This procedure explains how to install the Broken Tool Detection Camera on UMC machines.

Machine Compatibility:

Important: UMC machines built before August 2023 — this option is not field installable.

• UMC-400/SS
• UMC-500/SS
• UMC-750/SS
• UMC-1000/SS/P
• UMC-1250/SS
• UMC-1500/SS/DUO

This procedure applies to the following service kits:

• 93-1001218: BROKEN TOOL DETECTION FIELD KIT UMC-500
• 93-1001219: BROKEN TOOL DETECTION FIELD KIT UMC-1250
• 93-1001220: BROKEN TOOL DETECTION FIELD KIT UMC-400
• 93-1001221: BROKEN TOOL DETECTION UMC750/1000/1500

Secure the brace [1] to the inside of the corner of the enclosure near the tool changer.

Install the brace with six 1/4"-20 flange nuts [2].

Install the broken tool detection sub-assembly [1] by securing it with four 1/4"-20 X 1/2" flanged button head cap screw (FBHCS) [2] to the brace.

Apply a small amount of loctite on the threads of the screws.

Install the end brace [1] to the inside of the enclosure using two 1/4-20 flange nuts [3] and to the brace with two 1/4"-20 X 1/2" FBHCS [2].

Apply a small amount of loctite on the threads of the FBHCS.

 NOTE: UMC-500s do not use this bracket and skip this step.

Route the BTD cables around the machine's enclosure panels into the control cabinet. route the camera cable into the cable magnets and spiral wrapping closest to the window. 

Install the camera cable into the camera. Use the velcro to hold the cables together.

 NOTE: For machines built before February 25, 2024 that do not have an enclosure on the main processor, use the provided bracket [3] from the service kit to mount the BTD PCB.

Install the A62 processor [2] on top of the mounting plate [3].

Install the BTD A62 PFDM PCB [1] on top of the A62 processor [2].

 NOTE: The battery on the A62 processor is not replaceable. 

 NOTE: For machines built after February 25, 2024 with main processor P/N 32-4267 or 32-4269, the BTD PCB bolts directly onto the enclosure [2]. Discard the bracket for these machines.

Install the BTD A62 PCB [1] on top of the processor [2].

 NOTE: The battery on the A62 processor is not replaceable. 

Connect the BTD camera cable 79-0159 into the USB adapter 74-2003 [1] that connects into the USB port on the A62 processor. 

Connect both LED lights to the +12V LED power cable 33-1228 [2] that goes into J3 on the BTD A62 PFDM. 

Make sure that the A62 processor power cable 33-1256 [3] is connected from J26 on the A62 processor to J4 on the BTD A62 PFDM. 

Connect the BTD A62 PFDM cable 33-1227 [4] from J2 on the BTD A62 PFDM to J3 on the MAINCON. This cable also has a pigtail that connects to P20 on the PSUP. 

Connect the communication cable 79-0158 [5] from the mico USB B port on the A62 processor to the USB port J8 on the MAINCON. 

 IMPORTANT: Make sure to insert the translator cable into the lower USB port J8 on the MAINCON.

Add 64-1252 Ferrite filter to the USB extender 74-2003 where it connects to the A62 board.

Before the system can successfully detect a broken tool. the camera needs to be set up and calibrated. 

Follow the calibration procedure which will show you how to manually adjust the camera mount into the proper position and calibrate the Region of Interest.