If applicable, remove the previous version of the coolant ring.

Loosen the two fittings [1] and disconnect the PCOOL Auxiliary supply line [2] and the Flood Coolant MAIN supply line [3].

Use a 5/32" allen key to loosen the coolant ring clamps [1].

Remove the previous version of the coolant ring.

Install the updated version of the coolant ring by placing it inside the clamps and hand tighten screws to hold it in place.

Attach the coolant hoses to the new ring and tighten the fittings.

Screw in the side clamps first, then tighten the center last.

Jog the spindle down until the indicator touches the underside of the spindle nose.

Zero the indicator and the Z operator position in the control.

Jog the Z-axis away from the indicator.

Jog the machine so that the indicator touches the underside of the spindle housing flange [1].

Jog the Z-axis until the indicator is zeroed.

Record the operator Z value [A] to use in shim size calculation.

Take the [A] measurement that was just obtained and the [B] measurement that Rotary assembly takes and use the following equation to calculate the appropriate shim size. 

Shim Size [C] = Spindle Nose to Flange [A] - C-Axis Thickness (Paperwork) [B] -  .002' (Adjusted Constant)

Using the calculated value of [C]:

• Take the shim pack out of the C-axis drive packaging.
• Find a combination of shims that gets the closest to the [C] value.
• The smallest shim increment is 0.004 inch (0.1mm). Use calipers if needed to check the thickness of the shims.

 Note:  The shim stack height  should be within 0.002 inches of the value of [C].

Install the shim stack [1] on the mounting plate (Figure 1).

Make sure that the two large cutouts in the shims are aligned with the two large through holes on the mounting plate [2] (Figure 1).

Slide the mounting plate over the spindle nose. Check for any inteferences with the coolant ring rail clamps.

If the fit is satisfactory, remove 4 of the 3/8" mounting screws [1] and mark each with an X (Figure 2).

Do not remove the two bolts that are closest [2] and farthest [3] from the operator (Figure 2).

Slide the mounting plate and shim stack over the spindle nose. Use the provided longer length mounting bolts to secure the plate.

Tighten the plate until seated, then back off 1/8th of  a turn.

Install a tool into the spindle that allows a mag base to be attached and place the mag with an indicator to the tool.

Check that the plate is concentric with the spindle axis. Touch off the indicator on the inner rim of the plate, as shown. 

Check the runout of the plate  (NTE .002"). Use the set screws to adjust its position. A mallet may also be used to gently tap the high points on the sides of the plate.

Torque all of the bolts to 45 ft-lbs.

Remove the bolts closest and furthest from the operator and replace them with the provided bolts of longer length. 

Use the three aluminum stock blocks or thte vice grip to prop up the drive on the table. Ensure that the drive assembly is properly centered on the blocks or vice grip.

Lower the Z-Axis into the center bore until M8 bolts have thread engagement and it is lowered to the lip.

Thread in the M8 bolts to draw in the drive assembly to the mounting plate.

Tighten the bolts until seated and then jog the Z-axis upwards.

Torque the M8 mounting bolts to 25 ft-lbs

Before performing a tool change, remove the chip guard [1] from the tool changer enclosure by removing the four button-head screws. Replace the screws after removing the guard, to prevent chips from escaping. 

Remove the two button head screws [1] on the cable bracket located at the back of the enclosure of the machine.

Jog the X-Axis all the way to the right, and Y-Axis all the way back. Jog the Z-Axis down to the bottom of travel.

Route the conduit through the back of the enclosure [1]. Ensure the cable has enough slack, the cable should not be taut.

Plug Rotary Power Plug cable into plug labelled 4th Axis Power [1].

Plug Rotary Encoder Plug cable into plug labelled 4th Axis Encoder [2].

Press [SETTING].

Navigate to the Rotary tab. Find setting MILL SPDL C-AX-P20 [1]. Press [ENTER] to set axis [2].  

Note: If the model does not appear, follow the instructions in 4 - Update Rotary Configuration Files - NGC_Rev_A. This procedure can be found in HBC.

Set Axis Configuration to Axis C by pressing [C] [1].

Set Physical Connection to 4th Axis by pressing [4] [2].

Set Rotary Relation to Independent by pressing [I] [3].

Set Location to Tool by pressing [T] [4].

Press [C] + [ZERO RETURN] + [SINGLE] to enter the Zero Return page. Highlight each axis and press [F2] to zero it, until you reach the C-Axis. 

 Note: If this page does not appear, pull latest rotary paramters from HBC and try again. 

Handle jog the C-Axis and line up the center of the stopping block [1] with the notch closest to operator [2]. 

With the C-Axis highlighted [1], press [F2] [2] to zero return the C-Axis. 

 Note: If Alarm 165 Zero Return Margin is Too Small is generated, reset the alarm and proceed to the next step. 

Press [MDI] to exit the zero return page.

Press [SETTING]

Navigate to the Rotary tab. Highlight the 4th axis under Current Rotary Selections. Hit [ALTER] to set offsets. Select Set Grid Offset [1].

Press [C] + [ZERO RETURN] + [SINGLE] to enter the Zero Return page. Zero all axes. 

Highlight the C-Axis and press [HANDLE JOG]. Jog the C-Axis until the center of the stopping block [1] is realigned with the notch [2]. Press [F2] to zero return the C-Axis again. 

Jog to re-align C-Axis with the first notch again. This will be saved as the Tool Change Offset in the next step. 

Press [MDI] to exit the zero return page.

Press [SETTING]

Navigate to the Rotary tab. Select the 4th axis under Current Rotary Selections. Hit [ALTER] to set offsets. Select Set TC Offset [1].

Press [C] + [ZERO RETURN] + [SINGLE] to enter the Zero Return page. Zero all axes. 

Press [F2] to zero return the C-Axis again. 

 Note: To zero return the C-Axis by itself, use Home G28 or another method. [C] + [ZERO RETURN] + [SINGLE] should only be used to set the home position. 

Jog the tool until the C-Axis is at 0 and the tool is pointed to the right. 

Loosen the screws at the base of the tool [1] so that the tool can rotate independently of the spindle. 

 NOTE: The angle head tooling pin should be oriented in this position before executing a tool change.

Place an indicator on the table and so that the needle is zeroed on the flat side on the back of the tool [1].

Jog the X-axis and check the parallelism of the tool.

Use a mallet to gently tap the tool to adjust until within the tolerance of 0.0005". 

Tighten the screws to lock the angle head into position. 

Handle jog the C-Axis to +90.

Check the parallelism on the same flat spot on the tool.

Take note of the C-Axis position.

Press [DIAGNOSTIC] to open the Parameters, Diagnostics and Maintenance menu.

Navigate to the Parameters > Compensation > C tab. Navigate to the 90.000 position in the C Axis Lead Screw Compensation table [1]. Enter the C-Axis value. 

NOTE: Send the C-Axis to zero using G28 on the control.

Zero return C, then manually jog the C-Axis back to 90 and check the parallelism again.

If it is not within tolerance, note the position then add it to the existing compensation. Re-check the parallelism.

Repeat steps 2-4  for C-Axis positions at 180 and 270.

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.

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.