Side Mount (SMTC) - VF/VM/UMC/EC - Carousel and Pocket - How it Works and Troubleshooting Guide

How it Works

A DC or Servo motor turns a cam or gear that rotates the tool carousel. The cam driven carousel has two proximity sensors; tool in position and tool one in position, which relay the position of the carousel to the control.

If servo driven there is only an axis home switch. The tool pockets hold the tools. The pocket up/down solenoid activates an air cylinder that moves the active pocket up or down. The pocket pivots up and down on a tool pocket slide. The tool pocket slide trips two proximity sensors, pocket up and pocket down, which relay the position of the pocket to the control.

Four steel plungers put pressure on the tool's pull stud to hold it into the pocket. The pressure comes from a large spring that is wrapped around the tool pocket. Some 30 Taper pockets use leaf springs to retain the tools. The double arm pushes the tool up into the pocket, and pulls it out again when a tool change is commanded.

  1. Cam Follower: Keeps the pocket in the up position as the carousel rotates. The cam follower follows a groove on the carousel housing.
  2. Shaft: The axle upon which the pocket pivots up and down.
  3. Spring: Puts tension on the four plungers inside the tool pocket.
  4. Tool Pocket: Holds the tool.
  5. Plungers: The four plungers grip the tool pull stud. They are lubricated with grease.

 

 

Symptom Possible Cause Corrective Action Section
Alarm 625 CAROUSEL POSITIONING ERROR The carousel tool in position, tool one in position, pocket up or down proximity sensor is damaged or contaminated. Rotate the carousel in recovery mode and test the sensors and cabling. 1
No power to the carousel motor or the carousel motor is damaged. Check that the carousel can be rotated in the manual recovery mode. 2
Tool change was interrupted before completion. Do a Tool Change Recovery. 3
A tool change was attempted before adequate air pressure was present.
A tool change was attempted with the pocket already down.
Carousel rotation was prevented by an obstruction. Clear the carousel path. 4
Alarm 626 TOOL-POCKET SLIDE ERROR A tool change was attempted with the pocket already down. Do a Tool Change Recovery. 3
The incoming air flow or pressure is incorrect. Correct the incoming air supply. 5
There is contamination in the slide guides. Clean and lubricate the slide guides. 6
The air cylinder for the tool pocket does not move freely. Check the air cylinder for the tool pocket. 7
The pocket up or pocket down proximity sensors are contaminated, damaged or have loose connections. Clean and inspect the proximity sensors. 8
There is a problem with the pocket up/down system. Troubleshoot the check valve, air cylinder, and solenoid. 9
Movement is blocked by debris. Clear debris. 10
The tool pocket, air cylinder, pocket slide, or slide follower is loose or damaged. Diagnose and correct. 12
The tool pocket is noisy. There is a problem with the tool-pocket stop shock-absorber. Check the tool-pocket stop shock-absorber. 11
The tool pocket, air cylinder, pocket slide, or slide follower is loose or damaged. Diagnose and correct. 12
The tool falls from the tool pocket. The toolholders or pull studs are incorrect. Check for correct tool specifications. 13
The spring or the plungers are worn. Check the spring and the plungers for wear. 14
The tool pocket moves up and down too fast for heavy tools. Install the Pocket Slow Down Service Kit (P/N 93-0254). 15
The tool pocket is broken. Carousel rotation was prevented by an obstruction. Clear the carousel path. 4
The pocket up or pocket down proximity sensors are contaminated, damaged or have loose connections. Clean and inspect the proximity sensors. 8
The tool pocket, air cylinder, pocket slide, or slide follower is loose or damaged. Diagnose and correct. 12

Section 1

Symptom: Alarm 625 CAROUSEL POSITIONING ERROR.

Possible Cause: The carousel tool in position, tool one in position, pocket up or down proximity sensor is damaged or contaminated.

Corrective Action:

Test the tool in position sensor:

  1. Clear the alarms and go into tool changer manual recovery. Refer to VMC, HMC - Side-Mount Tool Changer - Manual Recovery.
  2. Press the LEFT or RIGHT arrow to move the carousel. Monitor the TOOL IN POS bit on a Classic Haas Control (CHC), or SMTC_CAROUSEL_POCKET_MARK on a Next Generation Control (NGC). This bit will be 0 unless the pocket is in position. It will be 1 when the pocket is in position.
  3. If the carousel moves but the bit does not change state, remove the carousel cover. If the carousel does not move, see Section 2.
  4. To make sure the proximity sensor is not tripped, turn the carousel until the flat side of the cam [2] faces the proximity sensor [1].
  5. Touch the end of the proximity sensor with a screwdriver. Watch for the light to change, and monitor the TOOL IN POS or SMTC_CAROUSEL_POCKET_MARK value.
  6. If the light or the bit value does not change state, use the Proximity Sensor - How it Works and Troubleshooting Guide to troubleshoot the proximity sensors.
Test the tool one position sensor:
  1. Find the proximity sensor [3].
  2. Press the LEFT or RIGHT arrow to move the carousel. Monitor the TOOL ONE POS bit on a Classic Haas Control (CHC), or SMTC_CAROUSEL_POCKET_ONE on a Next Generation Control (NGC). This bit should change state once per carousel revolution at pocket one.
  3. Touch the end of the proximity sensor with a screwdriver. Watch for the light to change, and monitor the TOOL ONE POS (CHC) or SMTC_CAROUSEL_POCKET_ONE (NGC) bit value.
  4. If the sensor does not change state, use the Proximity Sensor - How it Works and Troubleshooting Guide to troubleshoot the proximity sensors.

Section 2

Symptom: Alarm 625 CAROUSEL POSITIONING ERROR.

Possible Cause: No power to the carousel motor or the carousel motor is damaged.

Corrective Action:

  1. With the motor connected, check for voltage at the back of the motor power connector.
  2. Set your meter to DC voltage.
  3. Set the DC voltage range on your meter to at least 200 VDC.
  4. Select the Min/Max mode to capture the voltage.
  5. Reset all the alarms, and go into tool changer manual recovery VMC, HMC - Side-Mount Tool Changer - Manual Recovery.
  6. Press the LEFT or RIGHT arrow to move the carousel.
  7. The meter should record voltage between +/- 150 and +/-170 VDC in brief pulses.
  8. If you get the correct voltage and motor does not turn, the motor is damaged. If the voltage is incorrect, use the I/O PCB - How it Works and Troubleshooting Guide (Classic Haas Control) to troubleshoot the I/O PCB.

Section 3

Symptom: Alarm 625 CAROUSEL POSITIONING ERROR. Alarm 626 TOOL-POCKET SLIDE ERROR.

Possible Cause: Tool change was interrupted before completion. A tool change was attempted before adequate air pressure was present. A tool change was attempted with the pocket already down.

Corrective Action:

  1. Press RESET to clear the alarms.
  2. Refer to VMC, HMC - Side-Mount Tool Changer - Manual Recovery to complete a manual tool changer recovery.

Section 4

Symptom: Alarm 625 CAROUSEL POSITIONING ERROR. The tool pocket is broken.

Possible Cause: Carousel rotation was prevented by an obstruction.

Corrective Action:

  1. Make sure there are not "nests", broken tools, hanging hoses, or hanging cables that might catch on the carousel and prevent its rotation.
  2. Refer to VMC, HMC - Side-Mount Tool Changer - Manual Recovery to complete a manual tool changer recovery.

Section 5

Symptom: The tool pocket moves slowly into and out of the tool change position. Alarm 626 TOOL-POCKET SLIDE ERROR.

Possible Cause: The incoming air flow or pressure is incorrect.

Corrective Action:

  • Make sure that the air hose to the machine is the correct diameter.
  • Make sure that the air compressor supplies the correct air pressure and air flow.
  • Command a tool change on the machine. When the machine has the correct air pressure and flow, the needle on the air pressure gauge should not drop more than 10 PSI (0.70 bar) during a tool change. This test confirms that the air pressure and air flow into the machine is correct.
Refer to the "Compressed Air" requirements for your machine on New Machine Pre-Installation.

Section 6

Symptom: The tool pocket moves slowly into and out of the tool change position. Alarm 626 TOOL-POCKET SLIDE ERROR.

Possible Cause: There is contamination on the slide guides.

Corrective Action:

  1. Visually examine the slide guides [1] for the tool pocket. Remove all contamination.
  2. Lubricate the surfaces with red grease.
  3. Go into tool changer manual recovery VMC, HMC - Side-Mount Tool Changer - Manual Recovery.
  4. Press UP or Down arrow to move the tool pocket. Make sure the pocked moves smoothy into and out of the tool change position.

Section 7

Symptom: The tool pocket moves slowly into and out of the tool change position. Alarm 626 TOOL-POCKET SLIDE ERROR.

Possible Cause: The air cylinder for the tool pocket does not move freely.

Corrective Action:

  1. Power off the machine and disconnect the air supply.
  2. Find the tool pocket cylinder.
  3. If equipped, remove the pilot-operated check valve [1] and the hose to the bottom of the cylinder. For machines that do not have a pilot-operated check valve, disconnect the top and bottom hoses on the air cylinder.
  4. Move the cylinder [2] up and down.
  5. Make sure that the piston moves freely. Spray a small quantity of silicon lubricant into the cylinder to lubricate the piston seal.
  6. If the piston does not move freely, the tool pocket air cylinder is damaged.
  7. Make sure the air supply to the machine is clean and dry.

Section 8

Symptom: The tool pocket is broken. Alarm 626 TOOL-POCKET SLIDE ERROR.

Possible Cause: The pocket up or pocket down proximity sensors are contaminated, damaged or have loose connections.

Corrective Action:

Make sure the pocket up and pocket down proximity sensors [1] are clean. Contamination on the switches may cause the carousel to rotate and break a pocket before it is in the fully up position.

The DIAGNOSTICS page shows the state of the sensors. If the POCKET DOWN or POCKET UP (CHC), or the SMTC_TOOL_POCKET_UP or SMTC_TOOL_POCKET_DOWN (NGC), bits do not change state, the sensors may have chips or contamination on them.

Make sure that the tool pocket is up. Press PARAMETER/DIAGNOSTIC and go to the I/O tab.

Touch the end of the proximity sensor with a screwdriver [1]. This test can cause Alarm 626. Ignore the alarm. The proximity sensor operates correctly if the Pocket Down (CHC), SMTC_Pocket_Down (NGC), value changes from a 1 to a 0. Continue troubleshooting if the diagnostic value does not change.

To troubleshoot the pocket up sensor, make sure that the tool pocket is down. Touch the end of the proximity sensor with a screwdriver and monitor Pocket Up (CHC), SMTC_Pocket_Up (NGC). The value must change from a 1 to a 0.

Do these steps on CHC machines only: Find where the 820 cable connects to the I/O PCB at P3. Use an electrical jumper (P/N 33-8521) at P3 [1]. If the Pocket Down value changes from a 1 to a 0, the I/O PCB operates correctly. Replace the SMTC cable assembly. Refer to Proximity Sensor How it Works and Troubleshooting - Video. Use the Proximity Sensor - How it Works and Troubleshooting Guide to troubleshoot the proximity sensors.

To troubleshoot the pocket up sensor, reconfigure the jumper at P3 as shown [2]. Monitor the Pocket Up value. If the value changes from a 1 to a 0, the I/O PCB operates correctly. Replace the SMTC cable assembly.

If the Pocket Down or Pocket Up value does not change to a 0 when tested, use the I/O PCB - How it Works and Troubleshooting Guide (Classic Haas Control) to troubleshoot the I/O PCB.

Section 9

Symptom: Alarm 626 TOOL-POCKET SLIDE ERROR.

Possible Cause: There is a problem with the pocket up/down system.

Corrective Action:

Be sure to troubleshoot the system correctly. Do not replace any part that has not failed. Refer to Solenoid - How it Works and Troubleshooting Guide to troubleshoot the system. Refer to "4 Port Solenoid Applications."

Section 10

Symptom: Alarm 626 TOOL-POCKET SLIDE ERROR.

Possible Cause: Movement is blocked by debris.

Corrective Action:

Make sure the tool is not contaminated by debris. Look for and remove any "nests" of chips in the mechanism.

Refer to TOTD Episode 33 - Stringy Chips Wrapped Around Your Tools? Chip Clear Solution to troubleshoot the system.

Section 11

Symptom: The tool pocket is noisy.

Possible Cause: There is a problem with the tool-pocket stop shock-absorber.

Corrective Action:

  1. Make sure that the tool pocket is in the up position [1].
  2. Push the shock-absorber in with your thumb [3].
  3. Release the shock-absorber [2].

For CALM machines, replace the shock-absorber with the correct orifice (P/N: 58-0093) [4] between the solenoid and the muffler if:

  • There is no resistance when you push the shock-absorber.
  • The shock-absorber does not extend after you push it.
note: For all other machines, replace the shock-absorber with a new shock-absorber.

Section 12

Symptom: Alarm 626 TOOL-POCKET SLIDE ERROR. The tool pocket is noisy.

Possible Cause: The tool pocket, air cylinder, pocket slide, or slide follower is loose or damaged.

Corrective Action:

Examine the tool pocket, the pocket slide, the slide follower, and the air cylinder for signs of damage. Make sure each component is adjusted correctly for its range of motion. Look for loose tool pockets. If loose, tighten and use Loctite Blue on threads. Replace any faulty components.

Section 13

Symptom: The tool falls from the tool pocket. The tool cannot be removed from the pocket.

Possible Cause: The toolholder or pull studs are incorrect.

Corrective Action:

If the tool cannot be removed, remove the garter spring [3]. Wiggle the tool to loosen the plungers [1]. Be careful not to lose any plungers. Remove the tool. Replace spring.

Refer to these documents for the correct toolholder and pull stud [2] information:

Section 14

Symptom: The tool falls from the tool pocket.

Possible Cause: There is problem with the spring or the plungers.

Corrective Action:

  1. Make sure that the (4) plungers [1] are intact in each of the pockets.
  2. Inspect the plungers for wear. Replace the them if they are worn.
  3. Make sure that the hook on the spring is not on top of any of the plungers.
  4. Clean all of the debris from the tool pockets and lubricate the plungers [1] with grease. Apply grease to the tool pull stud.

Refer to Replace a Tool Pocket on Your Haas Side Mount Tool Changer (SMTC) - Video for more information on how to remove the pocket.

Some pockets use leaf springs. Look for broken leaf springs. They are stacked (2) per corner. Replace any broken leaf springs.

Section 15

Symptoms: The tool falls from the tool pocket.

Possible Cause: The tool pocket moves up and down too fast for very heavy tools.

Corrective Action:

Install the Pocket Slow Down Service Kit (P/N 93-0254). This kit restricts the air escaping from the pocket up/down cylinder to slow down the pocket.

Refer to 30-Taper Spindle - Toolholder and Pull Stud Information.

Refer to 40-Taper Spindle - Toolholder and Pull Stud Information.

Refer to 50-Taper Spindle - Toolholder and Pull Stud Information.

Be aware: Many service and repair procedures should be done only by authorized personnel. The service technicians at your Haas Factory Outlet (HFO) have the training, experience, and are certified to do these tasks safely and correctly. You should not do machine repair or service procedures unless you are qualified and knowledgeable about the processes.

Danger: Some service procedures can be dangerous or life-threatening. DO NOT attempt a procedure that you do not completely understand. Contact your Haas Factory Outlet (HFO) and schedule a service technician visit if you have any doubts about doing a procedure.

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