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Haas Technical Documentation

Umbrella Tool Changer - Scan code to get


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Troubleshooting Guide
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1. Shuttle motor: DC motor that drives the slip clutch arm


assembly to move the shuttle in and out of the spindle.
2. Carousel motor: DC motor that rotates the carousel.
3. Tool Changer pocket assembly: Holds the tools in the
carousel, it consits of two extractor fingers, spring, locating tool
key.
4. Slip clutch arm: Mechanism that couples the shuttle motor to
the carriage casting, it will slip if there is a crash to prevent
damage to tool changer.
5. Carousel motor connector bracket: The motor and sensors
will connect to this connector bracket.
6. Shuttle in and out sensors: These sensors let the control know
the shuttle position.
7. Tool #1 and tool mark sensors: These sensors let the control
know the carousel position.

Electrical Diagram

Copyright 2018 by Haas Automation, Inc. No unauthorized reproduction | Last Published On January 30, 2018 1/7
Symptom Possible Cause Corrective Action
Chips interfere with the umbrella tool
Alarm 113 SHUTTLE changer proximity sensors or the Check the system for chips.
IN FAULT movement of the shuttle.
Check the voltage to the motor.
Alarm 114 SHUTTLE
OUT FAULT The motor does not receive power. Check resistance in the motor.
Alarm 125 SHUTTLE Check the motor brushes.
FAULT
The slip clutch arm is loose or
Inspect the slip clutch arm.
Alarm 856 ATC damaged.
SHUTTLE DRIVE The spindle orientation is incorrect. Set the correct spindle orientation.
TRAIN FAILURE
The extractor fingers or springs are
Alarm 859 ATC Rebuild the tool pockets.
damaged or worn.
SHUTTLE MOTOR
ELECTRICAL FAULT The carousel plate is bent. Find the cause of the bent carousel plate.

Alarm 2066 TOOL Damaged cable or loose cable


CHANGER HOME connection. (Especially if problem is
Inspect pins and cable for condition.
intermittent or during movement of
POSITION FAULT
shuttle)
One of the tool changer relays is faulty. Test the tool changer relays.
Alarm 115 Chips interfere with the umbrella tool
CAROUSEL changer proximity sensors or movement Check the system for chips.
POSITION FAULT of the shuttle.

Alarm 127 NO One of the tool changer relays is faulty.


Test the tool changer relays.
TURRET MARK (non-servo motor tool changers only)

Alarm 854 ATC Check resistance in the motor.


CAROUSEL DRIVE
TRAIN FAILURE

Alarm 942 The motor does not receive power.


CAROUSEL Check the motor brushes.
POSITION TIME
OUT

Set setting 81 TOOL AT POWER UP to 0, as a


Alarm 115 temporary work around. Check NGC software release
CAROUSEL notes for when the error was corrected.
There is a software error (NGC only).
POSITION FAULT,
during Power-up. Note: Only a Certified Service Technician can
upgrade the machine software.

The extractor fingers or springs are


Rebuild the tool pockets.
damaged or worn.
Tools fall or drop
from the tool changer. The pull studs are incorrect.
Check the tool specifications.
The tool is too heavy or too long.
The lock nut on the shaft axle is loose.
The bolts at the bearing housing are
loose.
The Umbrella Tool
Mounting hardware in the tool changer Check the lock nut on the shaft axle, bearing housing
Changer Carousel
assembly is loose. bolts and the 6 screws that hold the carousel plate.
Plate is Loose.

Copyright 2018 by Haas Automation, Inc. No unauthorized reproduction | Last Published On January 30, 2018 2/7
Symptom Possible Cause Corrective Action
The plastic riders on the carousel trap
door are damaged or missing.
Inspect the carousel trap door.
The guide pin on the carousel trap door
is damaged.
Use this procedure to align the Umbrella Tool Changer
The Tool changer is not aligned to the to the Spindle:Procedure:
spindle.
Umbrella Tool Changer to Spindle Alignment

Examine the geneva driver and the geneva star for


The Geneva driver or the Geneva star is damage.Use this procedure:
damaged.
Carousel Plate Replacement - Umbrella Tool Changer
Tool changes are
noisy.
Use this procedure to adjust or replace the shuttle
The shuttle roller bolts are not adjusted rollers.
correctly.
Procedure: Shuttle Roller Replacement and Adjustment

The sliding panels do not move smoothly. The tools


make scores or scratches on the inner surface of the
carousel. Clean the slider and spring assembly.
The sliding panels do not fully retract.
Use the correct procedure for slider and spring removal.
Refer to Umbrella Tool Changer - Pocket -
Replacement.

The trap door pivot point is not greased. Grease the trap door pivot point.
The Umbrella Tool
There are chips between the trap door
Changer Trap Door
and the carousel. Inspect the carousel trap door.
Does Not Open
The plastic trap door riders are worn.

Copyright 2018 by Haas Automation, Inc. No unauthorized reproduction | Last Published On January 30, 2018 3/7
Rail Guides and Proximity Sensors
Corrective Action:

Check the top [1] and bottom [2] V-rails, and the wheels for
chips. Check for damaged or worn wipers [3]. Some machines
do not have a wiper bracket [4].

Remove any chips that prevent correct sensor operation.


Remove the carousel motor from the carriage assembly.
Remove the sensors [5] on both sides of the carousel motor
plate to clean them.

Remove the cam follower assembly [6] and lower the slip clutch
arm [8] to move the carriage assembly and access the sensors
[7] behind the carriage assembly.

Older machine models use roller switches [5] in place of the


proximity sensors. The plunger and roller must operate smoothly
without sticking. If the switches or sensors are clean, but do not
operate correctly, go to Mechanical Limit Switch -
Troubleshooting Guide or Proximity Sensor - Troubleshooting
Guide to troubleshoot them.

Copyright 2018 by Haas Automation, Inc. No unauthorized reproduction | Last Published On January 30, 2018 4/7
Carousel and Shuttle Motor
Corrective Action:

How to access the shuttle motor to troubleshoot alarms


113, 114, 125, 856, 859, and 2066: Remove the support arm
cover [1] and cable channel cover [2]. Measure the voltage to the
power cable.

How to access the carousel motor to troubleshoot alarms


115, 127, and 854: Remove the cover [4] to the carriage.
Measure the voltage to the power cable [5] on the connector
bracket.

Measure the voltage:

Measure for DC voltage at the connector that goes to the motor


from the I/O PCB. Adjust the range to 0.0 and set your
multimeter for Min/Max. The power to the motor will only be on for one second before an alarm generates and the power is
shut off to the motor. Command a tool change. The reading must be 135-165 VDC, or show a signal change when it is
commanded to run. Some multimeters are not fast enough to read the voltage before the alarm occurs. It should still show
a signal change or OL before the alarm is generated. If there is no voltage, go to I/O PCB - Troubleshooting Guide (Classic
Haas Control) to troubleshoot the I/O PCB.

Inspect the brushes.

1. Normal wear on brush.


2. Bad wear on brush.

Disconnect the motor from the connector. Measure the


resistance from pin to pin. The resistance must be between 5-20
Ohms. Measure the resistance from one of the pins to the motor
chassis. The resistance must be greater than 100k Ohms.

If the measurements are low, there is not a good contact


between the brushes and the commutator. Vacuum and clean
any contamination between the brushes and the commutator.
Check for damage or wear. Make sure there are no signs of oil
or coolant in the motor. Inspect the area around the DC motor for
causes of contamination.

Copyright 2018 by Haas Automation, Inc. No unauthorized reproduction | Last Published On January 30, 2018 5/7
Slip Clutch Arm
Corrective Action:

Inspect the slip clutch arm: Remove and inspect the cam
follower assembly [1] for damage and chips. Push the carousel
motor housing in the direction of the spindle to get access to the
slip clutch arm [2]. Manually turn the slip clutch arm [2] through
180° of movement. It should rotate smoothly, but with heavy
resistance. If the arm does not move smoothly, the shuttle motor
[3] is faulty.

Spindle Orientation
Corrective Action:

Find the cause of the spindle orientation error.

Make sure spindle drive and encoder belts have the correct
tension. Make sure the spindle motor pulley and encoder pulley
are not worn.

Refer to VMC - Umbrella Tool Changer - Set Parameter 257 -


Spindle Orientation Offset.

Tool Changer Relays


Corrective Action:

Test the suspected relay: Exchange the relay with another


relay. If the alarm changes to a different alarm, the relay is at
fault.

For example: If the machine displays Alarm 113, change the K9


relay with the K10 relay. If the alarm changes to Alarm 114, the
relay is faulty. If the alarm does not chage, proceed to other
troubleshooting sections.

Copyright 2018 by Haas Automation, Inc. No unauthorized reproduction | Last Published On January 30, 2018 6/7
Tool Pocket
Corrective Action:

The extractor fingers and spring hold the tool in the tool pocket.
Worn or damaged fingers or springs can let the tool fall.

Go to VMC - Umbrella Tool Changer - Pocket - Replacement for


tool changer pocket rebuild instructions. Go to diy.haascnc.com
to watch Video - Umbrella/Carousel Tool Changer Maintenance
for video instructions.

Carousel Plate and Tool Release Piston Adjustment


Corrective Action:

If the tool-release piston (TRP) sensors are not adjusted


correctly, a tool can get stuck in the spindle taper, or the drawbar
might not release a tool. Damage to the umbrella tool changer
can occur. Adjust the tool release piston switches correctly.
Refer to VMC - 20/30/40-Taper- TRP - Proximity Sensor -
Adjustment for instructions to adjust the TRP sensors correctly.

Go to Umbrella - Tool Changer – Carousel Plate - Replacement


for carousel plate replacement instructions.

Carousel Trap Door


Corrective Action:

Check for damage to the guide pin [1], trap door [2], and the
plastic riders [3].

Go to parts.haascnc.com for umbrella component replacement


parts and diy.haascnc.com for replacement instructions.

Copyright 2018 by Haas Automation, Inc. No unauthorized reproduction | Last Published On January 30, 2018 7/7