Service Home Rotary - Troubleshooting Guide - NGC
Last updated: 11/21/2022

Rotary - Troubleshooting Guide - NGC

Rotary - Troubleshooting Guide - NGC

Symptom Table

Do not perform any type of maintenance on the rotarty if it is under warranty, contact your Haas Factory Outlet for further assistance.

Symptom Possible Cause Corrective Action
Alarm 5.108, 6.108 or 7.108 A, 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 5.103, 6.103, 7.103 A, B or C AXIS SERVO ERROR TOO LARGE The air brake did not disengage.  Remove the air from the rotary and see if the unit will now rotate without an alarm.  
The connection to the encoder or power is faulty.  Check the encoder and power cable connections to the motor. 
The machined part has inaccurate features.  There is lost motion or backlash in the rotary.  Do the rotary backlash test. 
The feeds and speeds are too high for the work.  Decrease the feeds and speeds. 
The tilt (A) axis of the trunnion does not find a home.
 The home sensor or cable is faulty. 

Jog the tilt axis from the positive travel limit to the negative travel limit. Make sure the A HOME SWITCH bit changes (on the Diagnostics INPUT 2 screen). If the bit does not change, replace the home switch.

This can be done in the field This cannot be done on TR110 units.

Note: The A HOME SWITCH change cannot be seen on machines with software version 18.16A or higher.

Caution: If the A axis (tilt) moves more than 20 degrees past the home position,

Push [EMERGENCY STOP]
The tilt (A) axis does not home to a horizontal position.
 The tool change offset parameter has not been set.  Set the rotary platter flatness: Refer to the Rotary - TR/TRT/T5C - Platter Flatness - Adjustment procedure.
Starting in software version 100.19.000.1120 when using P11, P12, and P13 parameters for T5C/Trunnions. There is an excessive rotation when the unit is commanded to zero return.    The parameter *.161 AXIS HOME SWITCH ACTIVE HIGH is incorrectly set to TRUE. Go to the Haas Service Portal and download the latest configuration files.  Update the rotary configuration files refer to the Update Rotary Configuration Files - NGC procedure. 

Alarm 5.423, 6.423 or 7.423 A, B or C AXIS SECONDARY ENCODER POSITION MISMATCH

Alarm 5.9944, 6.9944 or 7.9944 A, B or C AXIS SECONDARY ENCODER Z FAULT

Alarm 5.9945, 6.9945 or 7.9945 A, B or C AXIS SECONDARY ENCODER Z CHANNEL MISSING

Alarm 5.9946, 6.9946 or 7.9946 A, B or C AXIS SECONDARY ENCODER CABLE FAULT

 

 The rotary scale or scale cable is faulty.  Check the rotary scale cable. 

Alarm 175 GROUND FAULT DETECTED

Alarm 552 TRIPPED CIRCUIT BREAKER

 

 There is a short to ground in the axis motor cable.  Test the axis motor cable for short. 
There is a short to ground in the axis motor.  Test the axis motor for short.
HRC rear seal is popping out  Oil level is too high.  Drain oil until the correct level is reached, use sight glass to identify if oil is filled to the top of the glass. 
Internal pressure is unable to escape 

 NOTE: ONLY DO THIS ONCE THE OIL LEVEL HAS BEEN VERIFIED AND THE SEAL CONTINUES TO POP OUT.

Replace two of the break fasteners with modified fasteners see "Rear seal popping out" section below for further instructions. 
Alarm 5.9948, 6.9948 or 7.9948 A, B or C AXIS SECONDARY ENCODER SERIAL FAULT The encoder read head software is outdated.  Please contact Customer Service for assistance. 
Air leak/hissing sound coming from the motor enclosure. Motor enclosure ballooning out. Excessive bubbles leaking between the side plate and the motor enclosure. Oil is leaking from behind the platter.  The pressure switch may have failed and is leaking.  Install a 0-15 PSI pressure gauge on the enclosure cover. Do not actuate the rotary brake. If the gauge reads any pressure, check the fittings, airlines, and pressure switch for a leak. If the pressure switch is the source of the leak, replace the pressure switch and reseal the cover when reinstalling.
HRT 160 & HRT 210 Brake Booster assemblies are leaking air from the brake  There is an excessive amount of pressure build up in the reservoir. 

A change to the brake booster manifold was made to address this issue. Return the rotary unit to the factory for the brake booster upgrade. 

Refer to the HRT-160/210 Manifold Identification section to see if the A version of the manifold is already on the brake booster assembly.
HRT 160 & HRT 210 Brake Booster assemblies are blowing out the reservoir feed lines 
Custom rotary config file generated with, Custom Rotary Configuration Setup, does not load properly.  All of the XML objects in the config files need to have the tag "<name>[contents]</name>". It is possible for this tag to not be properly generated.  Open the XML file in a text editing program and check that each XML object has the necessary tag. If The tag is missing remove the XML object. 
Alarm 5.4004 A-AXIS AXIS MOTION OCCURRED WHILE THE ROTARY BRAKE WAS ENGAGED Faulty solenoid.  Test the solenoid. 
Pressure switch failure.  Check the pressure switch. 
The break switch is not being read correctly.  Press [Diagnostics] then navigate to the Diagnostics ---> MOCON tab and find "CH 4 [A] axis brake air pressure". Make sure the is reading the proper state of the brake and that it changes when the brake is toggled. 
Oil leaks under the platter, rotary, or trunnion  Machine shop air pressure builds up slowly.  Add a valve and gauge inline to the rotary and open valve once pressure builds up to 85 psi or higher. 
Positive pressure builds up inside the enclosure.  Follow the instructions in the section titled "Leaking Pressure Switch" lower on this page. 
Noise, when the unit is movingIncorrect parametersNGC clear rotary models, cycle power, and reselect the rotary model. weight of the fixture and part,  Incorrect parameters NGC clear rotary models, cycle power and reselect the rotary model. 
weight of the fixture and part might exceed the limit of the rotary.  Remove the fixture and part to see if the noise is the same.
no ferrites on the encoder and power cables.  Add ferrites to the encoder and power cable, and make sure the ferrite is not placed around the chassis ground cable. 
The unit crashed.  Contact HFO for repair options. 
Alarm 4011, 5.4011, 6.4011, 7.4011 ROTARY BRAKE ENGAGEMENT FAILURE Air not connected.  Check the air connection
Air in the brake.  Bleed the brake. For HRT160SS/HRT210SS/HRT310SS refer to HRT160SS/HRT210SS and HRT310SS Brake Bleed - Instructions.  
Pressure switch failure.  Check the pressure switch. 
Faulty solenoid.  Test the solenoid. 
Damaged brake booster seals.  Use the bleed tool kit to check for pressure. 
The air cylinder is seized.  Repair the cylinder shaft. 
Alarm 9961 INVALID OR MISSING ROTARY FILE is generated after the software update. 
Updated software to a version that does not include reverse rotary files while a reverse rotary file was enabled. 
Follow the procedure Reverse Rotary Direction Setup - NGC. to install and activate reverse rotary files. 

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.

Axis Obstruction

Possible Cause: There is a mechanical blockage in the axis of travel.

Corrective Action:

Make sure the axis has a clear path of travel. Tools, part fixtures, or work pieces that are too large can crash into the machine enclosure.

Mechanical Obstruction

Possible Cause: There is an internal mechanical obstruction in the rotary unit.

Corrective Action:

Disconnect the air supply to rotary unit. Press [ZERO RETURN], press the rotary axis letter, Press [SINGL], and jog the axis. If an alarm is generated, remove the necessary enclosure covers to get access to the faulty axis. Rotate the axis motor drive pulley by hand. If the axis cannot be rotated by hand, there is internal mechanical bind. The rotary unit needs to be serviced. For instructions on where to find a rotary repair facility and how to send your rotary unit, go to Rotary Repair on our website.

Brake Solenoid

Possible Cause: The brake solenoid for the rotary unit has an electrical fault.

Corrective Action:

Make sure the air supply is connected to the rotary unit. In MDI mode, push the rotary axis letter. Push [HAND JOG], you should hear air go out from the rotary unit. For solenoid test instructions, refer to Solenoid - 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.

Servo Amplifier

Possible Cause: The servo amplifier has a problem.

Corrective Action:

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

Backlash

Possible Cause: There is lost motion or backlash in the rotary.

Corrective Action:

Test for backlash. For backlash test instructions, refer to HA5C Indexer - Backlash Test or Rotary Tables - Backlash Test.

Proximity Sensor

Possible Cause: The home proximity sensor is faulty.

Corrective Action:

For proximity sensor troubleshooting instructions, refer to Proximity Sensor - Troubleshooting Guide.

TRT70 Servo Errors

Possible Cause:

There is an O-ring inside the TRT70's 5th axis head that can cause the following symptoms:

  • Servo Humming
  • Servo Error Alarms
  • Accuracy Issues

Corrective Action: 

The O-ring has been removed on current production rotaries but previous models will need to have it removed in the field. A plug bolt may need to be added, 40-1631 & 49-4101.

Go to the TRT70 O-ring Removal procedure for details.

Rotary Scale

Possible Cause: The rotary scale or rotary scale cable is faulty.

Corrective Action:

Make sure the cables are connected correctly.

Inspect the rotary scale cables for wear or damage. 

Inspect the internal rotary scale cable interface cable, slightly pull on the wires to make sure they have a good crimp.  If the cables are connected correctly and not damaged, and the alarm persists, the rotary unit needs to be serviced.

For instructions on where to find a rotary repair facility and how to send your rotary unit, go to Haas Rotary Repair Center page.

HRT 450 Brake Bleeding

A fully extended rod indicates a full resevoir [1]

After bleeding the rod will stick out slightly less. 

Disconnect one of the oil lines and dip the tube in oil. Push and  pull the rod to fill the resevoir. Reconnect the line and perform bleeding procedure.

Disconnect the the oil line [2] and insert tube into a container of hyraulic fluid when filling resevoir.

1

Bleeding Procedure

  1. Set regulator A to the max
  2. Set regulator B to zero 
  3. Loosen top air bleed plug [1] until air is out. 
    NOTE: Use bleed plug [2] if top plug is not accessable.
  4. Set regulator B to 80 PSI 
  5. Set regulator A to 7 PSI

Check the main gauge, it should be 0 PSI when unclamped  and 1000 PSI when clamped.

2

Use the image on the left for additional reference.

HRC Units - Rear Seal Popping Out

Do not perform any type of maintenance on the rotarty if it is under warranty, contact your Haas Factory Outlet for further assistance.

This section will show explain what to do if the rear seal keeps popping out. 

NOTE:  This should only be done if the oil level has been verified and the seal is still popping out. 

1

Before starting a fixture needs to be fabricated, the fixture will have two through holes [1] to be threaded to the back of the brake cap and two threaded holes [2] on the outer section that will act like a jack and be placed on a plate [3] so it will not damage the rotary casting

 

An example of this is shown.

2

Remove the air supply to the table.

Place the rotary on its platter face and remove the rear M5 brake bolts.

Use the fixture made to thread to the back of the brake cap and remove it [1].

The threaded holes should be the ones denoted [2] and should be across from each other.

By using the other bolts on the threaded holes [3] as jacks turn the bolts on each side evenly so the plate comes off.

Make sure to use place plates of some sort [4] to prevent damage to the rotary.

3

Using the same fixture pull out the brake piston.

 

NOTE: Longer bolts will be neeed to reach the brake piston [1]. Make sure the jack bolts are in the position indicated by the arrows to have leverage. Make sure plates are under the bolts to avoid damage to the rotary.

4

Remove the two M5 brake fastners that are 180 degrees apart [1] and replace with the modified fastners. 

The modified fastners have through hole to relieve pressure from under the rear brake seal. These have no part number at the moment and will need to be made.

Leaking Pressure Switch

1

Install a 0-15 PSI pressure gauge on the enclosure cover. Do not actuate the rotary brake. If the gauge reads any pressure, check the fittings, airlines, and pressure switch for a leak. If the pressure switch is the source of the leak, replace the pressure switch and reseal the cover when reinstalling.

Electrical Diagrams

SIGMA-5 Cable Diagram

HRT-160/210 Manifold Identification

The dimple [1] indicates the brake booster manifold is an A version. 

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