10.6 UMC ROTARY - TROUBLESHOOTING

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

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

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. 

Corrective Action:

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

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.

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
  

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.

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.

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.