add a small amount of silicone dielectric grease to encoder cable connection [1]. Grease should be a thin layer, but cover all the pins.

Apply two small drops of anti-oxidant (99-2130) to the mounting surface on the read head in the locations shown [2].

Connect the encoder cable [4] to the encoder read-head.

Insert cable by carefully lining up electrical pins with cable connector.

Install the encoder read-head [1] from the service kit with the provided hardware,  SHCS 8-32 x 1/2 bolts (x2) [2] and Washer .17ID x .4OD (2x) [3].

 Note: Do not torque mounting screws yet.

Set the gap between the scale ring and read-head as shown [1] using the appropriate mylar shim (0.008").

 Note: Do not use a metal shim.

Starting on the left side of the read-head [2], torque the two read-head mounting bolts to 20 in-lbf.

After torquing, double check the gap with the shim to verify the read-head has not shifted.

Reinstall the C-Axis bottom cover being sure no tools, shims, etc. have been left in the casting.

Press [SETTING].

Navigate to the Rotaty tab.

Check the 4th Axis.

Rotate the B-Axis back to zero when done.

Press [DIAGNOSTIC].

Navigate to Parameters > Configuration > Axis > B > Travel Limits.

Change: 6.108 B-Axis Positive Travel Limit from 180 to 110.

Press [DIAGNOSTIC].

Navigate to Parameters > Factory.

Set 7.083 C-Axis Linear Scale Enabled to "Scale Linear".

Power cycle the machine.

Zero-Return the C-Axis.

Zero-Return All Axis.

Set new Tool Change offset by following the UMC - X and Y Axes - Tool Change Offsets and the Side-Mount Tool Changer - Z-Axis Tool Change Offset - NGC procedures.

Clear the Compensation table for the C-Axis.

Press [DIAGNOSTIC].

Navigate to Parameters > Compensation > C.

Press [ORIGIN].

To update compensation table values for the C-Axis a laser calibration is required. The calculated compensation values will then be entered into the C-Axis Compensation Table.

: Warning: Only certified service personnel should perform this procedure. Reorientation of Z-pulse or Trip-Flag will require laser calibration to populate rotary compensation tables with new, correct, values.

Zero-return all Axis.

Press [EMERGENCY STOP].

Remove the bulkhead sheet metal [1] to access the B-Axis hard stop [2]. 

Rotate the B-Axis approximately 100 degrees, or until there is enough room to access the hard stop [1].

Remove the B-Axis hard stop [1].

Remove the two rear sheet metal panels [1] to access the B-Axis components.

Insert a service key and enter service mode.

Press [DIAGNOSTIC].

Navigate to Parameters > Factory > 6.021.

Change: 6.021 B-Axis Check Travel Limit from TRUE to FALSE .

Handle jog B to +180°.

Remove the C-Axis bottom cover.

Press [DIAGNOSTIC].

Navigate to Parameters > Factory.

Set 6.083 B-Axis Linear Scale Enabled to "Scale Disabled".

Power off the machine.

Disconnect all of the cables and hoses [1] running to the C-Axis through the B-Axis encoder ring. 

 Note: Mark the cables and hose to make reconnecting them easier later in this procedure. 

Remove the corrugated conduit [2].

Uninstall the encoder read-head [1] by disconnecting the encoder cable [2] and removing the bolts and washers.

Note the Z-Pulse orientation before removing the encoder ring hub.

Uninstall the encoder ring hub [1] by removing the screws and washers mounting the encoder ring hub to the taper-lock. 

Mount and loosely install the encoder ring hub [1] from the service kit with the provided hardware, SHCS 10-32 X 3/4 (x4) and WASHER #10 FLAT (x4).

Verify the Z-Pulse is in the same location as the ring that was uninstalled. 

 Note: If the Z-Pulse is in the wrong location the B-Axis will not zero return correctly and can damage the cables and hoses.

 Note: Do not torque mounting screws yet.

Route all of the cables and hoses [1] for the C-Axis through the corrugated conduit [2] and through the B-Axis encoder ring. 

Reconnect all of the cables and hoses to their original locations in the C-Axis.

Turn on the machine.

Zero return all axis.

 Note: The B-Axis should zero return in the Clockwise direction.

 Warning: Do not place the Mag Base anywhere near the Encoder.

Check and document the runout on the OD of the scale encoder ring hub using the upper-most diameter, as shown.

Adjust as necessary. TIR must be 0.0005" or less.

Torque the 4 bolts of the encoder ring hub to 30 in-lbf in the star pattern.

After torquing, double check the runout to verify the ring hub has not shifted.

Clean the back surface of the encoder read-head and the mounting surface.

Add a small amount of silicone dielectric grease to encoder cable connection [1]. Grease should be a thin layer, but cover all the pins.

Apply two small drops of anti-oxidant (99-2130) to the mounting surface on the read head in the locations shown [2].

Connect the encoder cable [1] to the encoder read-head.

Insert cable by carefully lining up electrical pins with cable connector.

Install the encoder read-head [2] from the service kit with the provided hardware,  SHCS 8-32 x 1/2 bolts (x2) [4] and Washer .17ID x .4OD (2x) [3].

 Note: Do not torque mounting screws yet.

Set the gap between the scale ring and read-head as shown [1] using the appropriate mylar shim (0.008").

 Note: Do not use a metal shim.

Starting on the left side of the read-head [2], torque the two read-head mounting bolts to 20 in-lbf.

After torquing, double check the gap with the shim to verify the read-head has not shifted.

Reinstall the C-Axis bottom cover being sure no tools, shims, etc. have been left in the casting.

 Note: You will have to set a new tool change offset and update compensation table values for the B-Axis. This will require laser calibration.

Rotate the B-Axis to the same position when the hard stop was removed. 

Install the B-Axis hard stop [1].

Press [DIAGNOSTIC].

Navigate to Parameters > Factory > 6.021.

Change: 6.021 B-Axis Check Travel Limit from FALSE to TRUE.

Rotate the B-Axis back to zero when done.

Press [DIAGNOSTIC].

Navigate to Parameters > Factory.

Set 6.083 B-Axis Linear Scale Enabled to "Scale Linear".

Power cycle the machine.

Zero-Return the B-Axis.

Zero-Return All Axis.

Set new Tool Change offset by following the UMC - X and Y Axes - Tool Change Offsets and the Side-Mount Tool Changer - Z-Axis Tool Change Offset - NGC procedures.

Install the bulkhead sheet metal [1] once the B-Axis hard stop [2] has been installed. 

Install the two rear sheet metal panels [1].

Clear the Compensation table for the B-Axis.

Press [DIAGNOSTIC].

Navigate to Parameters > Compensation > B.

Press [ORIGIN].

To update compensation table values for the B-Axis a laser calibration is required. The calculated compensation values will then be entered into the B-Axis Compensation Table.