Solved Section 1: True and False 1 Mark Each - 10 Marks

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Section 1: True and False 1 Mark Each - 10 Marks Total 1. Safety in the machine shop is everyone's responsible a True b. False 2. Compressed air should be used to clean chips and debris from your clothing a True b. False 3. The Inch micrometer can also provide metric readings a True b. False 4. Safety glasses should be worn in the machine shop at all times a. True b. False 5. Steel toed safety shoes only need to be worn when lifting something he a. True D False 6. Surface plates are a type of precision gauge a True b False 7. The horizontal bandsaw can cut profiles in thin metals a True b. False 8. Micrometers are more accurate than Vernier calipers a. True b. False 9. A scriber can be used to mark sharp lines when doing a layout a. True b. False 10. Before handling a part, you should file it to remove burrs and sharp edges 2. True 8. False Section 2.Multiple Choice - Circle Only One Answer 10 Marks total 1. What is the biggest hazard in the machine shop? a. Long, continuous, and sharp metal chips b. Hot parts from machining processes C. Chuck keys being left in the chuck d. Becoming entangled in rotary power equipment 2. Which precaution best reduces the risk of becoming entangled in the chuck of a lathe a. Ensure the E-Stop is pressed b. Ensure the chuck guard is in place &#; Wear appropriate clothing d. Wear safety glasses 3. What is the most common type of injury while using power equipment, such as the lathe, millor drill press in the machine shop? a. Blindness 6. Small Cuts, Abrasions and Bruises c. Broken Bones and Severe (Big) Cuts d. Fatality (Death) 4. When operating power rotary equipment such as a lathe, millor drill press, we it important to wear safety glasses? a. Potential to become entangled (caught) in moving equipment The Flying debris may hit eyes C. Machined parts can get hot d. Long, continuous chips may catch hand potential hazards are typically presen? Trip hazards b. Enclosed space hazard b. Provides a color contrast to see scribed lines better 10. If you have to find the center of a piece of round stock, which of the following 7. Which type of equipment would used the following tool 8. Which measuring device has a Vernier scale and is typically used on a surface plate? a. Drill Press 6. Lathe & Milling Machine d. Grinder a Vernier Caliper b. Micrometer C. Height Gauge d. Telescopic Gauge 9. Why is layout dye used when performing a layout? a. It adds a nice color to the part c. It is easier to apply and remove than markers d. It provides a surface treatment to the part 71 layout tools would be best to find the center? a. Vernier Caliper and Scriber b. Centering Head and Steel Rule c. Micrometer and Scriber 1 Divider and Rule

Symptom Possible Cause Corrective Action Alarm 6.108 or 7.108 B or C AXIS SERVO OVERLOAD The feeds and speeds are too high for the work. Decrease the feeds and speeds. The cutting tool is not sharp or is damaged. Install a new tool or a new tool insert. There is a mechanical blockage in the axis of travel. Make sure the axis has a clear path of travel. There is an internal mechanical obstruction in the rotary unit. Test the rotary unit. The brake solenoid for the rotary unit has an electrical fault. Troubleshoot the brake solenoid. The servo amplifier has a problem Troubleshoot the servo amplifier. Alarm 6.103, 7.103 B or C AXIS SERVO ERROR TOO LARGE The connection to the encoder or power is faulty. Check the encoder and power cable connections to the motor. The input shaft on the Cycloidal unit is loose

Check for lateral and vertical movement of the input shaft. 

Verify the Lock Nut on input shaft has not came loose. 

See Input Shaft section.

Collant contamination under the platter causing Moly grease to harden.

See Coolant Contamination section

HSG-A 06/28/

Verify C axis Platter seal is not damaged. Refer to AD The machined part has inaccurate features The feeds and speeds are too high for the work. Decrease the feeds and speeds.  Refer to the UMC - Applications - Troubleshooting Guide.

Alarm 6.423 or 7.423 B or C AXIS SECONDARY ENCODER POSITION MISMATCH

Alarm 6. or 7. B or C AXIS SECONDARY ENCODER Z FAULT

Alarm 6. or 7. B or C AXIS SECONDARY ENCODER Z CHANNEL MISSING

Alarm 6. or 7. B or C AXIS SECONDARY ENCODER CABLE FAULT

 

The rotary scale or scale cable is faulty. Check the rotary scale cable. The rotary scale encoder is not grounded correcty.

See UMC B and C Axis Rotary Scale Encoder section.

HSG-A 02/03/

Alarm 6.994 or 7.994 AMPLIFIER OVERLOAD Brake ring is damaged or leaking due being over pressurized Replace the brake ring or add brake regulator service kit - AD

Alarm 6. or 7. B or C AXIS SECONDARY ENCODER SERIAL FAULT

Alarm 6. or 7.  B or C AXIS SERIAL ENCODER INTERNAL DATA ERROR

Alarm  6. or 7.  B or C AXIS MOTION CHANNEL FAULT DETECTED

Alarm  6. or 7.  B or C AXIS SOFTWARE DETECTED ENCODER FAULT

Alarm  6. or 7. B or C AXIS SERIAL ENCODER POOR COMMUNICATION

Alarm  6. or 7.  B or C AXIS SERIAL ENCODER DISCONNECT

Alarm  6. or 7. B or C AXIS SOFTWARE DETECTED SECONDARY ENCODER FAULT

Alarm 6. or 7.B or C AXIS SOFTWARE DETECTED SECONDARY ENCODER FAULT

Alarm 6. or 7. B or C AXIS SECONDARY ENCODER SERIAL COMMUNICATION FAULT

Alarm  6. or 7.  B or C AXIS SECONDARY SERIAL ENCODER CABLE FAULT

 

The software is outdated.

Alarm is obsolete 

New alarm for encoder faults updated in software. Update to latest version 100.21.000. or Higher;

Added Alarms and for Encoder Fault Detection on Mocon Primary and Secondary Axis.

Alarm , 6., 7. ROTARY BRAKE ENGAGEMENT FAILURE Pressure switch failure. Check the pressure switch. Faulty solenoid. Check the solenoid.

Refer to the Solenoid Troubleshooting Guide

Air in the brake. Bleed the brake. Damaged brake booster seals. Use the bleed tool kit to check for pressure. Air cylinder is seized. Repair the cylinder shaft. Brake ring is damaged or leaking due being over pressurized Replace the brake ring or add brake regulator service kit - AD Backlash. Poor surface finish. Air in the brake. Bleed the brake. Faulty solenoid. Test the solenoid. Damaged brake booster seals. Use the bleed tool kit to check for pressure. Alarm or 6. Rotary Brake Release Failure Air cylinder does not have the return line installed Install air line, refer to Rotary - Hydraulic Brake Booster Retract Air Line - Installation. Pressure switch failure. Check the pressure switch. Alarm 6. or 7. AXIS MOTION OCCURRED WHILE THE ROTARY BRAKE WAS ENGAGED Coolant contamination under the platter causing Moly grease to harden.

See Coolant Contamination section There is hydrualic oil leaking from below the platter. The rotary brake seal may be damaged.

Verify incoming air pressure to the machine, if higher then 105 psi / 6.8 bars add the appropriate Service Kit. Refer to the Rotary Brake Service Kits below.

Brake continues to leak after service kit is installed Refer to the Rotary Brake Ring replacement below.  

Alarm 6., 7.  B or C AXIS PRIMARY ENCODER SERIAL FAULT

Alarm Subcode (0x1) Encoder Data Fault = (Alarm  SERIAL ENCODER INTERNAL DATA ERROR)

Encoder signals are affected by noise from high power cables.

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(Faulty servo motor encoder.)

Refer to Serial Data Communication Faults / Electrical Noise section below.

(Check the servo motor for coolant contamination.)

Alarm  6., 7.   B or C AXIS PRIMARY ENCODER SERIAL FAULT

Alarm Subcode (0x2) Encoder Internal Axis Fault 1 = (Alarm  MOTION CHANNEL FAULT DETECTED)

(The motion channel has reported an internal fault of a type that is not recognized by the control)  Cycle power to the machine, If the issue persists, take an error report (Shift F3) and to Haas Service

Alarm 6., 7.  B or C AXIS PRIMARY ENCODER SERIAL FAULT

Alarm Subcode (0x3) Encoder Internal Axis Fault 2 = (Alarm  SOFTWARE DETECTED ENCODER FAULT)

 (Software has report an internal fault of a type that is not recognized by the control.)

 Cycle powe to the machine. If the issue persists, take an error report (Shift F3) and to Haas Service

Alarm  6., 7.   B or C AXIS PRIMARY ENCODER SERIAL FAULT

Alarm Subcode (0x4) Encoder CRC Fault = (Alarm  SERIAL ENCODER POOR COMMUNICATION)

 (Encoder signals are affected by noise from high power cables.)

 (Refer to Serial Data Communication Faults / Electrical Noise section below.)

Alarm  6., 7.   B or C AXIS PRIMARY ENCODER SERIAL FAULT

Alarm Subcode (0x5) Encoder Cable Fault = (Alarm  SERIAL ENCODER DISCONNECT)

 (Cables are not connected correctly or encoder is faulty.)

 (Inspect the cables and connectors. Refer to the Main Processor/Encoder Cable section below.)

Alarm  6., 7.  B or C AXIS SECONDARY ENCODER SERIAL FAULT.

Alarm Subcode (0x1) Encoder Data Fault  = (Alarm  SECONDARY ENCODER INTERNAL DATA ERROR)

Scale signals are affected by noise from high power cables.

(Faulty Linear Scale, Configuration File issue; incorrect motor type or incorrect Scale type.)

Refer to Serial Data Communication Faults / Electrical Noise section below.

(Check Scale Encoder for coolant contamination.)

Alarm  6., 7. B or C AXIS SECONDARY ENCODER SERIAL FAULT

Alarm Subcode (0x2) Encoder Internal Axis Fault 1 = (Alarm  SOFTWARE DETECTED SECONDARY ENCODER FAULT)

(The motion channel has reported an internal fault of a type that is not recognized by the control)

 Cycle power to the machine. If the issue persist, take an error report (Shift F3) and Haas Service

Alarm 6., 7. B or C AXIS SECONDARY ENCODER SERIAL FAULT

Alarm Subcode (0x3) Encoder Internal Axis Fault 2 = (Alarm  SOFTWARE DETECTED SECONDARY ENCODER FAULT)

 (Software has report an internal fault of a type that is not recognized by the control.)

 

Cycle power to the machine. If the issue persist, take an error report (Shift F3) and to Haas Service

Alarm 6., 7. B or C AXIS SECONDARY ENCODER SERIAL FAULT

Alarm Subcode (0x4) Encoder CRC Fault = (Alarm  SECONDARY ENCODER SERIAL COMMUNICATION FAULT)

(Liner Scale signals are affected by noise from high power cables.)

(Refer to Serial Data Communication Faults / Electrical Noise section below.)

Alarm  6., 7. B or C AXIS SECONDARY ENCODER SERIAL FAULT

Alarm Subcode (0x5) Encoder Cable Fault = (Alarm  SECONDARY SERIAL ENCODER CABLE FAULT)

(Cables are not connected correctly or Linear scale is faulty.)

(Inspect the cables and connectors. Refer to the Main Processor/Encoder Cable section below.)

UMC-350HD Machines built before 6/14/

Tools 1.25 inches or longer do not reach the OTS Probe.

If you are looking for more details, kindly visit Non-contact rotary caliper.

Longer tools will need to update the probe mount. Refer to the UMC-350HD Probe Mount Retro Fit procedure to determine if the machine has the old probe mount and retrofit the new one if needed. Machines with software 100.23.000. having issues applying User Rotaries. Software is outdated. Upgrade to software version 100.24.000. or later.