8.1 Rotary - Troubleshooting - NGC

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, and slightly pull on the wires to ensure they have a good crimp.  If the cables are connected correctly and not damaged, and the alarm persists, the rotary unit must be serviced.

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

A fully extended rod indicates a full reservoir [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 reservoir. Reconnect the line and perform the bleeding procedure.

Disconnect the oil line [2] and insert a tube into a hydraulic fluid container when filling the reservoir.

Bleeding Procedure

1. Set regulator A to the max
2. Set regulator B to zero 
3. Loosen the top air bleed plug [1] until the air is out. 
   NOTE: Use bleed plug [2] if the top plug is not accessible.
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.

Use the image on the left for additional reference.

This section will 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. 

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.

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.

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.

Using the same fixture, pull out the brake piston.

NOTE: Longer bolts will be needed to reach the brake piston [1]. Ensure 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.

Remove the two M5 brake fasteners 180 degrees apart [1] and replace them with the modified fasteners. 

The modified fasteners have a through hole to relieve pressure under the rear brake seal. These have no part number and will need to be made.

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

Note: This does not apply to HRT310SS. 

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

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.

Corrective Action:

If the unit is a TRT 160 or TRT 210, ensure the breather hole on the bottom of the tilt axis casting is 0.25" in diameter. If the breather hole is smaller, it needs to be drilled to correct size.

Note: The dimple [1] indicates the location of the breather hole on a TRT 160 or TRT 210.  

Possible Cause: Potential leak detected inside the enclosure. Alarm 4011 has been triggered. 

Corrective Action: If the front rubber plug is missing, it is a clear indication that the pressure switch has failed and must be replaced. 

Note: If the pressure switch is replaced on an HRTSS, the brake must  be bled. For brake bleed instructions, refer to HRTSS Brake Bleed Instructions.