Umbrella Tool Changer - How it Works and Troubleshooting Guide

How It Works

  1. Shuttle motor
  2. Carousel motor assembly
  3. Tool Changer pocket assembly
  4. Slip clutch arm
  5. Carousel motor connector bracket
  6. Shuttle in and out sensors
  7. Tool #1 and tool mark sensors

The Umbrella Tool Changer is an electric, fixed, shuttle-type system that uses DC drive motors controlled by the I/O PCB. It has two separate assemblies: the shuttle and the carousel.

The shuttle assembly is driven by a DC motor [1] connected to a clutch arm [4] that rotates 180°. The shuttle travels on a V-rail to move the carousel assembly in and out of the tool-change position. Two proximity sensors [6], mounted at either end of the V-rail, indicate the position of the shuttle. The clutch arm [4] activates the proximity sensors [6].

The carousel contains a drive motor [2], two proximity sensors [7], and a Geneva gear system. A Geneva drive is attached to the motor. Cam followers on the drive engage the Geneva wheel and rotate the carousel to bring the tool pocket into the correct position. One of the proximity sensors indicates the presence of tool #1. The other sensor indicates the position of the tool pocket.

Symptom Possible Cause Corrective Action Section
Alarm 113 SHUTTLE IN FAULT

Alarm 114 SHUTTLE OUT FAULT

Alarm 125 SHUTTLE FAULT

Alarm 856 ATC SHUTTLE DRIVE TRAIN FAILURE

Alarm 859 ATC SHUTTLE MOTOR ELECTRICAL FAULT

Alarm 2066 TOOL CHANGER HOME POSITION FAULT

Chips interfere with the umbrella tool changer proximity sensors or the movement of the shuttle. Check the system for chips. 1
The motor does not receive power. Check the voltage to the motor. 2
Check resistance in the motor.
Check the motor brushes.
The slip clutch arm is loose or damaged. Inspect the slip clutch arm. 3
The spindle orientation is incorrect. Set the correct spindle orientation. 4
The extractor fingers or springs are damaged or worn. Rebuild the tool pockets. 6
The carousel plate is bent. Find the cause of the bent carousel plate. 7
One of the tool changer relays is faulty. Test the tool changer relays. 5
Alarm 115 CAROUSEL POSITION FAULT

Alarm 127 NO TURRET MARK

Alarm 854 ATC CAROUSEL DRIVE TRAIN FAILURE

Chips interfere with the umbrella tool changer proximity sensors or movement of the shuttle. Check the system for chips. 1
One of the tool changer relays is faulty. (non-servo motor tool changers only) Test the tool changer relays. 5
The motor does not receive power. Check resistance in the motor. 2
Check the motor brushes.
Tools fall from the tool changer. The extractor fingers or springs are damaged or worn. Rebuild the tool pockets. 6
Tool changes are noisy. The plastic riders on the carousel trap door are damaged or missing. Inspect the carousel trap door. 8
The guide pin on the carousel trap door is damaged.

Section 1

Symptom: Alarm 113. Alarm 114. Alarm 115. Alarm 125. Alarm 127. Alarm 854. Alarm 856. Alarm 859. Alarm 2066.

Possible Cause: Chips interfere with the umbrella tool changer proximity sensors or the movement of the shuttle.

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 diy.haascnc.com to troubleshoot them.

Section 2

Symptom: Alarm 113. Alarm 114. Alarm 115. Alarm 125. Alarm 127. Alarm 854. Alarm 856. Alarm 859. Alarm 2066.

Possible Cause: The motor does not receive power.

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 diy.haascnc.com 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.

Section 3

Symptom: Alarm 113. Alarm 114. Alarm 125. Alarm 856. Alarm 859. Alarm 2066.

Possible Cause: The slip clutch arm is loose or damaged.

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.

Section 4

Symptom: Alarm 113, Alarm 114, Alarm 125, Alarm 856, Alarm 859, Alarm 2066.

Possible Cause: The spindle orientation is incorrect.

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.

Section 5

Symptom: Alarm 113. Alarm 114. Alarm 125. Alarm 127. Alarm 854. Alarm 856. Alarm 859. Alarm 2066.

Possible Cause: One of the tool changer relays is faulty.

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.

Section 6

Symptom: Alarm 113 SHUTTLE IN FAULT. Alarm 114 SHUTTLE OUT FAULT. Tools fall from the tool changer.

Possible Cause: The extractor fingers or springs are damaged or worn.

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.

Section 7

Symptom: Alarm 113. Alarm 114.

Possible Cause: The carousel plate is bent.

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 diy.haascnc.com for carousel plate replacement instructions.

Section 8

Symptom: Tool changes are noisy.

Possible Cause: The plastic riders on the carousel trap door are damaged or missing. The guide pin on the carousel trap door is damaged.

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.

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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