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HAAS SERVICE AND OPERATOR MANUAL ARCHIVE Horizontal

Contents

1. Check wiring to POWER OFF button on front control panel Check wiring to AUTO OFF relay to IOPCB Check connection between 24V transformer and K1 contactor Machine can be powered on but turns off by itself Check Settings 1 and 2 for Auto Off Timer or Off at M30 Check AC power supply lines for intermittent supply Check low voltage power supply for intermittent supply Check wiring to POWER OFF button on front control panel Check connection between 24V transformer and K1 contactor Check Parameter 57 for Power Off at E STOP Machine turns on keyboard beeps but no LCD display Check for power connections to LCD from IOPCB Close doors and Zero Return machine possible bad monitor Check video cable from VIDEO PCB to LCD Check for lights on the processor Replace LCD see Electrical Service Machine turns on LCD works but keyboard keys do not work Check keyboard cable 700 from VIDEO to KBIF PCB Troubleshooting 5 96 0189 rev L June 2005 VIBRATION Vibration is a subjective evaluation with perceptions varying among individuals making it difficult to determine in mild cases if there is an actual problem In obvious cases it is a matter of determining the source which is not easy since all parts rotate together and sound can be transferred readily Vibrations also need to be distinguished from noise such as a bad bearing One crude method of me
2. 1 ZERO RETURN the Z axis 2 In TCR mode extend the double arm and re insert the split tool into the double arm Orient the spindle dogs for a tool change If the orientation has changed reset Parameter 257 Refer to section on setting spindle orientation If spindle dogs are not aligned with the tool holder slot manually rotate the spindle dogs 3 Retract and extend the double arm to move the tool in and out of the spindle Check for alignment 4 Check the X axis alignment of the split tool to the spindle center Tool Equalize Gap All Around Spindle Centerline Tool Centerline Double Arm Spindle Top View Double Arm to Spindle Center Alignment along the Y axis 5 If necessary loosen the five ATC mounting SHCS Mechanical Service 82 96 0189 rev L June 2005 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 21 Carousel Number Disc 8X BHCS Spindle Assembly Double Arm Assembly ATC Covers Carousel Assembly ATC Mounting Bracket ATC Assembly Pocket Stop ATC Assembly Alignment 6 Use a mallet to align the ATC mounting bracket Adjust the bracket to align the split tool in the double arm to the center of the spindle in the X axis 7 Torque the SHCS to 80 ft lbs 8 Check the Y axis alignment of the spl
3. 12 13 14 15 16 17 27 28 29 30 31 32 33 34 35 36 37 1 3 42 43 44 45 46 47 48 48 49 330 Assembly Drawings 96 0189 rev L June 2005 1 25 4979 Left intermediate panel 2 25 4962B Tool changer panel 3 28 0168 TC access window 4 25 9248 Plate window handle 5 25 6718A SMTC switch box 25 6719 SMTC side panel 6 25 5991A SMTC side panel 7 25 4961A TC pan 8 25 4972 Left rear apron 9 55 0671 Coolant drain tube 10 25 5247 TC panel rear apron 11 58 1679 Bulkhead fitting 58 1693 LBO fitting 2 12 52 6042 TSC filter 13 25 7581B TSC filter bracket 14 25 4978A TC rear panel 15 25 0440A Tool tray 16 25 4959C Left rear panel 17 25 4960B TC panel header 18 22 9673 Spacer 2 19 30 2464 Idler assembly 20 25 0974 Chain Retainer 21 25 5032 TC door top connect bracket 22 54 0072 Chain 23 50 0012A Linear guide 24 59 0641 Cylinder rod aligner 25 59 0612 Air cylinder 26 25 5033 TC door bottom connect bracket 27 25 4221A Opposite window rest 2 28 28 0167 TC window extrusion 2 29 25 5284A TC left chip shield 24TL 30 25 5295 TC left chip shield 40TL 31 25 4976 TC coolant drip pan 32 25 4961 TC pan 33 30 6753 Coolant fitting assembly 34 25 4985 TC panel lower chip shield 35 25 5283 TC front chip shield 36 28 0151 window TC panel operator door 37 25 5228 TC operator door window Z frame 38 25 5030 Top door 39 20 2087 Door guide 25 5034 Door guide
4. 260 244V 243 227V 226 211V 210 195V I O Board I O Board Power amplifiers X Y Z A B amp PC Power amplifiers X Y Z A B amp PC Transformer Terminal block Terminal block HAAS Vector Drive HAAS Vector Drive Y Delta Contactors underneath Y Delta Contactors underneath 3 phase breaker 3 phase breaker K1Contactor Power PCB Power PCB T5 Transformer T5 Transformer Low volt power supply Low volt power supply SERVO DRIVE ASSEMBLY SERVO DRIVE ASSEMBLY Single Axis Brake PCB Single Axis Brake PCB MOCON 2 Processor LCD Video Floppy MOCON 1 MOCON 2 Processor LCD Video Floppy MOCON 1 Optional Servo Tool Changer Amp Optional Servo Tool Changer Amp Figure 4 2 1 Control panel general overview EC 300 Shown 181 Electrical Service 96 0189 rev L June 2005 ELECTRICAL CONNECTIONS NOTE The machine must have air pressure at the air gauge or a Low Air Pressure alarm will be present on power up 40 L1 Main Circuit Breaker Ground Line T5 Transformer L2 L3 1 Hook up the three power lines to the terminals on top of the main switch at upper right of electrical panel and the separate ground line to the ground bus to the left of the terminals NOTE Make sure that the service wires actually go into the terminal block clamps It is easy to miss the clamp and tighten the screw The connection looks fine but the machine runs intermittently or has other pr
5. 4 Remove the four 4 FHCS that attach the top of the lower Y axis way cover to the spindle head casting Collapse the way cover down fully 5 Remove the way cover from the bottom Installation 1 Install the four SHCS at the bottom of the way cover and tighten evenly 2 Slide the bottom of the way cover up and down to ensure it moves freely 3 Slide the top flange of the waycover under the spindle head cover plate and fasten it to the spindle head cover and upper waycover using four 4 BHCS 4 Replace the left and right vertical guides using twenty six 26 BHCS 63 Mechanical Service 96 0189 rev L June 2005 3 2 SPINDLE MOTOR REPLACEMENT Removal 1 Remove the rear enclosure panel 2 Disconnect the electrical cable to the fan 3 At the rear of the spindle and motor shroud remove the four 4 SHCS that hold the fan mounting bracket in place Remove the electrical and pneumatic connections from the solenoid valve assem bly Fan Fan Guard Fan Mounting Bracket 4X SHCS 4X Lockwashers 6X Hex Nut 6X Lockwasher 2X Two Washers as Spacer EC 300 Motor Shroud 8X BHCS Cable Carrier Assembly 4X BHCS EC 400 Motor Shroud Spindle Motor Assembly Spindle Encoder 4X SHCS 4X SHCS Encoder Mounting Bracket 4X SHCS 4 EC 400 Remove the motor shroud which is held on with four 4 BHCS Disconnect the encoder cable 5 EC 300 Remove Y axis cable carrier and bracke
6. 750A JOG HANDLE DATA CABLE SHIELD 4 ALL 24 751A 0 VDC 752A A 753A B 754A 5 VDC 755A SHIELD DRAIN 750B JOG HANDLE DATA CABLE SHIELD ALL 24 750B JOG HANDLE DATA CABLE SHIELD 6 ALL 24 750B 1 5 VDC JOG HANDLE 750B 2 0VDC 750B 3 JOG HANDLE A CHANNEL 750B 4 JOG HANDLE A CHANNEL 750B 5 JOG HANDLE B CHANNEL 750B 6 JOG HANDLE B CHANNEL Cable List 284 96 0189 rev L June 2005 760 MONITOR VIDEO DATA CABLE SHIELD 7 ALL 24 FROM VIDEO P13 TO CRT 770 EMERGENCY STOP INPUT CABLE SHIELD 2 771 SIGNAL 20 772 RETURN D GROUND 20 773 SHIELD DRAIN 770A SECOND E STOP COUNTER BALANCE SHIELD 2 771A SIGNAL 20 772A RETURN D GROUND 20 773A SHIELD DRAIN 780 SPARE 781 SPARE 782 SPARE 783 SPARE 784 SPARE 790 PALLET CHANGER CW CCW SHIELD 3 ALL 20 791 PALLET CW 792 PALLET CCW 793 COMMON 794 SHIELD DRAIN 800 10VAC TO PALLET READY LAMP SHIELD 2 801 UNSWITCHED LEG 1 20 802 SWITCHED LEG 2 20 803 SHIELD DRAIN 800A LAMP SWITCH JUMPER 801A JUMPER TO 802A 801A JUMPER TO 801A 810 160 VDC TO LOAD STATION DRAWBAR MOTOR SHIELD 2 811 MOTOR 20 812 MOTOR 20 813 SHIELD DRAIN 810A 160 VDC TO MAIN DRAWBAR MOTOR SHIELD 2 811A MOTOR 20 812A MOTOR 20 813A SHIELD DRAIN 820 TOOL CHANGER AND MAIN DRAWBAR INPUT STATUS ALL 20 821 TOOL CHANGER IN SIGNAL 822 TOOL CHANGER OUT SIGNAL 823 MAIN DRAWBAR UP SIGNAL 824 MAIN DRAWBAR DOWN S
7. 8 9 11 172 Mechanical Service 96 0189 rev L June 2005 3 24 4TH AXIS TABLE ASSEMBLY EXPLODED PARTS LIST 1 SHCS 2 Machined Platter 3 Ring Gear 4 SHCS 5 Brake 6 SHCS 7 Bearing Crossroller 8 Bearing Retainer Ring 1 2 3 4 5 6 173 96 0189 rev L June 2005 Mechanical Service 3 Thread a Reducer into the hydraulic port Thread the Swivel Elbow into the Reducer Thread the Hydraulic Hose from the Pressure Booster into the Swivel Elbow Orient the Swivel Elbow as shown below and tighten 4 Thread Elbow into the air port Orient the Elbow as shown below Hydraulic Cylinder Swivel Elbow Hydraulic Hose Elbow Hydraulic Port Air Port Hydraulic Cylinder side view 5 Cut the Tubing to fit once installed in the Table Insert one end of one piece of Tubing into the Elbow on the air side of the Hydraulic Cylinder 6 Thread one of the two remaining Elbows into the low pressure port of the Pressure Booster located in the middle of the Pressure Booster Insert one end of one piece of Tubing into the low pressure Elbow Coil the Tubing and mark with masking tape See Figure 7 Place the Pressure Booster flat on the work surface Route the Braided Hose upward and use caution to avoid fluid spillage 8 Thread the remaining Elbow into the high pressure port located on the rear of the Pressure Booster cylinder Insert one end of one piece of Tubing into the high pressure El
8. HIGH VOLT HIGH VOLT 488 458V 457 429V 428 403V 402 377V 376 354V Polyphase bank transformer PRIMARY CONNECTION TO T1 Input power to T1 is supplied through CB1 the 40 amp three phase main circuit breaker Three phase 230 to T1 is connected to the first three terminals of TB10 VOLTAGE SELECTION TAPS There are four labeled plastic terminal blocks Each block has three connections for wires labeled 74 75 and 76 Follow the instructions printed on the transformer SECONDARY CONNECTION TO T1 The secondary output from T1 is 115V AC three phase CB2 protects the secondary of transformer T1 and is rated at 25 amps 210 Technical Reference 96 0189 rev L June 2005 OPTIONAL 480V 60HZ TRANSFORMER All machines will get the 45KVA transformer For domestic installations and all others using 60Hz power the primary side should be wired as follows Input Voltage Range Tap 493 510 1 504 481 492 2 492 469 480 3 480 457 468 4 468 445 456 5 456 433 444 6 444 420 432 7 432 OPTIONAL 480V 50HZ TRANSFORMER Input Voltage Range Tap 423 440 1 504 412 422 2 492 401 411 3 480 391 400 4 468 381 390 5 456 371 380 6 444 355 370 7 432 5 14 FUSES The brushless amplifier has one fuse F1 15 amps This fuse protects the amplifier itself from drastic damage If this fuse is ever blown the associated motor will stop A light on the amplifier will tell of a blown fuse If necessary replac
9. Installation 1 Generously apply red grease to the outer ring of the Brake completely filling the two grooves Apply Moly grease around the Stud Flex Nuts filling the counterbores on the Brake Ring horse shoe brake only Apply moly grease to the Pinion Gear and Ring Gear 2 Stone and clean the Platter where it will mate with the Bearing Rotate the inner Bearing holes so they line up on the X and Y axis 3 Use the Backlash Adjusting screws to fully retract the Pinion Gear Harmonic Drive Assembly 4 Cut the heads off of two 3 8 16 x 7 threaded rods 40 0021 Insert each through a bearing mount ing hole in the Platter so that they are 180 apart Use these to rotate the Platter to align it with the holes in the inner Bearing Install the threaded rods into the bearing use them as a guide when lowering the platter 5 Hoist the Platter over the Table using a chain fall Do not use synthetic lifting straps to move or position the Platter 6 Carefully lower the Platter over the pilot rods and onto the bearing Thread the rods from Step 4 into the Bearing Retaining Ring Ensure the bolt holes in the Platter line up with the bolt holes in the Bearing 7 When the Ring Gear attached to the Platter contacts the Pinion Gear manually jog the A axis so that the teeth mesh and the Pinion Gear does not force the Platter into position 8 Slowly guide the Platter down the remaining distance CAUTION Do not crash the Platter
10. OVERHEATING Servo motor overheating If a motor OVERHEAT alarm occurs ALARMS 135 138 check the parameters for an incorrect setting Axis flags in Parameters 1 15 or 29 can invert the overheat switch OVER TEMP NC If the motor is actually getting hot to the touch there is excessive load on the motor Check the user s application for excessive load or high duty cycle Check the ball screw for binding Accuracy Backlash section If the motor is binding by itself replace in accordance with Axis Motor section FOLLOWING ERROR Following Error alarms occur on one or more axes sporadically Check DC bus voltage on Diagnostics page 2 Verify this voltage on the drive cards in the control panel If it is at the low side of the recommended voltages change the transformer tap to the next lower voltage group as explained in the Installation section of the Reference manual Check motor wiring for shorts Replace driver card Electrical Service Replace servo motor Axis Motor 18 Troubleshooting 96 0189 rev L June 2005 BALL SCREWS VISUAL INSPECTION The three main causes of Ball Screw failure are Loss of Lubrication Contamination Machine Crash Wear of the nut balls and the screw threads is generally a non issue under proper operating conditions Each type of suspect cause will leave telltale signs on the Ball Screw itself Loss of Lubrication The lubrication system of the machine provide
11. and press the tool release button again Feel for movement in the aluminum block Repeat this until move ment is felt Note the last position where the block was tight If the position is 0 070 or more add shims to the tool release fork If the aluminum block is loose at 0 060 jog the Z Axis downward 0 001 at a time and check for movement in the aluminum block If the position where the block becomes tight is 0 050 or less remove shims from the tool release fork 7 If shims were added to the TRP fork add half that amount to the TRP spacers supporting the TRP This will keep the two clearance gaps between the TRP and the rotating Spindle equal approxi mately 0 095 each If shims were removed from the TRP fork remove half that number of shims from the TRP spacers 8 Apply red grease to the shoulder bolts used to mount the TRP when the shim adjustments are complete Use blue Loctite on the threads Mechanical Service 146 96 0189 rev L June 2005 Figure 3 2 11 TRP shim location 50 TAPER SWITCH ADJUSTMENT Figure 3 2 12 Tool Clamp Unclamp Switches 1 Setting the upper switch Tool Clamped Push the switch in slowly until it trips then push it a little farther Lock down the screws Double Check the switch by turning on the TRP a few times The bit in the Diagnostics Page should always turn on 1 when the TRP is completely retracted 147 Mechanical Service 96 0189 rev L June 2005 2 Setting the lower
12. 1 Remove the APC cylinder shield to access the up switch 2 Loosen the switch clamp 3 Find the correct position for the switch Go to the APC diagnostics page The status of H Frame Up should be 0 for most of the air cylinder s travel but will change to 1 when the cylinder is within 1 16 of being fully extended It will remain 1 for the last 1 16 of travel 4 Slide the switch lengthwise on the air cylinder to its correct position then tighten the clamp Replace the APC cylinder shield H frame down sensor There is no adjustment for the H frame down sensor AIR CYLINDER 1 At the APC recovery page confirm that the H frame is commanded down 2 Disconnect the machine s air 3 Remove the APC cylinder cover 4 Remove the H frame up reed switch Disconnecting it is not necessary 5 Disconnect the two 2 air hoses 6 Remove the shoulder bolts and washers that retain the air cylinder and remove the air cylinder 7 Remove the air fittings rod end and jam nut and assemble them on to the new air filter Leave the rod end loose 8 Wrap the air fittings with teflon tape 9 Mount the fixed end of the air cylinder to the bridge using a shoulder bolt and two washers on either side of the spherical bearing 10 Rotate the APC cam lever cams and seal housing clockwise as viewed from the top until it stops 11 Adjust the rod end as required to easily insert the shoulder
13. 215 FREE MEMORY PTR CHANGED Indicates that the amount of memory used by the programs counted in the system disagrees with the variable that points to free memory Possible processor board problem 37 Alarms 96 0189 rev L June 2005 216 EPROM SPEED FAILURE Possible processor board problem 217 X PHASING ERROR Error occurred in phasing initialization of brushless motor This can be caused by a bad encoder or a cabling error 218 Y PHASING ERROR Error occurred in phasing initialization of brushless motor This can be caused by a bad encoder or a cabling error 219 Z PHASING ERROR Error occurred in phasing initialization of brushless motor This can be caused by a bad encoder or a cabling error 220 A PHASING ERROR Error occurred in phasing initialization of brushless motor This can be caused by a bad encoder or a cabling error 221 B PHASING ERROR Error occurred in phasing initialization of brushless motor This can be caused by a bad encoder or a cabling error 222 C PHASING ERROR Error occurred in phasing initialization of brushless motor This can be caused by a bad encoder or a cabling error 223 DOOR LOCK FAILURE In machines equipped with safety interlocks this alarm occurs when the control senses the door is open but it is locked Check the door lock circuit 224 X TRANSITION FAULT Illegal transition of encoder count pulses in X axis This alarm usually indicates that the encoder has been damaged and encoder position data is
14. 28 The top cam is rotated back to its original position allowing the H frame and pallets to lower As the H frame lowers a lock pin under the H frame drops into a hole in the bumper mount It keeps the H frame from being moved while the servo power is off 29 The pallet in the machine is lowered onto the receiver and the pallet on the load station is lowered onto the index disc pallet pins 30 Power is turned off to the clamp unclamp solenoid and air blast solenoids located at the rear of the ma chine 31 The unclamp air pressure is exhausted from the unclamp side of the receiver piston and air blast is turned off while simultaneously applying 100 PSI of air pressure to the clamp side of the receiver piston 32 The clamp plate moves down to clamp the pallet The clamp plate will move approximately 400 and clamp the pallet It will trigger the pallet clamp sensor indicating that the pallet is clamped The clamp plate position is monitored by a sensor assembly located on the bottom of the A axis 33 The load station lock plate prevents the load station pallet from falling off if it is rocked severely while loading parts 22 Troubleshooting 96 0189 rev L June 2005 EC 300 PALLET CHANGER Introduction Unclamped Springs and air clamp Air Unclamp Exhaust Switch Normally Open Clamp Plate Table Clamp Springs Clamp Piston Clamped Air Clamp Pressure Operation Note Pallet is pulled down by clamp plate
15. 5 Set the main switch to ON rotate the shaft that engages the handle on the panel door clockwise until it snaps into the ON position Check for evidence of problems such as the smell of overheat ing components or smoke If such problems are indicated set the main switch to OFF immedi ately and call the factory before proceeding WARNING Through the Spindle Coolant TSC pump is a three phase pump and must be phased correctly Improper phasing will cause damage to the TSC pump and void the warranty Refer to the TSC start up section IF YOUR MACHINE IS EQUIPPED WITH tsc 6 After the power is on measure the voltage across the upper terminals on the contactor K1 located below the main circuit breaker It should be the same as the measurements where the input power connects to the main breaker If there are any problems check the wiring 183 Electrical Service 96 0189 rev L June 2005 7 Apply power to the control by pressing the Power On switch on the front panel Check the high voltage buss on the Vector Drive pin 2 with respect to pin 3 on the terminal bus at the bottom of the drive It must be between 310 and 360 volts If the voltage is outside these limits turn off the power and recheck steps 2 and 3 If the voltage is still outside these limits call the factory Next check the DC voltage displayed in the second page of the Diagnostic data on the CRT It is labeled DC BUS Verify that the displayed voltage matches the volt
16. AXIS AXIS X X SPARE SMTC INPUT SPARE SPARE SERIAL SERIAL PORT 2 PORT 2 PORT 1 PORT 1 SERIAL SERIAL SPARE SMTC OUTPUT SPARE PALLET CHANGER COOLANT COOLANT CONVEYOR CONVEYOR FUNCTION FUNCTION M M CHIP CHIP TSC TSC TOOL TOOL SWITCHES SWITCHES LIMIT LIMIT CHANGER CHANGER Connectors on side of control cabinet 202 Technical Reference 96 0189 rev L June 2005 5 5 SERVOS SERVO ENCODERS Haas machines are equipped with brushless motors which provide for better performance and no mainte nance The brushless motors have built in 8192 line encoders built in which result in differences a resolution of 32768 parts per revolution The motor controller board has a dedicated processor which does all the servo control algorithm SERVO AMPLIFIERS NOTE Refer to Cable Locations section in the Service manual for a diagram of the amplifiers The brushless servo amplifier is a PWM based current source The PWM outputs control the current to a three phase brushless motor The PWM frequency is either 12 5 KHz or 16 KHz The amplifiers are current limited to 30 amps peak 45A peak for a medium amplifier However there are fuse limits both in hardware and software to protect the amplifiers and motors from over current The nominal voltage for these amplifiers is 320 volts Therefore the peak power is about 9600 watts or 13 H P The amplifiers also have short circuit over tem
17. Lifting Device 1000lb capacity for ATC removal Spanner Wrench Split Tools Mechanical Service 76 96 0189 rev L June 2005 Removal 1 Power Off machine 2 Unscrew the BHCS from the carousel number disc and remove 3 Using a spanner wrench remove nut on the center shaft of the carousel 4 Carefully pull carousel assembly from the ATC center shaft Lift carousel away from the machine and carefully avoid hitting the sheet metal covers Place assembly in service area CAUTION Be careful not to bend the tool pocket orientation tabs when storing the carousel assembly 5 Unscrew the FHCS for each tool pocket Remove the tool pocket holders from carousel Installation 1 Carefully lift and place carousel on to the center shaft 2 Install new carousel retaining nut on to the ATC center shaft and torque to 85 ft lbs place the locking portion of the nut towards the end of the shaft Remove the pocket stop and slider Carousel Number Disc Mounting BHCS 8 Carousel Shaft Nut Carousel Carousel Housing Tool Pockets Top View Tool Pocket Load Position Tool Pocket Mounting FHCS Carousel Slider Position Pocket Orientation Tabs Pocket Stop Carousel Assembly Carousel and Tool Pocket Installation 3 Install each tool holder through the spindle Attach the tool pocket to the carousel Apply blue loctite to the Torx and torque to 15 ft lbs 1 4 20 23 ft lbs 5 16 1
18. P9 690 A ENCODER INPUT A ENCODER P30 690B B ENCODER INPUT B ENCODER BRUSHLESS TOOL CHANGER P10 550 MOTIF INPUTS I O OUTPUTS I O PCB P4 P11 510 I O RELAYS 1 8I O PCB P1 P12 520 I O RELAYS 9 16 I O PCB P2 P13 530 I O RELAYS 17 24 I O PCB P51 P14 540 I O RELAYS 25 32 I O PCB P3 P15 860 LOW VOLTAGE POWER SUPPLY PCB P16 720 SP LOAD METER LOAD METER P17 980 VOLTAGE MONITOR N A N A P18 750 JOG ENCODER INPUT JOG HANDLE P19 ADDRESS BUSS VIDEO PCB MICRO PROC PCB P20 1000 SP ENCODER INPUT SPINDLE ENCODER P21 X AXIS TEMP SENSOR P22 730B SP DRIVE LOAD SPINDLE DRIVE P24 990 HOME SENSORS X Y amp Z LIMIT P26 Y AXIS TEMP SENSOR P27 Z AXIS TEMP SENSOR P31 690C C AXIS ENCODER INPUT SPINDLE MOTOR lathe P33 640C VCTR DR CUR CMD VECTOR DRIVE J3 273 Cable Locations 96 0189 rev L June 2005 RS 232 PORT 1 PCB CABLE CONNECTIONS PLUG CABLE TO LOCATION PLUG P1 850 VIDEO amp J13 INTERNAL KEYBOARD J1 EXTERNAL GND PIN 1 P1 P2 P3 34 4090 Cable Locations 274 96 0189 rev L June 2005 Y DELTA SWITCH ASSEMBLY P N 32 5851B 40T 10HP P N 32 5864A SUPER SPEED AND 50T K4 K5 TO IO PCB P58 TO IO PCB P12 TO HAAS VECTOR DRIVE TO SPINDLE MOTOR 650A TO K5 AUX TO K5 COIL TO K5 COIL TO K4 COIL TO K4 COIL 650B Y
19. SWITCH REPLACEMENT NOTE This section is applicable for the POWER ON POWER OFF EMERGENCY STOP CYCLE START and FEED HOLD switches 1 Turn the machine power off 2 Remove the four screws holding the cover panel on the back of the control panel Take care to hold the cover panel in place until all screws have been removed 3 Disconnect all leads to the switch s connectors Ensure all leads are properly marked for recon necting later Refer to Fig 4 5 1 for proper locations 4 Unscrew the two small set screws one on top and one on the bottom and turn the switch counter clockwise to loosen Separate from the front portion and pull out 5 For replacement screw the front and rear portions together reverse of removal and tighten down the two small set screws when the switch is properly positioned NOTE The POWER ON POWER OFF and EMERGENCY STOP switches must all have the connectors on the bottom of the switch 6 Reconnect all leads to the correct switch 195 Electrical Service 96 0189 rev L June 2005 SPINDLE LOAD METER REPLACEMENT 1 Turn the power off and disconnect power to the machine 2 Remove the four screws holding the cover panel on the back of the control panel Take care to hold the cover panel in place until all screws have been removed 3 Disconnect the two leads at the back of the spindle load meter assembly Ensure the two leads are properly marked for reconnecting later 4 Unscrew t
20. The table trips the clamp switch not the clamp plate 1 Table Indexes into position based on servo control parameters Clamp plate is in un clamp position it is held there by air pressure compressing the springs Clamp status switch plunger is away from the Normally Open NO proximity switch 2 When ta0ble is in position the solenoid valve actuates to pressurize the clamp side of the piston A combi nation of air pressure and spring force combine to clamp the table approximately 10 000 pounds of clamp force depending on air pressure The table lowers and contacts the clamp status switch plunger The plunger is pushed down and trips the normally open NO status switch to close contacts 3 To unclamp the solenoid switch shuttles to exhaust the clamp side and pressurize the unclamp side of the piston The unclamp air pressure must compress the clamp springs to raise the clamp plate For the first portion of the travel the springs between the table and the H frame aid in raising the clamp plate At the top of piston travel the clamp status switch plunger raises it is pushed up by a spring and comes clear of the proximity switch The NO switch is now open and the table is ready to index Table Clamp Status Under Different Conditions Troubleshooting 23 96 0189 rev L June 2005 Table Clamp A Condition is clamped when machine is normally powered off or when first powered on or when table index is completed P 1 3
21. 26 27 28 29 30 31 32 33 34 9 315 Assembly Drawings 96 0189 rev L June 2005 EC 300 Clolumn Assembly 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 17 4 16 10 7 1 25 2767 Mounting Bracket 2 32 2130 Prox Switch 3 62 0017 Servo Motor 4 25 7042 Cover Plate 5 20 2686 Ballscrew Bumper 6 20 2588 Column Casting 7 20 6361 Y Axis Bumper 8 25 5732 Column Cover 9 20 7009 Bearing Housing 10 21 2131 Prox Switch 11 62 0014 Servo Motor 12 20 2734 Bumper Cover 13 24 0023 Ballscrew Assembly 14 25 7080 Bracket 15 50 3400 Linear Guides 16 24 0041 Ballscrew 17 30 6403 Y Axis Lube Line Assembly 316 Assembly Drawings 96 0189 rev L June 2005 EC 300 Spindle Head Assembly 1 2 3 4 5 6 7 8 9 10 11 12 13 14 16 17 18 20 21 22 19 15 23 16 14 1 20 7016 Spindle housing 2 50 0017 Linear Guide 35mm truck 3 20 1693 TRP Incline Cylinder 4 73 3055 Terminal Buss 5 25 5242 Shroud Bracket 6 30 6465 TSC Fitting Assembly 7 25 5213 Motor Shroud 8 62 3013 Spindle Motor 9 20 2520 Stand Off 10 20 2674 Spindle Head 11 25 6592 Junction Bracket 12 20 7022 Spindle Lock 13 20 2512 Incline Spindle Shaft 14 25 5970 Shim 15 20 1691 Shaft Inline 16 25 4648 Bracket Switch Mounting 17 20 1693 Cylinder Inline 18 30 2200 Prox Switch Unclamp 19 20 1696 Spring Retain Inline 20 30
22. 289 B LINEAR SCREW OFFS See parameter 285 for description 291 A AXIS BRAKE OIL TIME This parameter supports the EC1600 A axis brake oil sensor The units are seconds When this parameter is set to a non zero number and the sensor indicates a low oil condition for more than that amount of time the control will cause the red beacon to flash and display the message LOW BK OIL on the screen If the low oil condition continues alarm 643 LOW BRAKE OIL A AXIS will be generated when the program ends 292 AUTO DOOR PAUSE This parameter supports the Auto Door feature It specifies the length of a pause in 50ths of a second that occurs during the door close sequence As the door closes and the switch is activated the motor is turned off for this amount of time and the door coasts This allows the door to close smoothly This parameter should be set to 1 0 02 sec onds nominally It works in conjunction with parameter 293 293 AUTO DOOR BUMP This parameter supports the Auto Door feature It specifies the length of time in 50ths of a second that the motor should be reactivated after the pause specified by parameter 292 This causes the motor to close the door fully and smoothly This parameter should be set to 2 0 04 seconds nominally 294 MIN BUSS VOLTAGE This parameter specifies the minimum Haas Vector Drive buss voltage It should be set to 200 the units are volts Alarm 160 will be generated if the voltage falls below this value 295 SHTL SETTLE
23. 29 25 5893 Panel Top Partition 30 32 2300 Proximity Limit Switch Door Open 31 20 2696 Front Door Guide Bar 32 20 2317 Rail Load Station 2x 33 28 0165 Front Door Window 34 25 0668 Side Window Retainer 2x 35 59 6400A Guide Wheel 49 2015 PTHS 20x7 8 49 0015 NVT 45 16390 Washer 36 25 0669 Top Bottom Window Retainer 2x 37 59 9743 Front Door Spring 38 30 2009 Lower Right Corner Roller Assembly 39 25 5810 Front Door View Rotated for Clarity 6 1 2 3 4 5 7 9 8 10 11 12 13 14 15 16 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 17 18 19 20 25 5680 Front Panel Top Cover 310 Assembly Drawings 96 0189 rev L June 2005 EC 300 Operator Door Panels View Rotated 180 Looking Up 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 1 25 5888 Center Channel Cover Plate 2 25 5891 Cable Channel Cross Top 3 25 5799 Top Operator Side Cables Tray 4 25 5892 Cable Channel Cover Plate 5 25 5792 Right Intermediate Top Panel 6 20 2685 Operator Door Upper Door Rail 7 25 2684 Operator Door Lower Door Rail 8 25 5798 Operator Door Trip Bracket 9 25 5791 Operator Door 10 59 6210 Red Door Handle 11 30 7359 Operator Door Right Roller Assembly 2x 12 30 7358 Operator Door Left Roller Assembly 2x 13 25 5796 Left End Hinge Assembly 14 25 5
24. 29 PAL READY BUTTON This parameter accommodates both the APC on the vertical mill the Rotary Pallet Changer on the Horizontal mill This bit should be set to 1 on 2 pallet APC s to designate a single pallet button configuration Four pallet APC s have a 2 schedule pallet button and should have this bit set to zero Note that this bit should be zero on Horizontal Mills as it is intended for future pallet changer software that replaces the macro program 30 UNUSED 31 SPINDLE NOWAIT When 1 the machine will not wait for the spindle to come up to speed immediately after an M03 or M04 command Instead it will check and or wait for the spindle to come up to speed immediately before the next interpolated motion is initiated This bit does not affect rigid tapping or the TSC option 210 X AXIS TOOL CHANGE OFFSET Used on the HS 2RP mill for X axis displacement from the home position to tool change position If this parameter contains an incorrect value a horizontal mill will crash when it does a tool change 211 Y AXIS TOOL CHANGE OFFSET Used on the HS 2RP mill for Y axis displacement from the home position to tool change position If this parameter contains an incorrect value a horizontal mill will crash when it does a tool change 212 A TOOL CHANGE OFFSET This parameter sets the distance between the A axis grid offset Parameter 128 and the spindle home position The A axis will be limited in movement to the area between the positive value of t
25. 335 Z SCALES PER REV This parameter is used on machines equipped with linear scales This parameter should be set to 50 000 on mills fitted with linear scales On all other mills they should be set to zero 244 Parameters 96 0189 rev L June 2005 336 A SCALES PER REV This parameter is used on machines equipped with linear scales This parameter should be set to 0 on mills with or without linear scales 337 B SCALES PER REV This parameter is used on machines equipped with linear scales This parameter should be set to 0 on mills with or without linear scales 339 X SPINDLE THERM COEF This parameter supports the Spindle Head Thermal Compensation feature and should be set to 0 340 Y SPINDLE THERM COEF See parameter 339 for description 341 Z SPINDLE THERM COEF See parameter 339 for description 342 A SPINDLE THERM COEF See parameter 339 for description 343 B SPINDLE THERM COEF See parameter 339 for description 345 X SPINDLE THERM TIME CONST This parameter supports the Spindle Head Thermal Compensation feature and should be set to 0 346 Y SPINDLE THERM TIME CONST See parameter 345 for description 347 Z SPINDLE THERM TIME CONST See parameter 345 for description 348 A SPINDLE THERM TIME CONST See parameter 345 for description 349 B SPINDLE THERM TIME CONST See parameter 345 for description 351 THRML SENSOR OFFSET This is a parameter used for Ball Screw Thermal Compensation via a temperature sensor attached to t
26. 620 Y DRIVE SIGNAL MOCON PCB P3 TB HV HV 335VDC SPINDLE DRIVE Z AXIS AMP P 590 LOW VOLTAGE L V POWER SUPPLY TB A B C MOTOR DRIVE Z SERVO MOTOR P 630 Z DRIVE SIGNAL MOCON PCB P4 TB HV HV 335VDC SPINDLE DRIVE A AXIS AMP P 600 LOW VOLTAGE L V POWER SUPPLY TB A B C MOTOR DRIVE A SERVO MOTOR P 640 A DRIVE SIGNAL MOCON PCB P5 TB HV HV 335VDC SPINDLE DRIVE 265 Cable Locations 96 0189 rev L June 2005 POWER PCB FU7 C4 C3 C2 C7 C6 C5 C1 NE2 10A 115V MAIN 10A 230V COOLANT 10A 115V RTY USER POWER 10A 230V TSC COOLANT SPARE FUSES P1 P2 P3 P4 P5 P6 P7 P8 P9 P10 P11 P12 P13 P14 P15 P16 P17 P18 P19 P20 P21 P22 P23 P24 P25 P26 P27 P28 P30 P31 P32 P33 P34 P35 P29 TB1 TB3 TB2 NE1 NE4 FU8 FU12 FU11 FU10 FU9 NE6 NE5 NE3 FU13 FU12 NE12 NE11 NE10 NE9 NE8 NE7 NE13 FU14 FU1 FU2 FU3 Cable Locations 266 96 0189 rev L June 2005 POWER PCB CABLE CONNECTIONS PLUG CABLE SIGNAL NAME TO LOCATION PLUG P1 12VDC CNC Unit Fan P2 90B 115VAC Low Voltage Power Supply P3 90B 115VAC Probe PS P4 90B 115VAC Work Light P5 90B 115VAC Switch Door Fan P6 90B 115VAC Servo Fan P7 90B 115VAC Delta Wye P8 860 12 12 5 VDC In From Low Volta
27. 687 U MOTOR Z FAULT Encoder marker pulse count failure This alarm usually indicates that the encoder has been damaged and encoder position data is unreliable This can also be caused by loose encoder connectors 688 U AXIS Z CH MISSING Z Reference signal from encoder was not received as expected Can be caused by loose connections encoder contamination or parameter error 689 V AXIS Z CH MISSING Z Reference signal from encoder was not received as expected Can be caused by loose connections encoder contamination or parameter error 690 W AXIS Z CH MISSING Z Reference signal from encoder was not received as expected Can be caused by loose connections encoder contamination or parameter error 54 Alarms 96 0189 rev L June 2005 691 U AXIS DRIVE FAULT Current in U servo motor beyond limit Possibly caused by a stalled or overloaded motor The servos are turned off This can be caused by running the axis into a mechanical stop A short in the motor or a short of one motor lead to ground can also cause it 692 V AXIS DRIVE FAULT Current in V servo motor beyond limit Possibly caused by a stalled or overloaded motor The servos are turned off This can be caused by running the axis into a mechanical stop A short in the motor or a short of one motor lead to ground can also cause it 693 W AXIS DRIVE FAULT Current in W servo motor beyond limit Possibly caused by a stalled or overloaded motor The servos are turned off This can be caused by r
28. If the axis is made visible to service or adjust it the safety interlocks are disabled and the automatic operation of the tool changer is prohibited Be sure the spindle head is out of the way before rotating the double arm Offsets Both the Tool Change Offset and the Grid Offset must be set before using the tool changer The Grid Offset must be set first Setting the Grid Offset The control can calculate grid offset parameters with a GRID command A grid offset is an offset that is applied to the home position of an axis so that the zero location for that axis is re defined to be half an encoder revolution away from the home switch It is recommended that the GRID command be used on each axis separately 1 Zero Return all the axis 2 Turn the machine off and back on This will un zero all the axes 3 Select the ALARMS screen and enter DEBUG mode 4 Perform a ZERO SINGLE AXIS on the Tt axis Ignore the ZERO RET MARGIN TOO SMALL alarm if it occurs The tool arm is out of position and must be repositioned using tool change recovery if a tool arm fault is generated 5 Select the Positions screen enter GRID TT and press ENTER The message GRID OFSET DONE should appear and the GRID OFFSET parameters for the homed axes will have been updated If the message NO ZERO appears this indicates that none of the axes had been zeroed Mechanical Service 94 96 0189 rev L June 2005 Setting the Tool Change Offset
29. LEG 1 SECONDARY 295 LEG 2 SECONDARY 300 115VAC TO SPINDLE MOTOR FAN OILER PUMP SHIELD 2 301 LEG 1 115VAC PROTECTED 20 302 LEG 2 115VAC PROTECTED 20 303 SHIELD DRAIN 310 PC PALLET CW CCW 350 SPARE 115 VAC SERVO BRAKE 390 115VAC TO 4 TH AXIS BRAKE SHIELD 2 391 LEG 1 20 392 LEG 2 SWITCHED 20 393 SHIELD DRAIN 410 TOOL CHANGER DOOR OPEN 420 PALLET CLAMPED UNCLAMPED CLAMP ERROR 430 PC PALLET UP 440 SMTC CAGE DOOR OPEN MORI ARM OUT 450 MORI ARM CW CCW 460 MORI SLIDE 1 2 WAY MORI SLIDE LEFT 470 SMTC MOTOR STOP ORIGIN CLAMP UNCLAMP 490 ALL BRUSHLESS AXIS SERVO MOTOR DRIVE POWER CABLE 491 A PHASE 492 B PHASE 493 C PHASE 494 GROUND 490A 325VDC FROM SPINDLE DRIVE TO THE AMPLIFIERS SHIELD 2 491A HIGH VOLT P1 RED 12 492A HIGH VOLT N BLACK 12 493A SHIELD DRAIN 281 Cable List 96 0189 rev L June 2005 490B 325VDC FROM AMPLIFIER TO SERVO POWER SUPPLY 491B HIGH VOLT RED 20 492B HIGH VOLT BLACK 20 510 RELAY CARD 1 DRIVE CABLE 16 WIRE RIBBON 24 520 RELAY CARD 2 DRIVE CABLE 16 WIRE RIBBON 24 530 RELAY CARD 3 DRIVE CABLE 16 WIRE RIBBON 24 540 RELAY CARD 4 DRIVE CABLE 16 WIRE RIBBON 24 550 INPUTS CARD CABLE MoCon P10 34 WIRE RIBBON 24 570 LOW VOLTAGE BRUSHLESS AMPLIFIER POWER CABLE ASSEMBLY 571 12 VDC 22 572 GROUND 573 12 VDC 22 610 X AXIS HAAS AMPLIFIER CABLE TO MOTOR CONTROLLER BOARD MOTOR CONTROLLER BOARD SI
30. P43 P44 P45 R52 D21 Cable Locations 268 96 0189 rev L June 2005 I O PCB CABLE CONNECTIONS I O PLUG CABLE TO LOCATION PLUG P15 890 Spin Head Status SP DB open P16 780 Spare 2nd VD OV contactor on cntr balance P17 410 T C Air Door SW P18 790 Pallet CW CCW P19 190 Frnt Door sw Lo phase P20 190A Op Station Locked Frnt Door sw P21 240 Pallet Up Down BF load bar Q grnd fault P22 1070 Skip P23 420 Mori pin in arm in P24 440 Mori arm in cage door open arm out P25 450 Mori arm CW CCW P26 460 Mori slide 1 2 way slide left P27 470 Mori swing spin SMTC shuttle mark P28 480 Spare P29 1040A Door Interlock P30 1040 Door Interlock P31 230 5th Axis Brake P32 250 HTC Shuttle mori manual tool release P33 270 TSC Purge P34 260 Pal Ready P35 200 Spare P36 280 Beacons P37 140A Side Chip Conv En Rev HOPT P5 P38 140 230V to Chip Conv Mtrs P39 160 230V to Chip Conv Circuit PSUP P21 P40 300 Panel Lube Oil Pump P41 300A SP Fan Oil Pump Luber P42 170 Auto Off PSUP P23 P43 940 Coolant Mtr P44 930 230V to TSC Coolant Circuit PSUP P20 P45 940A TSC coolant P46 390 4th Axis Brake P47 350 Axis Brake TRANS P6 P48 120 Coolant O T Sensor P49 350A Hyd En TRANS P4 P50 130 TSC O T Sensor P51 430 Pallet Up P52 710 BF Collet open close P53 880C Wye Delta Switch P54 880A High Low Gear 50T P55 880B Chuck unclamp P56 90 115V Pow
31. PHASE B 230VAC 143 PHASE C 230VAC 144 STARTING WINDING 230VAC 145 STARTING WINDING 230VAC 160 3PH 230VAC TO CHIP CONVEYOR CONTROLLER SHIELD 3 161 PHASE A 230VAC 20 162 PHASE B 230VAC 20 163 PHASE C 230VAC 20 164 SHIELD DRAIN 170 AUTO OFF FUNCTION SHIELD 2 171 UNSWITCHED LEG 1 20 172 SWITCHED LEG 2 20 173 SHIELD DRAIN 180 SPARE COOLANT SPIGOT DETENT SWITCH 190 PALLET CHANGER OPERATOR STATION LOCK FRONT DOOR 191 SIGNAL 20 192 RETURN 20 193 SHIELD DRAIN 200 SPARE 12 VDC COOLANT SPIGOT MOTOR 210 DATA CABLE TO 3 FLOPPY DISK DRIVE 34 PINS 230 5 th AXIS BRAKE PALLETS UP HS 1RP SHIELD 2 231 115VAC COMMON 232 115VAC SWITCHED 233 SHIELD DRAIN 240 PALLET CHANGER PALLET UP DOWN 241 PALLETS UP 20 242 PALLETS DOWN 20 243 COMMON 20 244 SHIELD DRAIN 250 HTC SHUTTLE MORI MANUAL TOOL RELEASE 251 LEG 1 20 252 LEG 2 20 253 SHIELD DRAIN 260 12 VDC RELAY OUTPUT TO PALLET READY LAMP SHIELD 2 261 SWITCHED LEG 1 20 262 UNSWITCHED LEG 2 20 263 SHIELD DRAIN Cable List 280 96 0189 rev L June 2005 270 115 VAC RELAY OUTPUT TO PURGE SOLENOID SHIELD 2 271 UNSWITCHED LEG 1 20 272 SWITCHED LEG 2 20 273 SHIELD DRAIN 280 115 VAC RED GREEN BEACON CABLE SHIELD 3 281 RED LAMP 115VAC 282 GREEN LAMP 115VAC 283 COMMON 115VAC 284 SHIELD DRAIN 290 115VAC TO XFORMER T2 10VAC OUTPUT 291 LEG 1 PRIMARY 292 LEG 2 PRIMARY 293 CENTER TAPPED GROUND 294
32. Parameter 320 specifies the pallet clamp timeout period 35 Alarms 96 0189 rev L June 2005 172 APC PALLET UNCLAMP TIMEOUT The pallet in the mill did not unclamp in the time allowed Check for foreign objects between the pallet and the clamp plate Verify there is an adequate supply of air pressure and air volume Check air solenoids for sticking and air release ports for clogging Check the pallet position switch for correct operation the switch and wiring for damage and pallet alignment Check the pallet clamp plate for damage After determining the cause and correcting the problem run M50 P1 in MDI to recover the pallet changer and then continue operation Parameter 321 specifies the unclamp timeout period 173 SPINDLE ENCODER Z CH MISSING The Z channel pulse from the spindle encoder is missing for hard tapping synchronization 174 TOOL LOAD EXCEEDED The tool load limit is set and the load limit for a tool was exceeded in a feed 175 GROUND FAULT DETECTED A ground fault condition was detected in the 115V AC supply This can be caused by a short to ground in any of the servo motors the tool change motors the fans or the oil pump 176 OVERHEAT SHUTDOWN An overheat condition persisted longer than the interval specified by parameter 297 and caused an automatic shutdown 177 OVERVOLTAGE SHUTDOWN An overvoltage condition persisted longer than the interval specified by parameter 296 and caused an automatic shutdown 178 DIVIDE BY ZERO Th
33. RS 232 32 4090 J1 PORT 1 Serial User s Port PORT 2 Aux Axis Port Figure 4 4 1 RS 232 wiring pictorial with serial keyboard 5 To remove the RS 232 board unscrew the two hex screws on the exterior of the cabinet holding the connector to the cabinet From the inside of the cabinet pull the connector through the panel and disconnect the cable 6 Replace the RS 232 board by first connecting the appropriate cable to the board 850 to SERIAL PORT 1 850A to SERIAL PORT 2 then inserting the board cable side up through the left side panel Attach with the two hex screws previously removed Ensure the board for Serial Port 1 is the upper connector and the board for Serial Port 2 is the lower connector 7 Replace the Serial Keyboard Interface KBIF board using the four screws previously removed starting at the top right Attach the screw and standoff loosely then all other screws and standoffs until all are mounted Tighten down completely 8 Reconnect all cables to the Serial KBIF board at their proper locations 191 Electrical Service 96 0189 rev L June 2005 RS 232 SERIAL INTERFACE There are two connectors used for the RS 232 interface The RS 232 connector on the back of most PC s is a male DB 25 so only one type of cable is required for connection to the controller or between controllers This cable must be a DB 25 male on one end and a DB 25 female on the other Pins 1 2 3 4 5 6 7 8 and 20 must
34. Until this light goes out there are dangerous voltages in the assembly EVEN WHEN POWER IS SHUT OFF 1 Turn machine power off 2 Turn the main switch upper right of electrical cabinet to the off position Figure 4 3 1 3 Open the cabinet door and wait until the red CHARGE light on the servo drive assembly goes out before beginning any work inside the electrical cabinet 4 On the POWER SUPPLY board there are three fuses located in a row at the upper right of the board these are the overvoltage fuses An orange light will be on to indicate the blown fuse s Electrical Service 186 96 0189 rev L June 2005 Figure 4 3 2 Power supply board fuse locations 5 Using a flat tip screwdriver turn the fuse s counterclockwise to remove and replace the blown fuse s with ones having the same type and rating amp type AGC 250V CAUTION When the left fuse is blown it is still possible to operate the machine thereby making an overvoltage situation possible VERIFY absolute volt age to the machine does not exceed 200 volts Max 260 leg to leg or leg to ground or 400 volts on high voltage machines max 520 volts leg to leg of leg to ground 187 Electrical Service 96 0189 rev L June 2005 4 4 PCB REPLACEMENT Please read this section in its entirety before attempting to replace any PCBs MICROPROCESSOR MOCON amp VIDEO KEYBOARD WARNING WARNING WARNING WARNING WARNING The electrical panel will have res
35. defaults to 1 4 of parameter 183 Max Frequency 10 X FUSE LEVEL Used to limit average power to motor If not set correctly this parameter can cause an overload alarm 219 Parameters 96 0189 rev L June 2005 11 X TORQUE PRELOAD TORQUE PRELOAD is a signed number that should be set to a value from 0 to 4095 where 4095 is the maximum motor torque It is applied at all times to the servo in the same direction It is used to compen sate in the vertical direction for gravity on a machine with an axis brake instead of a counterbalance Normally the brake is released when the servo motors are activated When the vertical axis is commanded to move the brake is released and the servo motors are activated This parameter specifies the bias torqu needed to compensate for gravity 12 X STEPS REVOLUTION Encoder steps per revolution of motor Thus an 8192 line encoder gives 8192 x 4 32768 13 X BACKLASH Backlash correction in encoder steps 14 X DEAD ZONE Dead zone correction for driver electronics Units are 0 0000001 seconds 15 Y SWITCHES See Parameter 1 for description 16 Y P GAIN See Parameter 2 for description 17 Y D GAIN See Parameter 3 for description 18 Y I GAIN See Parameter 4 for description 19 Y RATIO STEPS UNIT See Parameter 5 for description 20 Y MAX TRAVEL STEPS See Parameter 6 for description 21 Y ACCELERATION See Parameter 7 for description 22 Y MAX SPEED See Parameter 8 for description 23 Y
36. mechanism binding damaged motor or debris build up Use Tool Changer Restore to recover the ATC then resume normal operation 41 Alarms 96 0189 rev L June 2005 299 ATC SHUTTLE OUT OF POSITION The ATC shuttle mark switch is in an incorrect state Check for a sticking misaligned or damaged switch mechanism binding damaged motor or debris build up Use Tool Changer Restore to recover the ATC then resume normal operation 302 INVALID R IN G02 OR G03 Check your geometry R must be greater than or equal to half the distance from start to end with an accuracy of 0 0010 inches 0 010 mm 303 INVALID X Y OR Z IN G02 OR G03 Check your geometry 304 INVALID I J OR K IN G02 OR G03 Check your geometry Radius at start must match radius at end of arc within 0 001 inches 0 01 mm 305 INVALID Q IN CANNED CYCLE Q in a canned cycle must be greater than zero 306 INVALID I J K OR Q IN CANNED CYCL I J K and Q in a canned cycle must be greater than zero 307 SUBROUTINE NESTING TOO DEEP Subprogram nesting is limited to nine levels Simplify your program 309 EXCEEDED MAX FEEDRATE Use a lower feed rate 310 INVALID G CODE G code not defined and is not a macro call 311 UNKNOWN CODE Program contained a line or code that is not understood 312 PROGRAM END End of subroutine reached before M99 Need an M99 to return from subroutine 313 NO P CODE IN M98 M97 M96 G47 OR G65 In M96 M97 M98 or G65 must put subprogram number in P cod
37. 1 VF 11 40Taper 85psi 3 8 I D VF 5 VF 11 50 Taper 85psi 1 2 I D VR Series 85psi 1 2 I D VS 1 3 85psi 1 2 I D The recommended method of attaching the air hose is to the barb fitting at the back of the machine with a hose clamp If a quick coupler is desired use a 1 2 coupler NOTE Excessive oil and water in the air supply will cause the machine to malfunction The air filter regulator has an automatic bowl dump that should be empty before starting the machine This must be checked for proper operation monthly Also excessive contaminants in the air line may clog the dump valve and cause oil and or water to pass into the machine NOTE Auxiliary air connections should be made on the unregulated side of the air filter regulator WARNING WARNING WARNING WARNING WARNING When the machine is operating and the pressure gauge on the ma chine regulator drops by more than 10 psi during tool changes or pallet changes insufficient air is being supplied to the machine 252 96 0189 rev L June 2005 MAINTENANCE SCHEDULE The following is a list of required regular maintenance for the machining center Listed are the frequency of service capacities and type of fluids required These required specifications must be followed in order to keep your ma chine in good working order and protect your warranty Interval Maintenance Performed Daily Check coolant level each eight hour shift especially du
38. 1 Set the Tool changer axis to Visible This is done by setting bit 18 of Parameter 462 to zero 2 Make sure the spindle head is up out of the way 3 Go to the Discrete Inputs page and look at the cambox origin display 4 Handle jog rate 01 the TT B axis until Origin and Motor Stop are 1 5 Handle jog in the positive direction until both the Motor Stop and Origin are 0 Switch displays to the Position page and continue jogging the axis 3 5 degrees in the same direction past this position 6 Handle jog the axis in the negative direction 01 degrees per pulse until both Motor Stop and Origin are 1 Note that you cannot back up if the mark is missed If the mark has been missed go back to step 5 7 Go to the Pos Raw Data page Under the Command header the display shows the B axis encoder counts Write down the current number 8 Go back to the Discrete Inputs page Watch Motor Stop and Origin Handle jog in negative direction until one of them changes to 0 the first one to change 9 Go back to the Position page and write down the current number from the same column as step 7 Add both numbers and divide by 2 this is the amount of tool change offset but with the wrong sign 10 Return to the Discrete Inputs page and handle jog the axis back until the Motor Stop and Origin are 1 11 Enter the calculated number as a neg
39. 1 15 11 25 6022 Panel Tools 16 30 12 25 5998 Disk Section 2 13 20 2966 Carousel Ribs 14 20 2864A Pivot Packet 15 51 0045 Cam Follower 16 20 2913 Plate Index 17 20 0458A Tool Pockets 18 20 2828 Pocket Carousel 19 30 0145 Cambox Assembly 20 20 0455 ATC Cambox 21 20 0238 Bearing Cap 22 20 2825A Machining Mount 23 20 2121 Double Arm 24 20 0240F Hub Arm 25 20 2867 Stop Pocket EC 400 60 40 Tool changer 321 Assembly Drawings 96 0189 rev L June 2005 1 2 3 4 5 6 7 8 9 3 10 11 8 9 12 13 14 15 6 4 1 EC 400 Base Casting 1 62 0016 Motor 2 32 2130 Limit Switch 3 30 1215 Ball Screw Coupling 4 20 9212 Bearing Housing 5 20 2042 Casting 6 24 0026 Ballscrew 7 20 2084 Hard Stop X Axis 8 20 0152 Bearing Housing 9 50 3400 Linear Guides 10 20 0151 Motor Mount Assy 11 32 2134 Limit Switch 12 20 2450 Z Axis Bumper 13 30 6336 Z Axis Lube Assy 14 20 1992 Bumper 15 30 6337 X Axis Lube Assy 322 Assembly Drawings 96 0189 rev L June 2005 EC 400 Operator s Door 1 25 4954 Header Side Right 2 20 2036 Door Track Upper Operator 3 25 5228 Z Frame TC Operator s Door Window x2 4 28 0151 Window TC Panels Operator s Door 5 25 4966 Operator Door 6 20 2038 Door Track Lower 7 25 5198 Panel Operator Lower 8 25 4955 Pan Right Intermediate 9 25 4982 Apron Right Rear 10 25 5246 Chip Shield 11 25 5245 Chip Shield Lower Operator Panel 12 25 52
40. 125 SHUTTLE FAULT Tool shuttle not initialized at power on CYCLE START or spindle motion command This means that the tool shuttle was not fully retracted to the Out position 126 GEAR FAULT Gearshifter is out of position when a command is given to start a program or rotate the spindle This means that the two speed gear box is not in either high or low gear but is somewhere in between Check the air pressure the circuit breaker CB4 for the solenoids and the spindle drive Use the POWER UP RESTART button to correct the problem 127 NO TURRET MARK Tool carousel motor not in position The AUTO ALL AXES button will correct this but be sure that the pocket facing the spindle afterwards does not contain a tool 128 SUPER TRAVEL ENABLED ON MULTIPLE AXES Two or more axes are enabled for super travel Only one axis is allowed to have super travel capability Super travel is enabled when a tool change offset parameter is greater than or less than normal travel limits Check the Max Travel and Tool Change Offset parameter values for the X and Y axes 129 M FIN FAULT M Fin was active at power on Check the wiring to your M code interfaces This test is only per formed at power on 130 TOOL UNCLAMPED The tool appeared to be unclamped during spindle orientation a gear change a speed change or TSC start up The alarm will also be generated if the tool release piston is energized during Power Up This can be caused by a fault in the air solenoids the rela
41. 13 Remove the Encoder belt and the drive belts Mechanical Service 66 96 0189 rev L June 2005 CAUTION Measure the distance between the bottom of the Z axis motor and the ballscrew anchor mount Cut a wood block to the proper length and put in place This is necessary to counteract the Hydraulic Counterbalance mechanism when the transmission motor assembly is lifted off the ma chine 14 Mark and remove the power cables from the motor 15 Attach a heavy chain to the lifting eyeholes of the top motor plate using hooks or C clips of appropriate weight rating approximately 250 lbs CAUTION Before proceeding make sure you have appropriate lifting equipment to safely lift 250 lbs room to maneuver it and a stable place to set the transmission motor assembly once it is removed 16 Lift off the transmission motor assembly Installation CAUTION Before proceeding make sure you have appropriate lifting equipment to safely lift 250 lbs and room to maneuver 1 Lift the transmission motor assembly into place The next five steps 2 6 can be performed with the transmission motor assembly turned slightly to ease installation of accessory parts 2 Connect the power wires 3 Attach the electrical plug panel to the rear of the motor Reattach any Molex plugs to the panel if removed during the previous procedure 4 Slide on the drive belts 5 Place and secure the TRP solenoid assembly to the top of the motor lift p
42. 2005 VIDEO PLUG CABLE SIGNAL NAME TO LOCATION PLUG P1 860 LOW VOLTAGE POWER SUPPLY PCB J3 700 KEYBOARD INFO KEYBOARD INT J4 ADDRESS BUSS MICRO PROC PCB J5 DATA BUSS MOTIF PCB J10 FLOPPY DR POWER FLOPPY DRIVE J11 SPARE N A N A J12 FLOPPY DR SIGNAL FLOPPY DRIVE P13 760 VIDEO SIGNAL CRT J9 RS422 B N A N A J13 850 SERIAL DATA N A J1 Not used with Serial Keyboard Interface VIDEO amp KEYBOARD PCB W FLOPPY DRIVE 271 Cable Locations 96 0189 rev L June 2005 MOCON PCB P19 JU2 P1 P15 U43 INSTALL JUMPER FOR MOCON 2 P24 P16 P10 P12 P11 P14 P13 P18 P20 P6 P7 P8 P9 P30 P31 P33 P32 P5 P4 P3 P2 P34 P26 P21 P17 P22 P27 P28 P35 Cable Locations 272 96 0189 rev L June 2005 MOCON PCB CABLE CONNECTIONS MOCON PLUG CABLE SIGNAL NAME TO LOCATION PLUG P1 DATA BUSS VIDEO PCB MICRO PROC PCB P2 610 X DRIVE SIGNAL X SERVO DRIVE AMP P P3 620 Y DRIVE SIGNAL Y SERVO DRIVE AMP P P4 630 Z DRIVE SIGNAL Z SERVO DRIVE AMP P P5 640 A DRIVE SIGNAL A SERVO DRIVE AMP P P32 640B B DRIVE SIGNAL B SERVO DRIVE AMP P P6 660 X ENCODER INPUT X ENCODER P7 670 Y ENCODER INPUT Y ENCODER P8 680 Z ENCODER INPUT Z ENCODER
43. 2233 Prox Switch Clamp 21 20 2520 Standoff Inline 22 20 1692 Piston Inline 23 20 2521 Striker Plate Inline 317 Assembly Drawings 96 0189 rev L June 2005 EC 300 Pallet Changer 1 25 5880A Rotating Door Cap 2 25 5878A Rotating Door 3 59 0580 Name Plate P2 4 25 5874 Clamshell Cover Access 5 25 5875 Clamshell Cover Access 6 25 5873 Clamshell Pallet Cover 7 20 2782 Pallet 8 HRT210 9 20 2688 Pallet Changer Table 10 20 2218 Toe Clamps 11 22 9087 Table Bolt Plug Dowel Pin 12 59 0579 Name Plate P1 13 25 5883 Rotating Access Cover 14 20 2695 Rotating Door Fairlead P1 1 2 3 4 14 13 1 5 6 2 7 8 6 9 10 9 11 4 5 12 318 Assembly Drawings 96 0189 rev L June 2005 EC 300 Pallet Changer 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 A 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 17 48 8 49 50 51 52 Note The locations illustrate lifting points A 1 25 6845 Motor Cover 2 62 0014 Servo Motor 3 20 2724 Motor Flange 4 20 2812 Stabilizer Plate 5 25 5934 Retainer Button 6 40 1640 SHCS 10 32 x 7 20 2814 Stabilizer Button 8 20 2729 Pallet Support Frame 2x 9 25 5876 Clamshell Splash Shield 10 25 5877 Clamshell Splash Shield 11 59 0724 Harmonic Drive 12 25
44. 28 BRUSH MOTOR Enables the brushless motor option 29 LINEAR DISPL This bit changes the display from degrees to inches or millimeters on the A and B axes 30 SCALE X LO With SCALE X HI bit determines the scale factor used in bit SCALE FACT X 31 SCALE X HI With SCALE X LO bit determines the scale factor used in bit SCALE FACT X See below HI LO 0 0 3 0 1 5 1 0 7 1 1 9 2 X P GAIN Proportional gain in servo loop 3 X D GAIN Derivative gain in servo loop 4 X I GAIN Integral gain in servo loop 5 X RATIO STEPS UNIT The number of steps of the encoder per unit of travel Encoder steps supply four 4 times their line count per revolution Thus an 8192 line encoder and a 6mm pitch screw give 8192 x 4 x 25 4 6 138718 5 steps per unit inch mm ratio 6 X MAX TRAVEL STEPS Max negative direction of travel from machine zero in encoder steps Does not apply to A axis Thus a 20 inch travel 8192 line encoder and 6 mm pitch screw give 20 0 x 138718 2774360 7 X ACCELERATION Maximum acceleration of axis in steps per second per second 8 X MAX SPEED Max speed for this axis in steps per second 9 X MAX ERROR Max error allowed in servo loop before alarm is generated Units are encoder steps This is the maximum allowable error in Hz between the commanded speed and the actual speed The purpose of this param eter is to prevent motor runaway in case of phasing reversal or bad parameters If this parameter is set to 0 it
45. 320 VDC to 345 VDC with the machine powered up but not running If the voltage is not in this range adjust the taps on the main line transformer until this voltage range is achieved There is a possibility the drive is faulty but low Bus voltage can also be caused by a shorted REGEN load or a shorted amplifier If the DC Bus voltage is below 50 VDC and never goes any higher perform Steps 1 6 1 With the machine powered up is the green POWER ON L E D lit If not replace the Vector Drive unit 2 Power down the machine Disconnect the REGEN load terminals 1 and 2 on the Vector Drive unit and measure the resistance from each wire to chassis ground open and between the wire leads The resistance should measure 6 ohms If not replace the REGEN load or cabling 3 Disconnect cable 490 at terminals 2 and 3 of the Vector Drive and from the servo amplifiers With a multimeter in the diode mode place the red meter lead to the HV terminal and the black meter lead to the HV terminal of each amplifier The meter should read open 4 Reverse the leads Place the red meter lead on the HV terminal and the black lead on the HV terminal The meter should read 7 ohms in both instances If not replace the faulty amplifier 5 Measure the resistance between terminals 1 and 3 of the Vector Drive The meter should read greater than 100K ohms If not the Vector Drive is faulty 6 If the green POWER ON L E D was lit from Step 2
46. 58 1679 Fitting Bulkhead 3 8 x 1 9 58 1693 x2 Fitting Elbo 1 2 x 3 8 M Str 10 25 5247 Apron TC Panel Front 11 25 4978 Panel TC Rear 12 25 4959 Panel Left Rear 13 25 4992 Stiffner Bracket Panel 14 25 4960 Header TC Panel 15 22 9673 Spacer 16 30 2464 Idler Assembly 17 25 0974 Retainer Chain 18 25 5032 Connect Bracket Top TC Door 19 54 0072 Chain 20 50 0012A Linear Guide 21 59 0641 Cylinder Rod Aligner 22 59 0612 Air Cylinder 23 30 2464 Idler Assembly 24 22 9673 Spacer 25 25 5033 Connect Bracket Bottom TC Door 26 25 4978 Panel TC Rear 27 25 4992 Stiffner bracket Panel 28 25 4959 Panel Left Rear 29 25 5295 Chip Shield TC Felt 30 25 4976 Coolant TC Drip Pan 31 25 4961 Pan TC 32 25 5247 Apron TC Panel 33 30 6753 Fitting Assembly Apron Coolant 34 25 4972 Apron Left Rear 35 25 4985 Chip Shield TC Panel 36 25 5283 Chip Shield TC Front 37 28 0151 Window TC Panel Operator Door 38 25 5228 Z frame TC Operator Door Window 39 25 5030 Door Top 40 20 2087 Door Guide 25 5034 Door Guide Spacer 41 25 5031 Door Button 42 25 5029 Panel TC Internal EC 400 Tool Changer Panels 329 Assembly Drawings 96 0189 rev L June 2005 EC 400 60 and 70 Tool Tool Changer Panels SMTC 60 Pocket Only SMTC 60 Pocket Only 18 19 20 21 22 23 24 25 19 18 TC Door Assembly TC Door Assembly View Rotated 180 View Rotated 180 38 39 40 41 26 1 2 3 4 5 6 7 8 9 10 11
47. 7 58 3031 Lube Fitg Adaptor 8 20 0166 Bumper 9 50 3400 Linear Guide 10 20 2058 Hardstop Y axis 11 25 7267 Mounting Bracket 12 32 2131 Home Switch 13 30 6338A Lube Line Assy 14 62 0017 Servomotor YASK 13 15 58 1693 Fitg LBO 16 58 3625 Fitg Reducer 17 58 3650 Fitg 18 58 0097 Fitg LBO 19 58 0287 Hex Nipple 20 25 5294 Bracket TRP 21 58 1680 Fitg Bkhd 22 58 2066 Fitg Hose Barb 23 25 4937 Trip Bracket X Axis 24 20 0150 Nut Housing 25 30 6337 Oil Line Assembly X Axis 26 58 0634 Copper Tubing Column 27 58 0029 Fitg Hose Barb 28 58 1679 Fitg Bkhd 29 59 0640 Cable Carrier Y Axis 338 Assembly Drawings 96 0189 rev L June 2005 1 25 5238B Shade Rotating Door Top 2 25 4149 Z Frame Window SMTC 3 28 0043A Window Partition 4 25 1262A 2X Z Frame Partition Top 5 25 5233A 2X Z Channel Rotating Door 6 20 2283A 2X Support Bar Rotating Door 7 25 5237 4X Shade Rotating Door Seal 8 20 2048 Pallet 9 25 5229 Chip Shield Bridge Right 10 20 2254 Load Station Lock Housing 11 59 6225 Knob 12 20 2255 Load Station Lock Pin 13 20 2253 Load Station Lock Mount EC 400 Pallet Changer Assembly 14 20 2249 Load Station Pallet Pin 15 20 2256 Load Station Index Disc 16 20 2258 Load Station Shaft 17 20 2257 Load Station Lock Plate 18 20 2115 H Frame APC 19 20 2046 Bridge Machined 20 25 5230 Chip Shield Bridge Left 21 25 5235 Step Right Rotating Door Seal 22 20 2154 Actuator Mount Block 23 25 5232B 2X Pane
48. 96 0189 rev L June 2005 292 Electrical Diagrams 96 0189 rev L June 2005 293 Electrical Diagrams 96 0189 rev L June 2005 CNC UNIT DATA BUS ADDRESS BUS DATA BUS ADDRESS BUS BOARD MOCON IOPCB IOPCB IOPCB IOPCB Z DRIVE SIG A DRIVE SIG LOAD METER LOW VOLTAGE POWER X DRIVE SIG Y DRIVE SIG 530 510 720 540 P16 520 P21 P22 RELAYS 1 8 RELAYS 9 16 RELAYS 17 24 RELAYS 25 32 610 860 P15 670 680 550 VOLTAGE MONITOR 0 5V IOPCB Y ENCODER Z ENCODER 690B B ENCODER HOME SWITCHES A ENCODER 690 V DRIVE LOAD 1 THRU 32 LOW VOLTAGE POWER TO OPERATOR PENDANT AUX RS 232 INDEXER RS 232 SERIAL KEYBOARD P1 760 860 J2 VIDEO VIDEO BOARD P3 850A 850 PROCESSOR BATTERY LOW VOLTAGE POWER 860 ADDRESS BUS DATA BUS BOARD B DRIVE SIG 660 X ENCODER SPINDLE ENCODER JOG INFO 1000 750 990 730B INPUTS 620 630 640 640B MOCON INPUTS P5 P4 P3 P2 P18 P20 P6 P7 P8 P9 P10 P24 980 P11 P13 P14 P12 P4 P1 J13 RS232 USER SERIAL PORT POWER P10 SPARE P11 FLOPPY DRIVE FLOPPY J12 P5 P4 S1 J6 EXT BAT 690C C ENCODER P30 P31 P32 C DRIVE SIGNAL VECTOR DRIVE P33 SP ENCODER P20 850 ENET ZIP HDD J6 J8 J4 J2 J9 HARD DRIVE RS 232 SERIAL FLOPPY PARALLEL PORT ZIP ENET 294 Electrical Diagrams 9
49. AXIS DISABLED Parameter has disabled this axis 336 A AXIS DISABLED An attempt was made to program the A axis while it was disabled DISABLED bit in Parameter 43 set to 1 or invisible INVIS AXIS bit in Parameter 43 set to 1 or a program commanded the A axis while it was the outside rotary table ROTARY INDEX button feature MAP 4TH AXIS bit in Parameter 315 set to 1 337 GOTO OR P LINE NOT FOUND Subprogram is not in memory or P code is incorrect P Not Found 338 INVALID IJK AND XYZ IN G02 OR G03 There is a problem with circle definition check your geometry 339 MULTIPLE CODES Only one M X Y Z A Q etc allowed in any block only one G codes in the same group 340 CUTTER COMP BEGIN WITH G02 OR G03 Select cutter compensation earlier Cutter compensation must begin on a linear move 341 CUTTER COMP END WITH G02 OR G03 Disable cutter compensation later 342 CUTTER COMP PATH TOO SMALL Geometry not possible Check your geometry 343 DISPLAY QUEUE RECORD FULL Cycle power on the machine If the alarm reoccurs call your dealer and report the sequence of events that lead to the alarm 344 CUTTER COMP WITH G18 amp G19 Cutter compensation only allowed in XY plane G17 346 M CODE DISABLED A There was an M80 or M81 commanded These commands are not allowed if Setting 51 DOOR HOLD OVERRIDE is OFF the SAFETY CIRCUIT ENABLED or the Parameter 251 is set zero Also check Setting 131 for Auto Door and Parameter 57 for DOOR STOP SP B Ther
50. Assembly Motor Wave Generator Step 1 onto the Har monic Drive Be sure to orient the Pinion Assembly so that the bolt holes line up with the holes in the Harmonic Drive This is an interference fit item 8 Place sealer on the 8 MHHB and thread into the holes of the Pinion Assembly Tighten in a star pattern MHHB Pinion Assembly O Ring Harmonic Drive Assembly 152 Mechanical Service 96 0189 rev L June 2005 INSTALLATION BACKLASH TUBE AND PLATE 1 Apply grease to the outer side of the Tube and top side as installed of the Plate Also apply grease to the counterbore for the Tube and the machined surface underneath the Table the Plate will move against 2 Assemble four Spring Washers in series and one 3 8 Hard Washer onto each Shoulder Screw They should be assembled so that a small space appears between the top and bottom pairs of washers 3 Orient the Backlash Plate so that the Push Blocks face the access holes of the Table Insert the Backlash Tube Plate assembly into the counterbore from beneath the Table Use caution to avoid marring the surface of the Tube 4 Insert the Shoulder Screws through the slots in the Plate closest to the Tube place the Hard Washer against this Plate and thread into the Table Tighten with a hex wrench to standard torque 5 Place a Flat Washer 45 1725 and a Lock Washer 45 1720 onto each HHB Thread the HHB up into the Table through the outer slots of the Plate Leave
51. Bearing Stop Block Harmonic Drive Assembly Roller Cage If the thrust bearing and washers have to be removed remove the unit as a whole so as not to loose the bearings Inevitably some bearings will fall out therefore it is advisable to have spare bearings for replacement To service the Air Blast assembly the pallets must be rotated perpendicular to the home position and at least 1 Pallet table must be removed After removing the pallet rotate the frame assembly with the empty pallet space back over clamp plate and remove the clamp plate followed by the air blast ring To service the Pallet Clamp Switch follow steps above for servicing the Air Blast then unbolt the four socket screws and pull the assembly out To service the air tubing remove the motor motor flange plate and the harmonic drive assembly Re assembly APC Spring Seating Procedure Pallet 1 1 In MDI mode write a simple program M17 M18 M99 to clamp and unclamp pallet 2 While P1 is clamped loosen but do not remove shoulder bolts retaining springs 3 In single block mode cycle program to observe the direction of table movement 4 Adjust spring location by gently tapping springs in the opposite direction of the table movement Run the program to verify adjustment 5 Repeat previous step until all pallet movement is gone then torque shoulder bolts to 75 ft lbs Run the program again to verify the adjustment was not affected 6 Repeat this
52. COM 275 Cable Locations 96 0189 rev L June 2005 M CODE RELAY BOARD CABLE CONNECTIONS PLUG CABLE SIGNAL NAME TO LOCATION PLUG P1 540 MOCON INPUT IO PCB P62 P2 860A 12VD TO M CODE PCBA PSUP P31 P3 540A IOPCB OUTPUT P4 M21 M FUNCTION M22 PROBE OPTION M24 spare P5 M25 spare M26 spare M27 spare P6 540B M CODE OUTPUT 2nd MCD P1 Cable Locations 276 96 0189 rev L June 2005 50T TRANSMISSION P S HYDRAULIC C B PCB CABLE CONNECTIONS PLUG CABLE TO LOCATION PLUG P1 880B IO PCB P12 P2 90 POWER PCB P8 P3 410 GEAR BOX P4 350 IO PCB P54 TB2 340 HYDRAULIC MTR TB3 70 MAIN TRANSFORMER VECTOR DRIVE UNIT FU1 115 VAC 115 V Servo Brake 880B P1 277 Cable Locations 96 0189 rev L June 2005 SERIAL PORT 1 SERIAL PORT 2 ETHERNET SPARE 1 SPARE 2 A AXIS Z AXIS Y AXIS X AXIS LIMIT SWITCHES TSC TOOL CHANGER CONTROL CABINET 5TH AXIS SPARE 4 SPARE 3 COOLANT MFIN CLG CHIP CONVEYOR SPARE 5 APC DR RECVR QAPC R QAPC L 190 200 300A 880A 890 950 UNCLAMP FROM SPINDLE HEAD TO I O PCB COOLANT SPIGOT MOTOR 115VAC TO SPINDLE MOTOR FAN OIL PUMP OILER HIGH LOW GEAR UNCLAMP LOCK SOLENOID POWER SPINDLE STATUS SWITCHES LOW AIR PRESSURE SENSOR FUNCTION NAME WIRE NUMBER SPINDLE HEAD JOG CRANK DATA CABLE RJH POWER ON OFF CABLE TO FRONT PANEL ANALOG SPEED COMMAND TO SPINDLE SPINDLE LOAD METER RED GREEN STATUS LIG
53. CRT will have the message POWER FAILURE ALARM and all other functions of the control will be locked out 215 Technical Reference 96 0189 rev L June 2005 5 21 THE EQUATIONS OF MOTION An analysis of the physics of motion of a machine tool can give some important insights into the blocks per second issue The following mathematics calculates the block per second requirement in order to achieve a worst case chordal deviation error while moving around a curve made up of a series of points Let a acceleration v speed or feed rate r radius of curvature e error from chordal deviation l block length or travel length from point to point b blocks per second The following are known For a circular motion a v v r 1 and in motion v b l 2 which gives b v l 3 and e r sqrt r r l l 4 4 which gives r r 2 r e e e r r l l 4 5 and l sqrt 8 r e 4 e e 6 Since r gt gt e e e is small compare to r e and we can assume l sqrt 8 r e 7 And combining we get b sqrt a r sqrt 8 r e 8 Or b sqrt a 8 e 9 Thus block per second is dependent only on the machine acceleration and the maximum chordal error al lowed For a VF 1 acceleration is about 60 inches per second per second This means that if the maximum error is 0 00005 one half of one ten thousandth the block per second required is 380 blocks per second For a VF 9 an acceleration of 30 in
54. Check pre charge solenoid for proper operation May be generated if another machine alarm occurs during TSC operation 28 Troubleshooting 96 0189 rev L June 2005 1 7 ELECTRICAL TROUBLESHOOTING CAUTION Before working on any electrical components power off the machine and wait approximately 10 minutes This will allow the high voltage power on the brushless amplifiers to be discharged ELECTRICAL ALARMS Axis Drive Fault Alarm Blown amplifier indicated by a light at bottom of amplifier when power is on Replace amplifier Amplifier or MOCON is noise sensitive If this is the case the alarm can be cleared and the axis will run normally for a while To check an amplifier switch the motor leads and control cables between the amplifier and the one next to it If the same problem occurs with the other axis the amplifier must be replaced If the problem stays on the same axis either the MOCON or control cable The problem could also be the axis motor itself with leads either shorted to each other or to ground Amplifier faulting out for valid reason such as overtemp overvoltage or 12 volt undervoltage condition This usually results from running a servo intensive program or unadjusted 12 volt power supply Overvoltage could occur if regen load is not coming on but this does not usually happen The problem could also be the axis motor itself with leads either shorted to each other or to ground Axis Overlo
55. F3 F4 POWER UP RESTART TOOL CHANGER RESTORE A A B Z Z Y X X amp UP HOME END DOWN PAGE RESET Pendant Leveling Assembly
56. FAULT Cable from A axis scale does not have valid differential signals 291 LOW AIR VOLUME PRESSURE DURING ATC An Automatic Tool Change was not completed due to insufficient volume or pressure of compressed air Check air supply line 292 320V POWER SUPPLY FAULT Power to the servos will be turned off when this alarm occurs Note that error code 5 on the mini power supply may occur under this condition 293 INVALID CHAMFER OR CORNER ROUNDING DISTANCE IN G01 Check your geometry 294 NO END MOVE FOR G01 CHAMFER CORNER ROUNDING A chamfer or corner rounding move was requested in a G01 command but no end move was commanded 295 MOVE ANGLE TOO SMALL IN G01 CORNER ROUNDING Tangent of half angle is zero Move Angle must be greater than 1 deg 296 INVALID PLANE SELECTION IN G01 CHAMFER OR CORNER ROUNDING Chamfer or corner rounding move and end move must be in the same plane as the beginning move 297 ATC SHUTTLE OVERSHOOT The ATC shuttle has failed to stop within the allowable standby position window during a tool change Check for a loose drive belt damaged or overheated motor sticking or damaged shuttle standby switch or shuttle mark switch or burned gear motor control board relay contacts Use Tool Changer Restore to recover the ATC then resume normal operation 298 ATC DOUBLE ARM OUT OF POSITION The ATC double arm mark switch CW position switch or CCW position switch is in an incorrect state Check for sticking misaligned or damaged switches
57. MHz one 128K EPROM between 1MB and 16MB of CMOS RAM and betwen 512K and 1 5MB of FAST STATIC RAM It also contains a dual serial port a five year battery to backup RAM buffering to the system buss and eight system status LED s Two ports on this board are used to set the point at which an NMI is generated during power down and the point at which RESET is generated during power down The eight LED s are used to diagnose internal processor problems As the system completes power up testing the lights are turned on sequentially to indicate the completion of a step The lights and meanings are RUN Program Running Without Fault Exception Normally On If this light does not come on or goes out after coming on there is a problem with the microprocessor or the software running in it Check all of the buss connectors to the other two PCB s and ensure all three cards are getting power PGM Program signature found in memory Normally On If this light does not come on it means that the main CNC program package was not found in memory or that the auto start switch was not set Check that switch S1 1 is on and the EPROM is plugged in CRT CRT VIDEO initialization complete Normally On If this light does not come on there is a problem communicating with the VIDEO PCB Check the buss connectors and ensure the VIDEO PCB is getting power MSG Power on serial I O message output complete Normally On If this light does not come on there
58. Nut Housing 12 20 0156 Bumper 342 Assembly Drawings 96 0189 rev L June 2005 EC 1600 Column Assembly 1 20 2506 Casting 2 62 0017 Motor 3 30 1517 Coupling 4 30 0764 Bearing 5 32 2131 Limit Switch 6 24 0003a Ballscrew 7 30 0472 Bearing Assy 8 20 0156 Bumper 9 30 6954 Lube Line Assy 10 20 2677 Bumper 11 50 9010 Linear Guides 12 25 7267 Switch Brkt 343 Assembly Drawings 96 0189 rev L June 2005 EC 1600 Saddle Assembly 1 20 2536 Casting 2 20 0151 Motor Mount Assy 3 32 2133 Limit Switch 4 25 7267 Switch Brkt 5 30 7410 Lube Line Assy 6 20 0150 Nut Housing 7 20 0152 Bearing Housing 8 20 9822 Guide Bar 9 24 9961c Ballscrew 10 50 9806 Linear Guides 11 30 1222 Bearing Assy 12 30 1215 Coupling Assy 13 20 0166 Bumper 14 62 0016 Motor 344 Assembly Drawings 96 0189 rev L June 2005 1 2 3 4 5 6 7 8 2 1 9 10 11 11 12 13 14 15 16 17 18 20 21 22 23 24 19 29 25 26 28 27 30 31 25 32 33 34 35 36 37 38 40 39 41 42 43 44 45 46 48 49 50 47 1 25 5615 Panel Encl Top 2 25 5621 Post Encl Top Cross 3 25 5622 Track Encl Door Roll 4 25 5623 Post Encl LT Top 5 25 5625 Cover Encl Top LT 6 25 5627 Cover Encl Top RT 7 25 5624 Post Encl RT Top 8 25 5629 Header Support 9 25 5618 Panel Encl Top Door 10 25 5614 Panel Encl Top 11 25 5616 Panel Encl Side 12 25 5617 Main Post Encl 1
59. POSITIONING ERROR This alarm is generated by the tool changer if the conditions are not correct when The carousel or tool arm was started and illegal conditions are present for example The carousel or arm motor already running The arm is not at the Origin The tool carousel is not at TC mark or the tool pocket is not locked The tool carousel was in motion and the Tool One Mark was detected but the current pocket facing the spindle was not at pocket one Or the current pocket is at pocket one but Tool One Mark is not detected 626 TOOL POCKET SLIDE ERROR This alarm is generated by the tool changer It is generated if the tool pocket has not moved to its commanded position and settled within the total time allowed by parameters 306 and 62 627 ATC ARM MOTION This alarm is generated by the sidemount disk type tool changer It is generated if the tool arm failed to move within the time specified by Parameter 309 ARM START TIMEOUT or if the tool arm failed to move to the designated position such as origin clamp or unclamp within the time specified by Parameter 308 ARM ROTATE TIME or if the tool pocket failed to move up or down within the time specified by Parameter 306 POCKET UP DN DELAY 628 ATC ARM POSITIONING ERROR This alarm is generated by the tool changer if The arm was being moved from the ORIGIN position to the CLAMP position and it coasted past the MOTOR STOP point or could not get to the CLAMP point The arm was being m
60. PROG mode and possibly delete some programs 435 DISK ABORT Could not read disk Possible corrupted or unformatted disk Try a known good disk Also caused by dirty drive heads Use an appropriate cleaning kit 436 DISK FILE NOT FOUND Could not find file Possible corrupted or unformatted disk Try a known good disk Also caused by dirty drive heads Use an appropriate cleaning kit 457 AUX AXIS IS ENABLED One or more auxiliary axes are enabled For the macro variables 750 and 751 to work the auxiliary axes must be disabled Make sure Setting 38 is 0 471 OUT OF TOOLS The life of all tools in the Advanced Tool Management group has expired 472 ATM FAULT Indicates an error related to the Advanced Tool Management feature ATM software encountered a group which does not exist Usually it can be fixed by adding the corresponding group 501 TOO MANY ASSIGNMENTS IN ONE BLOCK Only one assignment macro assignment is allowed per block Divide block into multiple blocks 502 OR NOT FIRST TERM IN EXPRESSN An expression element was found where it was not preceded by or that start expressions 503 ILLEGAL MACRO VARIABLE REFERENCE A macro variable number was used that is not supported by this control use another variable 504 UNBALANCED BRACKETS IN EXPRESSION Unbalanced brackets or were found in an expression Add or delete a bracket 505 VALUE STACK ERROR The macro expression value stack pointer is in error Cycle power on the machin
61. Pocket Alignment 1 Remove all cam box sheet metal fasteners and covers Place protective covers on the machine table 2 Power Up machine Move the Z axis all the way toward the spindle Set the machine control to Tool Change Recovery Mode TCR 3 Push the ARROW DOWN button to activate the tool pocket down insure proper tool pocket operation 4 POWER OFF the machine Disconnect the air supply line at the rear of the machine The tool pocket will swing out once the air is disconnected 5 At the back of the ATC assembly reverse the two air lines going from the solenoid valve to the air cylinder Reconnect the air supply line at the rear of the machine The tool pocket holder in the tool change position should retract 6 At the back of the ATC assembly manually rotate the cam box pulley clockwise until the output shaft is extended and just before it begins to rotate 1800 7 Align the double arm to the tool pocket and the spindle with the unlocking finger buttons facing in Place the double arm on to the shaft and snug the lock ring on the bottom of the double arm with the SHCS 8 Place the split tool into the double arm end in front of the tool pocket The split tool P Ns for 40T are T 2084 for CT type and T 2087 for BT type P Ns for 50T are T 2089 for CT type or T 2088 for BT type Depress the tool release button on the keypad and insert the split tool Slightly push the double arm in the clockwise direction to remov
62. Regulator Adjustment section and reset if necessary Low pre charge pressure can cause coolant to dump into the spindle head Ensure the coolant pump relief valve has not been tampered with yellow paint band is intact Check the coolant pump pressure should be 300 psi 2068 kilosascals with a standard non TSC tool holder in spindle If pump pressure is above 310 psi reset the pump relief valve Excessive coolant flow out of drain line or pulsating flow through tool and drain line Check pre charge pressure in accordance with TSC Precharge Regulator Adjustment section Reset precharge pressure if necessary Low pre charge pressure will cause heavy or pulsating flow from the drain line Check main air pressure regulator for 85 psi 241 kilopascals A higher supply pressure will reduce precharge pressure Lower supply pressure will increase precharge pressure Ensure the coolant pump relief valve has not been tampered with yellow paint band is intact Check the coolant pump pressure should be 300 psi 2068 kilosascals with a standard tool holder in spindle If pump pressure is above 310 psi 2137 kilopascals reset the pump relief valve LOW COOLANT Alarm 151 Low Thru Spindle Coolant Check coolant tank level Check for slow coolant drainage from the machine enclosure Check the filter and intake strainer for any clogging Read filter gauges with TSC running with no tool in spindle Check coolant lines for any
63. TIME Used on mills with an air driven shuttle This parameter allows settling time for the shuttle after it has moved toward the spindle and before a tool change is performed It should be set to approximately half a second 500 on all mills with the Air Driven Shuttle This may very All other mills can be set to 0 as they are unaf fected by it 296 MAX OVER VOLT TIME Specifies the amount of time in 50ths of a second that an overvoltage condition alarm 119 OVER VOLTAGE will be tolerated before the automatic shut down process is started 297 MAX OVERHEAT TIME Specifies the amount of time in 50ths of a second that an overheat condition alarm 122 REGEN OVERHEAT will be tolerated before the automatic shut down process is started 298 MAX FEED DEG MIN Used on 5 axes mills This parameter specifies the maximum rotary feed rate in degrees per minute Any attempt at cutting faster than this will result in LIM being displayed next to the FEED message on the Program Command Check screen On mills with a Gimbaled Spindle this parameter must be set to 300 For all other mills this bit should be set to 99999 299 AUTOFEED STEP UP This parameter works with the AUTOFEED feature It specifies the feed rate step up percentage per second and should initially be set to 10 300 AUTOFEED STEP DOWN This parameter works with the AUTOFEED feature It specifies the feed rate step down percentage per second and should initially be set to 20 301 AUTOFE
64. Tool Changer Restore to recover the ATC then resume normal operation 698 ATC PARAMETER ERROR The ATC type cannot be determined Check Parameter 278 bit 10 HS3 HYD TC or Parameter 209 bit 2 CHAIN TC as appropriate for the installed tool changer Use Tool Changer Restore to recover the ATC then resume normal operation 791 COMM FAILURE WITH MOCON2 During a self test of communications between the MOCON2 and main proces sor the main processor does not respond Check cable connections and boards This alarm could also be caused by a memory fault which was detected on the MOCON2 792 MOCON2 WATCHDOG FAULT The self test of the MOCON2 has failed Call your dealer 799 UNKNOWN MOCON2 ERROR Mocon2 has reported an alarm to the current software The current version of software was unable to identify the alarm 900 A PARAMETER HAS BEEN CHANGED When the operator alters the value of a parameter alarm 900 will be added to the alarm history When the alarm history is displayed the operator will be able to see the parameter number and the old value along with the date and time the change was made Note that this is not a resetable alarm it is for information purposes only 901 PARAMETERS HAVE BEEN LOADED BY DISK When a parameter file has been loaded from disk alarm 901 will be added to the alarm history along with the date and time Note that this is not a resetable alarm it is for information purposes only 902 PARAMETERS HAVE BEEN LOADED BY R
65. When the disk drive is enabled and a directory is read the directory listing is placed into a program as comments The program is then made the current program so the user can read the contents of the disk drive This parameter designates where to write the directory listing Program 08999 is the default value 228 QUICKCODE FILE This parameter set the program numbers to store in the Quick Code definition program Usually this is 9999 229 X LEAD COMP 10E9 This parameter sets the X axis lead screw compensation signed parts per billion 230 Y LEAD COMP 10E9 This parameter sets the Y axis lead screw compensation signed parts per billion 231 Z LEAD COMP 10E9 This parameter sets the Z axis lead screw compensation signed parts per billion 232 A LEAD COMP 10E9 This parameter sets the A axis lead screw compensation signed parts per billion 233 B LEAD COMP 10E9 This parameter sets the B axis lead screw compensation signed parts per billion 235 TSC PISTON SEAT With the 50 TSC option the amount of time given for the piston to seat during system start up The default is 500 milliseconds If machine has a 50 Taper spindle and the TSC option this parameter must be set to 0 236 TSC LOW PR FLT After the TSC system has stabilized following start up Alarm 151 is generated if coolant pressure falls below 40 psi for the amount of time set in this parameter The default is 1000 milliseconds 237 TSC CLNT LINE PURGE The amount of time given for the coola
66. against the Table These components are machined to very close tolerances and can be easily damaged by hard metal to metal contact 9 Remove the threaded rods from Step 4 10 Install the 12 3 8 16x4 40 16430 SHCS to fasten the platter to the bearing NOTE You will need a T Handle wrench or a 6 long hex socket to tighten the SHCS in the Platter Socket extensions will not fit 166 Mechanical Service 96 0189 rev L June 2005 11 Tighten the SHCS incrementally in a star pattern to avoid misaligning the Bearing Torque the SHCS in stages up to a final torque of 45 ft lbs 12 Before replacing the encoder shaft plate make sure the set screws are backed off 13 Tighten the screws securing the encoder shaft plate to the platter 14 Tighten the set screws to clamp the shaft plate to the encoder shaft 15 Replace the encoder cover plate INSTALLATION ENCODER Pre assembly Verification Before assembling the encoder mounting parts perform the following checks 1 Verify that the encoder mounting plate can be inserted into the encoder mounting cup without binding The contacting surfaces must be burr free 2 Verify that the encoder shaft has no detectable side to side play Perform this test by hand 3 Verify that the encoder boss can be inserted into the encoder mounting plate without binding The contacting mating surfaces must be flat and free of burrs 4 Verify that the encoder shaft can be inserted int
67. an indicator on the non rotary part of the table and set the indicator needle against a T slot See figure 8 Begin tightening the left adjusting bolt and check the backlash Using the cheater bar between the lifting plates or fixtures nudge the table CW and CCW Take readings from the indicator Once the readings come close to 003 rotate the table and take readings every 10 for 360 Find the tightest of these spots and set the indicator up as in the previous step 9 Tighten the left adjusting bolt until the backlash is between 0005 and 0007 10 Snug the right adjusting bolt against the bracket 11 Tighten the 3 4 11 hex bolts that mount the cam backlash adjuster motor plate 12 Tighten the adjusting screw lock nuts 13 Recheck the backlash If adjustment is necessary loosen the plate s hex bolts and adjusting screw s lock nuts before making adjustments 171 96 0189 rev L June 2005 Mechanical Service 3 23 4TH AXIS HARMONIC DRIVE ASSEMBLY EXPLODED PARTS LIST 1 Tube Backlash Adjuster 2 Cam Backlash Adjuster 3 Push Block 4 SCHS 5 SHCS 6 Pinion Gear 7 Sigma Adapter 8 Harmonic Drive 9 O Ring 10 MSHCS 11 Shoulder Washer 12 Gearbox Adapter 13 SHCS 14 SHCS 15 Flat Washer 16 HHB 17 Spring Washer 18 Shoulder Screw 19 MHHB 20 O Ring 21 Yaskawa Motor Key 22 Wave Generator 23 SHCS 24 Yaskawa Sigma Motor 1 2 3 4 5 6 7 10
68. and zero when it has a tool changer When it is set to 1 an M06 will stop the program and display a message requesting the operator to change tools manually 7 RESET STOPS PAL CHG This parameter enables the RESET button to stop a pallet change It is intended for use with the future hard coded pallet changer macro program It should be set to zero 8 MINI POWER SUPPLY When parameter 315 bit 8 MINI MILL is set to 1 the Over Voltage discrete input will be displayed as P S Fault When it is set to 1 a The DC BUSS voltage that is normally displayed on the diagnostics screen for a Vector Drive machine will not be displayed b The conditions that would normally generate alarm 119 OVER VOLTAGE and alarm 160 LOW VOLTAGE will instead generate alarm 292 320V POWER SUPPLY FAULT and this alarm will be added to the alarm history only after a 1 second delay to prevent false 292 alarms being added to the alarm history at the moment power is turned off This parameter bit must be set to 1 on all Mini Mills 242 Parameters 96 0189 rev L June 2005 9 DOOR OPEN SWITCH The bit allows the software to work with an optional door open switch This bit should be set to 1 on all machines fitted with the second door switch If this bit is set to 1 the control will look for a second door switch when the door is opened automatically to the fully open position If the switch is not found alarm 238 DOOR FAULT will be generated If this bit is set to zero the con
69. and torque to 80 ft lbs 5 Indicate the top of the rotary table and take readings at 0 90 180 and 270 degrees If necessary adjust shims under rotary table to align the rotary axis perpendicular to XZ plane not to exceed 0 0003 117 Mechanical Service 96 0189 rev L June 2005 6 Indicate across rotary table surfaces along the X and the Z axes The indications should be parallel to within 0 0005 10 7 Rotate the pallet changer and indicate the other rotary table as described in step 5 above Pallet Changer Grid Offset 1 Make sure that Bit 28 in Parameter 209 has a value of 1 The pallet will stay up 2 Verify that the Pallet Changer Type in Parameter 605 is 3 NOTE The APC is on the B axis on machines with single Mocon PC board or the W axis on machines with two Mocon PC boards 3 The Grid offsets in parameter 445 should be the W axis and the offsets in parameter 170 should be the B axis Respectively tool Changer offsets in parameter 451 should be the W axis and the offsets in parameter 213 should be the B axis 4 Zero return the appropriate axis and set the Grid Offset for the individual axis only on Zero return again 5 Press the E stop and manually rotate the APC so that the locators on Pallet 1 are aligned with the locators on the APC 6 Lower the pallet onto the locators by lowering the air pressure at the main regulator Be careful not to damage either the locators or the pallet
70. as the pressure gets low and this alarm appears after some time has elapsed Check your incoming air pressure for at least 100 PSI and ensure that the regulator is set at 85 PSI 121 LOW LUBE OR LOW PRESSURE Way lube is low or empty or there is no lube pressure or too high a pressure Check tank at rear of mill and below control cabinet Also check connector on the side of the control cabinet Check that the lube lines are not blocked 122 REGEN OVERHEAT The regenerative load temperature is above a safe limit This alarm will turn off the servos spindle drive coolant pump and tool changer One common cause of this overheat condition is an input line voltage too high If this condition persists an automatic shutdown will begin after the interval specified by parameter 297 It can also be caused by a high start stop duty cycle of spindle 32 Alarms 96 0189 rev L June 2005 123 SPINDLE DRIVE FAULT Failure of spindle drive motor or regen load This can be caused by a shorted motor overvoltage overcurrent undervoltage failure of drive or shorted or open regen load Undervoltage and overvoltage of DC bus are also reported as alarms 160 and 119 respectively 124 LOW BATTERY Memory batteries need replacing within 30 days This alarm is only generated at power on and indicates that the 3 3 volt Lithium battery is below 2 5 volts If this is not corrected within about 30 days you may lose your stored programs parameters offsets and settings
71. be as tight as possible while still allowing the brake to actuate smoothly 157 96 0189 rev L June 2005 Mechanical Service INSTALLATION RING GEAR 1 Lubricate and stone the mating surfaces of the Platter and Ring Gear Wipe clean to remove grease and contaminents 2 Clean the mating surfaces of the Platter and Ring Gear with alcohol CAUTION The Ring Gear is a precision machined piece Take care in handling the Ring Gear Do not drop the Ring Gear or set it heavily on the teeth 3 Install eyebolts into the top of the Ring Gear With an assistant lift the Ring Gear by the eyebolts and place over the Platter 4 The Ring Gear is an interference fit item and will need to be clocked properly prior to the next Step If necessary adjust the position of the Ring Gear so that all the bolt holes line up exactly 5 Apply a drop of Loctite to each of the 16 SHCS and insert into the holes in the Ring Gear Start each SHCS by hand to ensure proper alignment of the Ring Gear and to prevent crossthreading the tapped holes 6 Tighten the SHCS incrementally in a star pattern to slowly pull the gear down onto the platter Do not tighten each SHCS completely in one attempt This will foul the location of the Ring Gear 7 When the Ring Gear is fully seated on the Platter tighten the SHCS to full torque value 158 Mechanical Service 96 0189 rev L June 2005 3 21 4TH AXIS AIR VALVE ASSEMBLY This section applies to machines wi
72. be calibrated and set correctly 49 A ACCELERATION See Parameter 7 for description 50 A MAX SPEED See Parameter 8 for description 51 A MAX ERROR See Parameter 9 for description 52 A FUSE LEVEL See Parameter 10 for description 53 A BACK EMF See Parameter 11 for description 54 A STEPS REVOLUTION See Parameter 12 for description 55 A BACKLASH See Parameter 13 for description 56 A DEAD ZONE See Parameter 14 for description 57 COMMON SWITCH 1 Parameter 57 is a collection of general purpose single bit flags used to turn some functions on and off The left and right cursor arrows are used to select the function being changed All values are 0 or 1 only The function names are 221 Parameters 96 0189 rev L June 2005 0 REVERSE CRANK DIR Reverses direction of jog handle 1 DISABLE TOOL CHANGER Disables tool changer operations 2 DISABLE GEAR BOX Disables gear box functions 3 POWER OFF AT E STOP Stops spindle then turns the power off at EMERGENCY STOP 4 RIGID TAPPING Indicates hardware option for rigid tap 5 REV SPINDLE ENCODER Reverses sense direction of spindle encoder 6 NETWORK HD USB Is used to activate the internal Zip Enet PC104 board at power on time When it is set to 0 the CNC will not access the board When it is set to 1 the CNC will access it at power on time and display the message LOADING on the Zip Enet settings page just below setting 139 After some time 2 minutes maximum the control will i
73. board Unscrew the remaining two screws at the top of the LVPS board taking care to hold the board in place until all screws have been removed 11 Replace the LVPS board attaching it to the cabinet with the two screws and two standoffs previ ously removed 12 Replace the POWER board as described in Steps 6 7 Electrical Service 190 96 0189 rev L June 2005 RS 232 PCB NOTE Refer to Cable Locations for a diagram of this board 1 Follow all precautions noted previously before working in the electrical cabinet See warning at beginning of Servo Driver amp SDIST section 2 Turn the main switch upper right of electrical cabinet to the off position 3 Using a large flat tip screwdriver loosen the three screws on the cabinet door and then open the door enough to safely work on the electrical panel NOTE It is suggested to make use of a step ladder high enough to allow you to work from the top of the electrical cabinet It will be necessary when replacing the RS 232 board to work from the inside and outside of the cabinet at the same time 4 On the left side of the cabinet at the top of the side panel are two serial port connections labeled SERIAL PORT 1 and SERIAL PORT 2 SERIAL PORT 1 being the upper connection Serial interface replaces cable 700 with cable 700B SERIAL KEYBOARD INTERFACE PCB VIDEO amp KEYBOARD PCB MICRO PROCESSOR PCB P1 700B 850 P850 P850A J13 J3
74. broken or loose coupling between the servo motor and the ball screw Replace or repair the coupling Axis Motor Check for a damaged ball screw and replace if necessary Ball Screw section NOISE Ball screw noise is usually caused by a lack of lubrication and is usually accompanied by heating Other causes are misalignment bearing sleeve damage or ball nut damage Check the alarm history of the machine and look for axis overcurrent and following error alarms NOTE Do not replace ball screws or bearing sleeves without due consideration they are extremely durable and reliable Verify that problems are not due to tooling programming or fixturing problems Servo motor noise Disconnect the servo motor from the ball screw and rotate by hand If the noise persists replace the motor assembly Axis Motor section Noise is caused by bearings Rolling grinding sound is heard coming from the motor If bearings are making a consistently loud sound replace the motor Ball screw noise Ensure oil is getting to the ball screw through the lubrication system Check for a plugged metering valve Check for damage to the bearing sleeve NOTE The current angular contact design sleeve has a fixed pre load it cannot be adjusted Run the axis back and forth The motor will get very hot if the bearing sleeve is damaged If so turn the axis by hand and feel for roughness in the ball screw Loosen the clamp nuts at b
75. but the control does not receive a signal that the table has raised Without the signal the control thinks the pallet is clamped After a period of time an alarm will be generated Comment This is a safe condition there is no threat of injury or machine damage However the machine will not function until the plunger problem is corrected 3 Failure Table index pallet change starts and then is E stopped in the middle of indexing Result the clamp plate remains in the unclamp position Comment This is a safe condition To resume machining clear the alarms and Zero Return all axes The machine will automatically home all axes and the clamp plate will clamp the table 4 Failure Table Indexer pallet change starts and then the machine is E stopped and powered off Result The clamp plate remains unclamped because the exhaust port on the unclamp side of the piston is blocked closed In other words the clamp plate is being pressurized in order to clamp but as the exhaust port is blocked this prevents the pallet from being clamped Comment This is initially a safe condition however due to leakage on the exhaust side of the piston the clamp plate will eventually move to its fully clamped position It is not safe to leave the table partially over the table locator teeth It should be rotated fully off of the clamp plate This can be done by manually rotating the pallet changer 5 Clamp valve solenoid loses power or burns up while machine
76. clogging or kinking Clean or replace as needed Check for overheating TSC pump motor Three phase motors have a thermal circuit that will interrupt power to the relay coil If received at start up check that the breaker has not tripped and that the pump is turning Check the electrical continuity of cables Check for pressure switch failure refer to Testing the Coolant Pressure Switch section and replace if necessary Check the electrical continuity of the switch cable and the control function by monitoring the LO CLNT bit on the Diagnostics page 0 pressure on 1 pressure off Shorting the leads should cause the bit to switch from 1 to 0 Check this before replacing the pressure switch Leaking switches can give intermittent alarms Check pump pressure with no tool in the spindle If the pressure is less than 60 psi replace the pump May be generated if another machine alarm occurs during TSC operation Troubleshooting 27 96 0189 rev L June 2005 PRE CHARGE FAILURE Alarm 198 Precharge Failure NOTE This alarm only applies to the TSC system Check for broken or disconnected pre charge air line and replace if necessary Check if the Tool Clamped limit switch is sticking replace if necessary Check the Tool Clamped limit switch adjustment refer to Tool Clamp Unclamp Switch Adjustment Check for low pre charge pressure refer to Precharge Regulator Adjustment section
77. coupling 4 Reinstall and tighten down the SHCS that hold the motor to the coupling housing 5 Tighten the SHCS on the motor coupling at the ball screw Place a drop of blue Loctite on the screw before inserting 6 Remove the shipping bolts from the column or raise the Y axis and remove the wood blocks from the column casting 7 Replace the rear enclosure panel 8 EC 300 Replace the right spindle head cover 9 Check for backlash in the Y axis ball screw Troubleshooting section or noisy operation 10 Check that Parameter 211 Y Axis Tool Change Offset is set correctly and adjust if necessary 11 Set the grid offset after the new motor has been installed Z AXIS MOTOR Coupling Z Axis Motor 4X BHCS Coupling Housing Cover Motor Bumper Key 4X SHCS Column EC 300 Z axis motor and ball screw assembly Motor Coupling Z Axis Motor Coupling Housing Cover Coupling Housing 4X BHCS 4X SHCS Key Z Axis Way Cover Receiver EC 400 Z axis motor and ball screw assembly REMOVAL 1 Power ON the machine Zero return all axes and put machine in HANDLE JOG mode 99 96 0189 rev L June 2005 Mechanical Service 2 EC 300 Jog the Y axis to the bottom of its travel Jog the Z axis to the back of the machine EC 400 Jog the Z axis away from the spindle 3 POWER OFF the machine 4 EC 400 Unbolt the Z axis way cover from the receiver and pull it away fro
78. displayed in the diagnostics display as DC BUSS 12 uP ENCLOSURE TEMP Microprocessor Enclosure Temperature When set to 1 the enclosure temperature will be displayed on INPUTS2 screen of the diagnostics display 13 HAAS REMOTE JOG HDL Haas Remote Jog Handle This bit must be set to 1 if the machine is equipped with a Haas 5 Axes Remote Jog Handle 14 SPIN MOTOR OTEMP NC Spindle Temperature Sensor Normally Closed This bit specifies the type normally open or normally closed of the spindle temperature sensor This bit should be set to 1 15 AIR DRIVE SHUTTLE This bit will cause the machine to use discrete outputs 21 and 26 to command the shuttle to move in and out On mills with the Air Driven Shuttle it must be set to 1 On all other mills it must be set to 0 16 GIMBAL SPINDLE Used on 5 axes mills This bit will cause the machine to check that the Z A and B axes are at zero before a tool change is started If one is not alarm 150 will be generated On mills with the gimbaled Spindle it must be set to 1 On all other mills it must be set to 0 17 NO MFIN CHK ON P UP When this bit is set it will prevent checking of MFIN at power up It should be set for 1 for all machines that have the Haas Automatic Pallet Changer attached and 0 for all other machines 18 DEL Y SWITCH ENABLE Delta Wye switch enabled This bit is used for the Vector Drive The bit enables the switching of spindle motor windings provided the hardware ENABLE is install
79. exist after the N character and cannot be longer than 5 digits 410 FILE INVALID V CODE Bad parameter or setting value Positive or negative number must exist after the V character and cannot be longer than 10 digits 411 RS 232 EMPTY PROG Check your program Between and there was no program found 412 RS 232 UNEXPECTED END OF INPUT Check Your Program An ASCII EOF code was found in the input data before program receive was complete This is a decimal code 26 413 RS 232 LOAD INSUFFICIENT MEMORY Program received does not fit Check the space available in the LIST PROG mode and possibly delete some programs 414 RS 232 BUFFER OVERFLOW Data sent too fast to CNC Computer sending data may not respond to X OFF 415 RS 232 OVERRUN Data sent too fast to CNC 416 RS 232 PARITY ERROR Data received by CNC has bad parity Check parity settings number of data bits and speed Also check your cables 417 RS 232 FRAMING ERROR Data received was garbled and proper framing bits were not found One or more characters of the data will be lost Check parity settings number of data bits and speed 418 RS 232 BREAK Break condition while receiving The sending device set the line to a break condition This might also be caused by a simple break in the cable 419 INVALID FUNCTION FOR DNC A code found on input of a DNC program could not be interpreted 420 PROGRAM NUMBER MISMATCH The O code in the program being loaded did not match the O co
80. following sequence is important to ensure proper installation of the ball screw Tighten the locknut and washer hand tight on the motor end Install and tighten the locknut on the bearing support Ensure that the nut does not touch the support bearing Install the shaft lock onto the bearing support end of the ball screw This will keep the ball screw from turning while torquing the bearing pack locknut Place a spanner wrench on the locknut at the motor end of the assembly EC 300 Torque the locknut against the bearing sleeve to 30 ft lb EC 400 EC 1600 Torque the locknut against the bearing sleeve to 50 ft lb With a T handle wrench hand tighten the lock nut screw and mark it with yellow paint Remove the shaft lock EC 300 Loosen the clamp screw and bearing lock nut and tighten to 4 IN lbs against the bearing Retighten the lock nut screw EC 400 EC 1600 Loosen the clamp screw and bearing lock nut and tighten to 10 ft lbs against the bearing Retighten the lock nut 11 Reinstall the axis motor in accordance with Y Axis Motor Installation 12 Reconnect the banjo oil fitting to the ball nut and use Vectra oil to lubricate the ball screw 13 To check for backlash or noisy operation in the ball screw see the Troubleshooting section 14 Reset the grid offset and tool changer height See Grid Offset and Setting Parameter 64 sections 15 EC 300 Replace the spindle head cover and the column ho
81. for proper operation and lubricate with light oil if necessary Place a dab of grease on the outside edge of the guide rails of the tool changer and run through all tools EC 400 Clean the locating pads on the A axis and the load station This requires removing the pallet Six Months Replace coolant and thoroughly clean the coolant tank Check all hoses and lubrication lines for cracking Check the rotary A axis If necessary add oil Mobil SHC 630 The correct oil level is halfway on the sight glass Annually Replace the gearbox oil Drain the oil from the bottom of the gearbox Remove inspection cover beneath spindle head Add oil slowly from top until oil begins dripping from overflow tube at bottom of sump tank For 50 taper spindles add oil from the side of the transmission Check oil filter and clean out residue at bottom of filter Check SMTC oil level in sight glass see Side Mount Tool Changer Oil Level in this section 2 years Replace air filter on control box every 2 years EC 400 Replace the Rotary A axis oil Maintenance 253 96 0189 rev L June 2005 PERIODIC MAINTENANCE A periodic maintenance page is found on the Current Commands screens titled Scheduled Maintenance and accessed by pressing Page Up or Page Down to activate and deactivate a series of checks An item on the list can be selected by pressing the up and down arrow keys The selected item is then activated or dea
82. in the proper place on the APC The pallet must be pushed back against the hard stop by hand After correcting the condition run an M50 to continue machining 635 APC PAL NUM CONFLICT REC amp CH Pallet Number Conflict Receiver and Pallet Changer The pallet number in memory does not agree with the actual pallet in use Run an M50 to reset this variable 636 APC UNLOAD SWITCH MISSED PAL 1 Pallet 1 did not return from the receiver to the APC in the allowable amount of time This can be caused by the chain switch block missing the limit switch or from another mechanical problem such as clutch slippage After correcting the condition run an M50 to continue machining 637 APC UNLOAD SWITCH MISSED PAL 2 Pallet 2 did not return from the receiver to the APC in the allowable amount of time This can be caused by the chain switch block missing the limit switch or from another mechanical problem such as clutch slippage After correcting the condition run an M50 to continue machining 638 APC DOOR NOT OPEN The automatic door did not open in the allowable time or may have fallen during an APC function This can be caused by a bad air solenoid a blocked or kinked airline or a mechanical problem After correcting the condition run an M50 to continue machining 639 APC DOOR NOT CLOSED The automatic door did not close in the allowable time when necessary after an APC function has been performed This can be caused by a bad air solenoid a blocked o
83. indexer position The indexer positions are multiples of parameter 647 Parameter 647 is in thousandths of a degree For example a value of 2500 represents 2 5 degrees 960 INDEXER SWITCH NOT FOUND IN TIME The A axis indexer down switch was not found within the allowed time specified by parameter 659 961 FLOPPY OFFSET NOT FOUND This alarm is generated because FNC has lost the offset place mark it needs to correctly advance program Try to reload program 962 UNABLE TO RETRIEVE FILE INFORMATION File functions are taking too long to process Try loading again 963 UNABLE TO FNC FROM THIS DEVICE This device may not function from FNC Please change setting 134 connec tion type to an appropriate FNC device from the operator s manual 968 DOOR HOLD OVERRIDE ENGAGED Whenever setting 51 is changed to ON alarm 968 will be added to the alarm history along with the date and time the change was made Note that this is not a resetable alarm it is for information purposes only NOTE Alarms 1000 1999 are user defined by macro programs The following alarms only apply to HS Series mills with a pallet changer 1001 Index St Unlocked The index station is not in the correct orientation for a pallet change 1002 Pallet Locked Down The pallet did not begin to lift within two seconds of command or did not complete lifting within six seconds 1003 Pallets Jammed The lift cylinder has not moved from the clockwise position within three seconds or has
84. look for an additional door switch and will generate an operator message 6 NO Z HOME IN TL CHG In Horizontal mills only This bit prevents Z axis motion to machine zero prior to a tool change 7 M36 AUTO PAL ROTATE In Horizontal only When set to 1 an M36 rotates the A axis after the PART READY button is pressed 8 AUX AXIS TL CHANGER In Horizontal mills only When enabled means the tool changer carousel is driven by an aux axis 9 APIGOT KEY INVERT This bit controls the direction the spigot moves when the Coolant Up and Coolant Down buttons are pressed Changing this bit reverses the direction the spigot moves when the buttons are pressed It has no effect on the direction the spigot moves when commanded by the M34 and M35 codes 12 REVERSE CONVEYOR Reverses the direction of the chip conveyor 13 PRE ORIENT TAP When this parameter bit is set to 1 a spindle orient command is issued automatically prior to the repeat rigid tap function 14 UNUSED 15 GREEN BEACON When 1 user relay M25 is used to flash a beacon If the control is in a reset state the beacon will be off If the control is running normally the beacon will be steadily on If the control is in a M00 M01 M02 M30 feedhold or single block state then the beacon will flash 16 RED BEACON When 1 user relay M26 is used to flash a beacon The beacon flashes if the control is experiencing an alarm or emergency stop condition 17 CNVR DOOR HOLD OVRD When 1 the conve
85. loose until final adjustment INSTALLATION HARMONIC DRIVE 1 Thread an eyebolt into the pilot hole in the shaft of the Harmonic Drive assembly 2 Connect a rope or hoist line to the eyebolt Have an assistant lift the rope up through the counterbore and raise the Harmonic Drive 3 Orient the Harmonic Drive so that the motor connectors can be accessed from the right of the Table Insert 8 70mm SHCS through the Gearbox Adapter into the Table Torque to 35 ft lbs 153 96 0189 rev L June 2005 Mechanical Service INSTALLATION CARRIER MOUNT BRACKET 1 Orient the Carrier Mount bracket so the edge side faces forward and the flush side is toward the center of the Table Turn the Carrier bracket so that the mounting holes face the bottom surface of the Table See the Figure below Cable Carrier and Bracket Installation 2 Place the Carrier bracket against the bottom side of the Table where indicated and insert the 4 SHCS through the bracket and thread into the Table Tighten 3 Orient the limit bracket so that the angled bottom edge faces to the right and the mounting tab faces toward the rear of the Table as shown in the Figure above Mount using two SHCS INSTALLATION CABLE BOX ENCODER 1 Place the Cable Box Encoder into the left rear corner of the accessory box of the Table Orient the Cable Box with the open sides against the casting of the Table for the Encoder cable 2 Install the three SHCS and insert through
86. machines This bit indicates that there is a switch visible through MOCON that detects if the axis has rotated all the way round It is used to tell the control to skip the first zero switch when zeroing so it can unwrap the cables 9 Z TEMP SENSOR This performs Ball Screw Thermal Compensation via a temperature sensor attached to the ball nut When this bit is set to 1 the feature is activated for that axis Note that this feature can only be used when temperature sensors are installed The following parameters must be set appropriately 235 Parameters 96 0189 rev L June 2005 201 132 133 XYZ SCREW COMP COEF 8000000 272 273 274 XYZ SCREW COMP T CONST 28000 351 TEMP PROBE OFFSET 450000 16 SCALE Z HIST For HAAS diagnostic use only 269 A SWITCHES Parameter 269 is a collection of single bit flags used to turn servo related functions on and off The left and right cursor arrows are used to select the function being changed All values are 0 or 1 only The function names are 0 A LIN SCALE EN Used to enable linear scales for the A axis 1 A INVRT LN SCL Used to invert the A axis linear scale 2 DSBL SCALE Z Used to disable the linear scale Z test 3 A ZERO AXIS TC Used to return axis to the position specified by the TOOL CHANGER OFFSET parameter prior to a tool change On mills with a gimbaled spindle this bit must be set to 1 on the A and B axes parameter 269 and 270 and 0 on all other axes 4 A 2ND HOME BTN Used to m
87. of the oil level eye 9 Reinstall the oil fill pipe plug form step 7 Troubleshooting 17 96 0189 rev L June 2005 A axis backlash adjustment for optional 1 indexer The facegear must be disengaged before checking backlash First raise the platter by applying air to the lift piston with Haas tool number T 2150 Disconnect the A axis and connect tool T 2150 as shown on drawing T 2150 Toggle air to the lift piston with the regulator set between 20 to 40 PSI 138 276 kilopascals Check backlash at each quadrant every 90 Backlash on the 1 indexer option is 0007 0015 nonstandard Adjust as necessary See the previous adjustment description VIBRATION Excessive Servo Motor Vibration If no A axis is present swap the suspected bad servo motor with the A driver and check to see if there is a driver problem If needed replace the DRIVER PCB Electrical Service Check all parameters of the suspected axis against the parameters as shipped with the machine If there are any differences correct them and determine how the parameters were changed PARAMETER LOCK should normally be ON A bad motor can cause vibration if there is an open or short in the motor A short would normally cause a GROUND FAULT or OVERCURRENT alarm check the ALARMS An ohmmeter applied to the motor leads should show between 1 and 3 ohms between leads and over 1 megohm from leads to ground If the motor is open or shorted replace
88. on the bottom of the A axis on indexer style machines There are no sensors monitoring the A axis platter position on machines with the full 4th axis option 5 The A axis is allowed to rotate once the platter lift sensor is triggered 6 When the A axis moves to the home position and lowered the platter down sensor is triggered and the platter lift sensor is turned off 7 Power is turned on to the pallet clamp unclamp solenoid located at the rear of the machine 8 The clamp air pressure is released from the clamp side of the receiver piston and 100 PSI of air is applied to the unclamp side of the receiver piston 9 The clamp plate rises 10 When the clamp plate moves approximately 400 it will trigger the pallet unclamp sensor The sensor sends a signal to the CNC control that the clamp plate is in the unclamp position A sensor assembly located on the bottom of the A axis monitors the clamp plate position 11 APC door switch amp load station lock switch are checked 12 The H frame down solenoid amp safety solenoid turn off 13 The H frame up solenoid turns on 14 Air pressure in the air cylinder rotates the top cam by rotating the seal housing The bottom cam does not rotate 16 The cage amp 3 balls rotate at half speed of the cam forcing the cams to separate 17 The top cam raises the H frame by lifting upward on the hub using the tapered bearing as a thrust bearing 18 The H frame engages and raises b
89. plate 141 Mechanical Service 96 0189 rev L June 2005 O Ring Replacement 1 Remove and replace the 4 O rings 57 0027 on the TRP 50T shaft 2 Remove and replace the 2 O rings 57 0092 on the TRP 50T piston 1 O ring per piston 3 Remove and replace the 3 O rings 57 0095 2 in the center of the TRP 50T housings and 1 in the center of the TRP 50T sub plate TRP ASSEMBLY 1 Place the TRP sub plate over the TRP shaft 2 Place the lower TRP piston grooved side up over the TRP shaft 3 Place the TRP lower spacer over the TRP shaft 4 Place the lower TRP housing over the TRP shaft 5 Place the upper TRP piston grooved side up over the TRP shaft 6 Place upper TRP housing over the TRP shaft 7 Replace the 8 bolts holding the TRP assembly together Pattern torque to 100 ft lb 8 Place the TRP upper spacer over the TRP shaft 9 Push the TRP shaft up from the bottom using the mallet handle The shaft will bottom out with approximately 1 4 of the shaft still showing 10 Place the switch trip and compression spring over the TRP shaft 11 Tighten the shaft clamp on the TRP shaft then the shaft clamp locking bolt 50 TAPER SPINDLE TRP INSTALLATION The following sections must be completed after installation Tool Push Out Adjustment Setting TRP Switches Extension Tube Installation if equipped with TSC Mechanical Service 142 96 0189 rev L June 2005 Figure 3 10 Shim and
90. position 16 POWER ON the machine and enter TCR mode For more information on TCR mode refer to the TCR flow chart located in the Technical Reference section 17 Press the ATC FORWARD button until the arm extends and is parallel to the x axis Insert a split tool into the double arm by pressing the tool release button located near the shaft Place a magnetic base and indicator on to the machine table Measure the end of the split tool to the nearest 001 18 Move the split tool and indicator setup to the other end of the double arm Measure the end of the split tool to the nearest 001 The maximum allowable height tolerance between the two ends is 030 Adjust the alignment as necessary Repeat this test with the arm rotated 1800 19 Remove the split tool from the double arm Return the double arm to the home position 81 96 0189 rev L June 2005 Mechanical Service Setting the Double arm Extension 20 Press the DOWN ARROW to command the tool pocket out Place the split tool with the pull stud into the tool pocket In TCR mode rotate the double arm near the tool pocket 21 Visually check the alignment of the double arm to the V groove on the split tool If necessary loosen the lock ring SHCS and adjust the extension of the double arm Torque the lock ring SHCS to 15 17 ft lbs 22 Repeat steps 9 amp 10 to re check radial alignment 23 Return the double arm to the home position Double Arm to Spindle Alignment
91. position is reached the indexer will automatically move forward or backward to the closest proper locking angle then settle into its clamped position The locking angle is computed from the INDEXER INCREMENT parameter which is in units of one thousandth of a degree For example if the A axis INDEXER INCREMENT parameter is set to 1000 1 0 degrees and the A axis is jogged to 25 5 degrees when the operator leaves jog mode the indexer will automatically settle and clamp itself at 26 0 degrees If the parameter contains a 1 one thousandth of a degree or less the rotary indexer feature is turned off and a regular rotary platform is assumed 645 Y Axis Indexer Increment See Parameter 644 646 Z Axis Indexer Increment See Parameter 644 647 A Axis Indexer Increment See Parameter 644 648 B Axis Indexer Increment See Parameter 644 650 U Axis Indexer Increment See Parameter 644 651 V Axis Indexer Increment See Parameter 644 652 W Axis Indexer Increment See Parameter 644 653 Sp Axis Indexer Increment See Parameter 644 247 Parameters 96 0189 rev L June 2005 654 Tt Axis Indexer Increment See Parameter 644 659 Indexer Down Timeout Supports the indexer rotary table It specifies the amount of time in ms allowed for seeking the indexer Down switch If the switch is not detected within the allowed time alarm 960 INDEXER SWITCH NOT FOUND IN TIME is generated When this parameter is set to zero the feature is bypassed Note that parameter
92. power on Lower the spindle head to a position that will allow you to easily work on the back of the spindle motor Turn machine off 2 Remove the fan and fan shroud see Mechanical Service section 3 Remove the four screws holding the encoder to the bracket Remove the encoder belt to avoid misplacing it Spindle Motor Assembly Spindle Encoder 4X SHCS 4X SHCS Encoder Mounting Bracket 4X SHCS Spindle Encoder Installation Fan and Fan Shroud Removed INSTALLATION 1 Loosely bolt the encoder to the bracket 2 Install the encoder belt to both the motor shaft pulley and encoder pulley 3 Tension the belt by sliding the encoder in the bracket 4 Tighten the encoder bolts 198 Technical Reference 96 0189 rev L June 2005 5 TECHNICAL REFERENCE 5 1 TOOL CHANGER CAUTION Extremely heavy tool weights should be distributed evenly Ensure there is adequate clearance between tools in the tool changer before running an automatic operation Tools are always loaded through the spindle and should never be installed directly in the carousel in order to avoid crashes The pocket open to the spindle must always be empty in the retracted position All wiring to the tool changer goes through connector P8 on the side of the control cabinet PULL STUDS The tool holders used are CT 40 taper V flange commonly called CT 40 Use A 45 Degree P40T Type 1 inch threads pull stud built to JMTBA stand
93. procedure for the other pallet NOTE For more information on the indexer see the Trouble Shooting chapter of this manual Mechanical Service 116 96 0189 rev L June 2005 Squaring The Pallet 1 Loosen all bolts from Pallet Changer to the base and align front machined surface of pallet parallel to X axis NTE 0 002 overall Perform a pallet change and verify other side 2 Level the pallet along the X axis by indicating across the pallet in the X axis direction Both pallets should be parallel to within 0 002 10 of each other 3 If the pallets are not level shim between the pallet changer and base as required and tighten the pallet changer base bolts 4 Rotate Pallet Changer and verify the other pallet 5 Level the pallet along the Z axis by indicating across the pallet in the Z axis direction 6 If necessary adjust the shims between the pallet changer and base as required ensure all of the bolts are tight before continuing 7 Rotate the Pallet Changer and verify the other pallet Align Rotary Tables 1 Clean and stone Pallet Changer surfaces before installing rotary tables 2 Install the 2 dowel pins into the pallets and place the rotary tables accordingly NOTE Make sure the dowel pins are seated in non threaded holes in the pallet 3 Connect the cables lubrication lines and air lines to the rotary table and ensure that the oil reser voir is full 4 Install table clamps 3 per table and fasteners
94. several seconds or even minutes is large enough to exceed the continuous rating of the motor The servos will be turned off when this occurs This can be caused by running into the mechanical stops It can also be caused by anything that causes a very high load on the motors 616 U AXIS MOTOR OVERHEAT Servo motor overheat The temperature sensor in the motor indicates over 150 degrees F 65 deg C This can be caused by an extended overload of the motor such as leaving the slide at the stops for several minutes 617 V AXIS MOTOR OVERHEAT Servo motor overheat The temperature sensor in the motor indicates over 150 degrees F 65 deg C This can be caused by an extended overload of the motor such as leaving the slide at the stops for several minutes 618 W AXIS MOTOR OVERHEAT Servo motor overheat The temperature sensor in the motor indicates over 150 degrees F 65 deg C This can be caused by an extended overload of the motor such as leaving the slide at the stops for several minutes 620 C AXIS DISABLED Parameters have disabled this axis 621 C OVER TRAVEL RANGE C axis will exceed stored stroke limits This is a parameter in negative direction and is machine zero in the positive direction This will only occur during the operation of a user s program 622 TOOL ARM FAULT This alarm is generated by the tool changer if the arm is not at the Origin position or the arm motor is already running when a tool change process is started 625 CAROUSEL
95. should stop the slides before they hit the limit switches Verify the value of parameter 445 Grid Offset and check the wiring to the limit switch and connector P5 at the side of the main cabinet Can also be caused by a loose encoder shaft at the back of the motor or coupling of motor to the screw 608 INVALID Q CODE A Q address code used a numeric value that was incorrect in the context used In M96 Q can reference only bits 0 to 63 Use an appropriate value for Q 609 U SERVO ERROR TOO LARGE Too much load or speed on U axis motor The difference between the motor position and the commanded position has exceeded Parameter 362 The motor may also be stalled disconnected or the driver failed The servos will be turned off and a RESET must be done to restart This alarm can be caused by problems with the driver motor or the slide being run into the mechanical stops 610 V SERVO ERROR TOO LARGE Too much load or speed on V axis motor The difference between the motor position and the commanded position has exceeded Parameter 398 The motor may also be stalled disconnected or the driver failed The servos will be turned off and a RESET must be done to restart This alarm can be caused by problems with the driver motor or the slide being run into the mechanical stops 611 W SERVO ERROR TOO LARGE Too much load or speed on W axis motor The difference between the motor position and the commanded position has exceeded Parameter 434 The motor may also b
96. spacer 40 25 5031 Bottom door 41 25 5029 TC internal panel 42 25 5992A SMTC60 top panel 43 25 5994A SMTC70 rear panel 44 25 5996A SMTC70 rear chip shield 45 25 5995 SMTC60 front chip shield 46 25 5283A TC front chip shield 47 25 4987 Left lower panel chip shield 48 25 4986 Left upper panel chip shield 49 25 5993B SMTC70 bottom pan EC 400 60 and 70 Tool Tool Changer Panels 331 Assembly Drawings 96 0189 rev L June 2005 1 25 5007 Bracket Frame Y Axis Stop 2 25 5001 Guide Right Y Axis 3 59 0605 Bellows Y axis Upper 4 25 5008 Bracket Frame Y Axis 5 59 0606 Bellow Y Axis Lower 6 20 2319 Plate Filler Y Axis Frame 7 25 5000 Guide Left Y Axis EC 400 Y Axis Frame Assembly 332 Assembly Drawings 96 0189 rev L June 2005 EC 400 Front Trough Assembly Auger System 1 57 0334A Gasket Coolant Trough 2 25 0548 Chute Discharge 3 25 5300 End Chute Cover 4 25 5301 Coolant Trough Extension COver 5 25 5025 Extension Box Front Trough 6 57 9846C Gasket Discharge 7 25 5297A Coolant Channel 8 20 2039 Auger Front 9 25 4944 2X Brace Auger Trough 10 25 5289 Extension Box Auger Motor 11 62 0050 Motor 115V 1 4HP 15 RPM 12 57 0332 Gasket Extension Box Top 13 25 5290 Extension Box Top 14 25 5024A Front Auger Trough 15 25 5288A Cooalnt Trough 16 25 5299A Auger Trough Screen 17 59 0661 Nozzle Assembly Screen Washdown 18 58 2071 Fitting Comp 1 2 x NPT 1 2M 19 58 1679 Fitting BKHD NPT 3 8 x 1 Dia 20 58 1722 Fitti
97. switch Tool Unclamped Use the air pressure regulator on the back of the machine or an extra regulator placed in line a Jog the Z Axis to 0 030 above the aluminum block b Go to Parameter 76 write down the value and then change it to 99999999 to prevent a low pressure alarm c Back off the air pressure to around 65 psi 75 psi for old style TRP s d Press the tool release and check for movement in the aluminum block Adjust the air pressure until the block is loose at 0 030 0 005 e While holding the Tool Release Button push the switch in until it just trips the bit on the Diag nostics Page should change to 1 Lock down the screws Double check the switch by turning the TRP on and off a few times f Back off the air pressure until the block is loose at 0 020 0 005 Press the tool release button the Tool Unclamped bit in Diagnostics should remain 0 If not repeat the above steps 3 Restore air pressure to 85 psi and reset parameter 76 to its original value 148 Mechanical Service 96 0189 rev L June 2005 3 19 HARMONIC DRIVE COMPONENTS The Harmonic Drive unit is used to drive the rotary table on machines such as the HS 3 4 6 7 adn the EC 1600 The Harmonic Drive Assembly is made up of the following components Housed Harmonic Drive O Ring Pack included in package Wave Generator included in package Yaskawa Sigma Motor Gearbox Adapter Pinion Gear 22 Tooth Cam Backlash Adjuster The Hou
98. switch When open these switches will also stop the machine with a Door Hold function If the doors are open you will not be able to start a program Door Hold will not stop a tool change operation or a tapping operation and will not turn off the coolant pump Also if the doors are open the spindle speed will be limited to 750 RPM The Door Hold function can be temporarily disabled with by turning Setting 51 on if Parameter 57 bits DOOR STOP SP and SAFETY CIRC are set to zero but this setting will return to OFF when the control is turned off LIMIT SWITCHES X Y Z TRAVEL LIMIT SWITCHES X Left side of saddle by X axis motor Y Top of column by Y axis motor Z Base by Z axis motor The machine zero position is defined by a limit switch for each of the X Y and Z axes After the search for machine zero has been completed these switches are used to limit travel in the positive direction In addition travel in the negative direction is limited by stored stroke limits It is not normally possible to command the servo axes past the machine zero as servo travel lookahead will decelerate and stop each motor prior to exceeding the stroke limits All limit switches are wired through connector P5 on the side of the control cabi net P5 also contains the wiring to the lubrication pump and an alternate connection to the DOOR OPEN switches 213 Technical Reference 96 0189 rev L June 2005 Prior to performing an AUTO ALL AXES operation
99. the Positions screen enter GRID and press ENTER The message GRID OFFSET DONE should appear and the GRID OFFSET parameters for the homed axes will have been updated If the message NO ZERO appears this indicates that none of the axes had been zeroed 5 Perform AUTO ALL AXIS and verify that the DIST TO GO value for each of the selected axes is now close to 0 118 133 Mechanical Service 96 0189 rev L June 2005 3 15 THROUGH THE SPINDLE COOLANT SYSTEM FLOW DIAGRAM In Line Drive AIR PRESSURE SWITCH 70 PSI 2 POSITION 3 WAY SP RET SOLENOID VALVE PRE CHARGE METERING ORIFICE 040 SHUTTLE VALVE TOOL RELEASE TOOL RELEASE SOLENOID ASSEMBLY CHECK VALVE ASSEMBLY INTAKE FILTER ASSEMBLY TSC FILTER 20 MICRON PURGE SOLENOID VALVE ASSEMBLY COOLANT PRESSURE SWITCH 40 PSI USE 20 MICRON FILTER ELEMENT SUCTION GAGE INTAKE FILTER INTAKE FILTER ASSEMBLY TSCHP FILTER ASSEMBLY FILTER GAGE TSC FILTER SHUTTLE VALVE PURGE 2 TOP OF SPINDLE MOTOR 1 SIDE OF MACHINE AND COOLANT TANK 2 POSITION 3 WAY SP RET 2 POSITION 3 WAY SP RET SOLENOID VALVE TOOL RELEASE COOLANT CHECK VALVE PURGE CHECK VALVE SOLENOID VALVE PURGE 300 PSI MAX V3 V4 SV3 SV2 V2 V1 TSCHP PUMP P1 TRSA PVA S2 SV1 S1 FA2 G1 OR G2 FA1 CVA F2 F1 100 MESH 2 IN SPINDLE HEAD 1 REAR OF MACHINE amp COOLANT TANK VF LOCATION EC 300 EC 400 LOCA
100. the abrasive properties of cast aluminum and cast iron will shorten pump life unless a special filter is used in addition to the 100 mesh suction filter Contact Haas for recommendations Maintenance 255 96 0189 rev L June 2005 LUBRICATION CHART System Lubricant Quantity Vertical Mills Way lube and pneumatics Mobile Vactra 2 2 2 5 qts Transmission Mobil DTE 25 40Taper 34 oz 50 Taper 51oz A and B axis VR Series Mobile SHC 630 A axis 5qts B axis 4qts EC Series Way lube and pneumatics Mobile Vactra 2 2 2 5 qts Transmission Mobil DTE 25 34oz Rotary Table Mobil SHC 630 Cover sight glass HS 3 4 6 7 incl R Way lube and pneumatics Mobile Vactra 2 2 2 5 qts Transmission Mobil DTE 25 34oz Rotary Table Mobil SHC 630 Cover sight glass COOLANT AND COOLANT TANK Machine coolant must be water soluble synthetic oil based or synthetic based coolant lubricant Using mineral cutting oils will damage rubber components throughout the machine Do not use pure water as a coolant machine components will rust Do not use flammable liquids as coolant If the mill is equipped with Through the Spindle Coolant TSC do not use coolants with extremely low lubricity these types of coolant can damage the TSC Coolant tip and pump The coolant tank must be thoroghly cleaned periodically especially for mills equipped with TSC Coolant Overview As the machine runs the water will evaporate which will change the concentration of th
101. the air cylinder per the instructions in the air cylinder removal section 13 Lift the seal housing off of the bridge The cam assembly is heavily greased and may be stuck inside the seal housing 14 Remove the cam assembly which consists of the cage and three 3 balls 15 Unbolt and remove the lower cam 16 Remove the SHCS from the shaft clamp 17 Loosen the tapered shaft clamp by loosening the mounting screws Remove the shaft clamp 18 Remove the 5 8 SHCS from the shaft mount located on the bottom of the shaft Remove the shaft by lifting it straight up Reassembly Reassemble the pallet changer in the order by which it was removed Align the H frame to the receiver pallet per the instructions in the Pallet Changer H frame to Pallet Alignment section 121 Mechanical Service 96 0189 rev L June 2005 H FRAME REPLACEMENT 1 Remove the rotating door 2 Remove the two 2 hardstops from the H frame 3 Remove the SHCS that fasten the H frame to the hub 4 Raise the H frame with an appropriate lifting device until the H frame is above the dowel pins 5 Carefully guide the opening of the H frame around the servo motor connectors and umbrella mount plate and remove the H frame from the machine 6 Replace the H frame in the reverse order from which it was removed Be sure that the servo motor electrical connections are on the same side as the hard stops on the H frame 7 Align the H frame per the Pall
102. the board 8 Replace the front and rear cover panels and fasten with the screws that were previously removed SERIAL KEYBOARD INTERFACE NOTE Refer to Cable Locations for a diagram of this board 1 Follow all precautions noted previously before working in the control cabinet See warning at beginning of Section 5 2 Turn the main switch upper right of electrical cabinet to the off position 3 Remove the four screws on the back of the control box then remove the cover panel Take care to hold the panel in place until all screws have been removed 4 Disconnect all leads to the Serial Keyboard Interface KBIF board Ensure all cables are properly labeled for reconnecting later 5 After all cables have been disconnected unscrew the four screws holding the Serial KBIF board to the control box Take care to hold the board in place until all screws have been removed Place the screws and standoffs aside for later use 6 Replace the Serial KBIF board using the four screws previously removed starting at the top right Attach the screw and standoff loosely then all other screws and standoffs until all are mounted Tighten down completely 7 Reconnect all cables to the Serial KBIF board at their proper locations 197 Electrical Service 96 0189 rev L June 2005 4 6 SPINDLE ENCODER REPLACEMENT Please read this section in its entirety before attempting to remove or replace encoder REMOVAL 1 Turn machine
103. the control and reattach the air line to the carousel assembly 5 Align the ATC assembly according to section on ATC alignment 6 Torque the SHCS to 100 ft lbs 7 Replace all carousel sheet metal covers and fasteners Apply blue loctite to all fasteners and tighten EC 1600 TC Lift Bracket 79 96 0189 rev L June 2005 Mechanical Service AUTOMATIC TOOL CHANGER ALIGNMENT Use Split Tool P N T 2086 for 40 taper CT type T 2088 for 50 taper BT type T 2087 for 40 taper BT type T 2089 for 50 taper CT type This procedure is for a newly mounted ATC assembly without the double arm installed Perform the grid offsets and change parameter 64 to 0 according to the instructions in this manual before proceeding 1 Power Up machine then zero return the Z axis 2 Go to the Debug mode and push the tool changer restore button Follow the instructions given 3 Install the appropriate split tool CT or BT 4 Move the ATC forward until it stops 5 In handle jog mode align the split tool by jogging the X and Y axes until the alignment pin goes through the split tool with as little resistance as possible 6 Go to the POS RAW data page and record the actual encoder steps for the X and Y axes Put the X axis encoder steps reading into parameter 210 and Y axis encoder steps into parameter 211 7 Measure the distance between the spit tool and multiply it by the Z axis ratio par 33 83231 steps unit Cam Box to Tool
104. the gear box which is connected to the spindle motor which is driven by the spindle drive which is connected to the I O BOARD which is driven by the MOCON which is driven by the processor The moral here is don t replace the spindle drive if the belt is broken Find the problem first don t just replace the easiest part to get to DON T TINKER WITH THE MACHINE There are hundreds of parameters wires switches etc that you can change in this machine Don t start randomly changing parts and parameters Remember there is a good chance that if you change something you will incorrectly install it or break something else in the process Consider for a moment changing the processor s board First you have to download all parameters remove a dozen connectors replace the board reconnect and reload and if you make one mistake or bend one tiny pin it WON T WORK You always need to consider the risk of accidentally damaging the machine anytime you work on it It is cheap insurance to double check a suspect part before physically changing it The less work you do on the machine the better 4 Troubleshooting 96 0189 rev L June 2005 1 1 GENERAL MACHINE OPERATION MACHINE NOT RUNNING Machine cannot be powered on Check input voltage to machine see Electrical Service Check main circuit breaker at top right of electrical cabinet switch must be at the on position Check overvoltage fuses see Electrical Service
105. the machine has a manual tool changer and an M06 is commanded from a running program there will be no beep or delay because the control will stop and prompt the operator to manually insert the tool 605 Pallet Changer Type This parameter defines the type of pallet changer on the machine Also see Parameter 606 606 Number of Pallets This parameter specifies the number of pallets present in the installed pallet changer Also see Parameter 605 Pallet Changer Parameter 605 Parameter 606 APC Pallet Ready button 0 2 APC Schedule Pallet Buttons 2 2 Rotary Pallet Changer HS 1 2 1 2 Quad APC 2 4 MDC 1 EC300 3 2 EC400 4 2 2 Pallet APC 2 2 612 Spigot Type This parameter supports the programmable coolant spigot Type 0 uses the peaks of the spigot fan for positioning Type 1 uses the peaks and valleys of the spigot fan for positioning All other values are treated the same as type 0 Note that if parameter 253 SPIGOT FWD POS DLY and parameter 304 SPIGOT REV POS DLY are non zero type 1 processing uses those values Otherwise the type 1 processing calculates the delay value for positioning from parameters 613 and 614 613 Spigot FWD MTR DLY This parameter supports the programmable coolant spigot It specifies the delay time in ms from the moment the spigot motor is turned off to the moment the spigot is stopped in the forward direction 614 Spigot REV MTR DLY This parameter supports the programmable coolant spigot It specifies t
106. the status of these switches and the CURNT COMDS display shows which gear is selected If the switches indicate that the gear box is between gears the display will indicate No Gear NOTE The transmission high low gear position switches are located at the bottom of the gearbox assembly and are extremely difficult to reach Removal of this assembly is necessary to replace these switches GEAR CHANGE SEQUENCE When a gear change is performed the following sequence of events occurs 1 If the spindle is turning it is commanded to stop 2 Pause until spindle is stopped 3 Gear change spindle speed is commanded forward 4 Pause until spindle is at speed 5 Command high or low gear solenoid active 6 Pause until in new gear or reversal time 7 Alarm and stop if max gear change time elapsed 8 If not in new gear reverse spindle direction 9 Turn off high and low gear solenoids 204 Technical Reference 96 0189 rev L June 2005 5 8 CONTROL PENDANT JOG HANDLE The JOG handle is actually a 100 line per revolution encoder used to move one axis at a time If no axis is selected for jogging turning of the crank has no effect When the axis being moved reaches its travel limits the handle inputs will be ignored in the direction that would exceed the travel limits Parameter 57 can be used to reverse the direction of operation of the handle POWER ON OFF SWITCHES The POWER ON switch engages the main contactor The On
107. the status to give the pallet 914 APC INVALID P CODE The P code must be the name of a program stored in memory The program name must not have a decimal point Remove any decimal points from the program name 915 APC ILLEGAL NESTING G188 or M48 G188 is only legal in main program M48 is only legal in a program listed in the Pallet Schedule Table or a first level subprogram 916 APC NEGATIVE PAL PRIORITY INDEX Software Error Call your dealer 917 APC NUMBER OF PALLETS IS ZERO Parameter 606 must have a value if parameter 605 is not zero Set param eter 606 to the number of pallets in your FMS system 918 APC LOAD SWITCH MISSED PAL 1 Pallet 1 did not complete its move from the APC to the receiver in the allowable time Pallet change sequence was halted because receiver switch was not activated Pallet is either unclamped or not on the receiver Ensure the pallet is correctly located on receiver against hard stop then run M18 to clamp the pallet After correcting the condition run an M50 to continue machining 919 APC LOAD SWITCH MISSED PAL 2 Pallet 2 did not complete its move from the APC to the receiver in the allowable time Pallet change sequence was halted because receiver switch was not activated Pallet is either unclamped or not on the receiver Ensure the pallet is correctly located on receiver against hard stop then run M18 to clamp the pallet After correcting the condition run an M50 to continue machining 920 APC LOAD SWITCH
108. to find high and low spots To ease this procedure place a long bolt into one of the holes in the inner race Do not use the MIS to rotate the Bearing NOTE The acceptable tolerance for the Bearing is 0002 This is due to the 3 1 distance differential between the Platter diameter and the Bearing diameter NOTE During the following adjustment procedure keep these guidelines in mind 1 Adjust the Bearing runout only from the high spots 2 Adjust out only 1 2 of needed measurement The high side will shrink by half the low side will grow by half 3 Periodically rotate the Bearing completely to realign the bearing rollers after adjustment 10 Turn the Bearing until the lowest spot is encountered Zero the Indicator Turn the Bearing until the high spot is encountered this should be 180 degrees opposite the low spot 11 Insert a long T Handle hex wrench into the bolt hole in the outer Bearing nearest the high spot Place pressure on the hex wrench towards the low side to adjust the Bearing 164 Mechanical Service 96 0189 rev L June 2005 NOTE Adjusting the Bearing in this manner will move the top part of the outer bearing in the direction pressed placing leverage against the bottom part of the outer bearing NOTE During this procedure it will be necessary to tighten selected bolts in the outer race to keep your adjustments This is not exactly defined depending upon adjustments necessary during this process 12 Perfo
109. unreliable This can also be caused by loose connectors at the MOCON or MOTIF printed circuit board 225 Y TRANSITION FAULT Illegal transition of encoder count pulses in Y axis This alarm usually indicates that the encoder has been damaged and encoder position data is unreliable This can also be caused by loose connectors at the MOCON or MOTIF printed circuit board 226 Z TRANSITION FAULT Illegal transition of encoder count pulses in Z axis This alarm usually indicates that the encoder has been damaged and encoder position data is unreliable This can also be caused by loose connectors at the MOCON or MOTIF printed circuit board 227 A TRANSITION FAULT Illegal transition of encoder count pulses in A axis This alarm usually indicates that the encoder has been damaged and encoder position data is unreliable This can also be caused by loose connectors at the MOCON or MOTIF printed circuit board 228 B TRANSITION FAULT Illegal transition of count pulses in B axis This alarm usually indicates that the encoder has been damaged and encoder position data is unreliable This can also be caused by loose connectors at the MOCON or MOTIF printed circuit board 229 C TRANSITION FAULT Illegal transition of count pulses in C axis This alarm usually indicates that the encoder has been damaged and encoder position data is unreliable This can also be caused by loose connectors at the MOCON or MOTIF printed circuit board 231 JOG HANDLE TRANSITION FAULT Ill
110. use in determining the solution to a known problem Solutions given are intended to give the individual servicing the CNC a pattern to follow in first determining the problem s source and second solving the problem The troubleshooting tips are organized in this section according to the area of the CNC that may be giving sign of a problem Ex Out of round circles in drilling will be found under the heading General Machine Operation Accuracy If the problem you are experiencing cannot be found under the heading you expect please try several other possible headings If the problem is still not found contact Haas Automation for further details BEFORE YOU BEGIN USE COMMON SENSE Many problems are easily overcome by correctly evaluating the situation All machine operations are composed of a program tools and tooling You must look at all three before blaming one as the fault area If a bored hole is chattering because of an overextended boring bar don t expect the machine to correct the fault Don t suspect machine accuracy if the vise bends the part Don t claim hole mis positioning if you don t first center drill the hole FIND THE PROBLEM FIRST Many mechanics tear into things before they understand the problem hoping that it will appear as they go We know this from the fact that more than half of all warranty returned parts are in good working order If the spindle doesn t turn remember that the spindle is connected to
111. warm up prior to high speed use The program number is O02020 Spindle Warm Up SPINDLE ORIENTATION Orientation is performed electrically Orientation of the spindle is automatically performed for tool changes and can be programmed with M19 commands Orientation is performed by turning the spindle until the encoder reference is reached the spindle motor holds the spindle in position If the spindle is orientated commanding spindle forward or reverse will release the spindle 201 Technical Reference 96 0189 rev L June 2005 5 4 CONTROL CABINET LOW VOLT 260 244V 243 227V 226 211V 210 195V I O Board I O Board Power amplifiers X Y Z A B amp PC Power amplifiers X Y Z A B amp PC Transformer Terminal block Terminal block HAAS Vector Drive HAAS Vector Drive Y Delta Contactors underneath Y Delta Contactors underneath 3 phase breaker 3 phase breaker K1Contactor Power PCB Power PCB T5 Transformer T5 Transformer Low volt power supply Low volt power supply SERVO DRIVE ASSEMBLY SERVO DRIVE ASSEMBLY Single Axis Brake PCB Single Axis Brake PCB MOCON 2 Processor LCD Video Floppy MOCON 1 MOCON 2 Processor LCD Video Floppy MOCON 1 Optional Servo Tool Changer Amp Optional Servo Tool Changer Amp Control cabinet general overview 5TH 5TH AXIS AXIS AXIS AXIS A A Z Z AXIS AXIS AXIS AXIS Y Y ETHERNET ETHERNET
112. 00 Chip Shield Rear Operator Door 13 25 4973 Chip Shiel Header Operator Door 14 25 4956 Panel Right Intermediate 15 25 4990 Trip Bracket Operator Door 16 32 2313 Operator Door Close Switch 17 30 7653 Door Roller Assembly 59 0604 Spring Operator Door 323 Assembly Drawings 96 0189 rev L June 2005 EC 400 In Line Spindle Assmebly 1 20 1686A Key Drawbar Inline 2 20 1693B TRP Cylinder In Line 3 20 1688 Tranfer tube In line 4 25 4761 Shim TRP In Line 5 20 1694A Standoff Motor In Line 6 20 1690 Striker plate Inline 7 20 7422D Oil Injector Cover 8 20 7016C Spindle Houseing 40T 9 20 9763C Spindle Lock Tapered 10 20 7018M Spindle Shaft 40T 11 20 1684A Adaptor Shaft In line 12 20 1687A Guide Release In line 13 25 4648B Bracket Switch Mounting In line Spindle 14 20 1696A TRP Spirng Retain Inline 15 20 1691 TRP Shaft In Line 16 52 0040 Shaft Coupling 324 Assembly Drawings 96 0189 rev L June 2005 EC 400 Spindle Head Assembly 325 Assembly Drawings 96 0189 rev L June 2005 1 58 1680 Fitting Bkhd NPT 1 2x1 125 dia 2 20 7381A Plate Prog Coolant 3 32 0199 Condit Assembly P Cool 4 20 7384A Nozzle Body 5 14 1905 P Cool Cover 6 25 5327 P Cool Mounting Bracket 7 58 3694 1 4 Valves Loc Line 8 58 1722 Fittin NPT 3 8F x NPT 3 8M 90 Degree 9 58 1686 Fitting NPT 1 4M x NPT 3 8F 10 58 0326 3 8 Full Pivot Ball Valve 11 58 3052 Fitting Comp 1 2 x NPT 3 8M 90 Degree 12 30 6460 Spindle Assmbly 12K in Line 13 58 067
113. 03 to 0 0007 NOTE Check backlash in each of the four quadrants every 90 3 Remove the 4 10 32 BHCS that retain the worm housing cover Place a drip pan beneath the black bearing housing cover to catch any gear oil keep this pan in place for Step 4 Remove the bearing housing cover It may be necessary to apply channel lock pliers to the bearing housing in order to remove it if this is necessary use a rag to prevent marring 4 Note the position of the dimple located on the flange of the bearing housing Mark this position on an adjacent part of the casting for reference Remove the four 5 16 18 cap screws Do not pull the housing out or gear oil will pour out of the housing Put two 2 screws part way in housing holes and turn housing with lever 5 Index the bearing housing one set of holes Move to the next set of holes by rotating the hole set upwards towards the platter This may be CC or CCW Bolt the bearing housing flange down Torque the bolts to 25 ft lbs Check the backlash in each of the four quadrants The factory specification is 0 0003 to 0 0007 If necessary repeat Steps 4 and 5 6 Replace the bearing housing cover Replace the side cover sheetmetal and reattach with the 4 BHCS removed in Step 3 7 Remove the oil filler pipe plug If the oil level covers less than half of the sight glass then add as follows in step 8 8 Refill the gear case with Mobil SHC 630 gear oil to the midpoint
114. 1 30 SWAP A amp C AXES This parameter causes the A and C axes to be swapped internally This parameter bit should be set to 1 for the bridge mill All other mills should set this bit to 0 31 INV SPIND SPD DECEL Inverse Spindle Speed Deceleration When this parameter is set to 1 the spindle decelerates faster at lower speeds resulting in a shorter deceleration time 279 X SCALE GAIN MULT This is used on machines with linear scales Linear scales are used to continuously correct any errors in the encoder position The parameter determines the gain of the correction factor that is how fast it corrects This parameter should be set to 40 280 Y SCALE GAIN MULT See parameter 279 for description 281 Z SCALE GAIN MULT See parameter 279 for description 282 A SCALE GAIN MULT See parameter 279 for description 283 B SCALE GAIN MULT See parameter 279 for description 284 RESERVED 285 X LINEAR SCREW OFFS This parameter is used on machines with linear scales This parameter accounts for the unused portion of the ball screw between zero and the actual motor This parameter should be a positive value 400000 unless the NEG COMP DIR bit for the axis is set in which case this parameter should be a negative value 400000 286 Y LINEAR SCREW OFFS See parameter 285 for description 287 Z LINEAR SCREW OFFS See parameter 285 for description 288 A LINEAR SCREW OFFS See parameter 285 for description 239 Parameters 96 0189 rev L June 2005
115. 153 Rear Cover 2 20 0731 Carousel 3 25 4152 Front Cover 4 32 2295 Prox Carousel Mark 5 32 1875 Carousel Motor 6 20 0809 Carousel Shaft 7 20 2759 Mounting Plate 8 62 0014 Servo Motor 9 20 0772 Motor Mount 10 54 0036 Drive Belt 11 22 0001 Output Shaft Cad 12 20 0224 Star Bearing Housing 13 20 0223 Star Gear 14 20 0225 Bearing Housing 15 30 4008 Cam Box 16 20 2694 Output Shaft 17 57 0059 Seal 18 25 5805 Cover Plate 19 20 0240 Arm Hub 20 20 0245 Arm Cap 20 0246 Arm Cap 21 30 7234 Double Arm Assy 22 20 0238 Bearing Cap 23 20 0226 Bearing Housing 24 32 2251 Prox Pocket Down 25 32 2252 Prox Pocket Up 26 20 2732 SMTC Shaft Support 27 20 2731 SMTC Support Plate 28 20 2730 Pocket Stop 29 20 0807 Tool Pocket Slide 30 32 2253 Prox Switch Tool One 31 59 0078 Air Cylinder 32 20 2735 ATC Housing 33 25 0800 Shroud Corner 34 20 0458 Tool Pocket 35 59 0290 Lock Nut 36 20 0392 Carousel Washer 37 54 0045 Belt Drive 320 Assembly Drawings 96 0189 rev L June 2005 Load Position ATC Assembly 17 18 25 19 24 23 21 20 22 1 4 5 6 2 3 15 16 13 7 8 10 12 11 9 14 1 40 0226 SHCS x3 2 59 0737 Plug Hole 3 20 2911A Hub Index Plate 4 20 2911A Hub Index Plate 5 20 2868A Shaft Assembly 6 40 1663 SHCS 13x1 7 25 6029 Panel Tools 31 45 8 25 6030 Panel Tools 46 60 9 25 5998 Disk Section 1 10 25 6021 Panel Tools
116. 2000 219 CONVYR RETRY LIMIT Number of times that the conveyor will cycle through the reverse forward sequencing when an overcurrent is sensed before the conveyor will shut down An overcurrent is sensed when chips jam the conveyor By reversing and then forwarding the conveyor the chip jam may be broken Default is 5 231 Parameters 96 0189 rev L June 2005 220 CONVYR RETRY TIMEOUT Amount of time in 1 50 seconds between consecutive overcurrents in which the overcurrents is considered another retry If this amount of time passes between overcurrents then the retry count is set to 0 Default is 1500 30 seconds 221 MAX TIME NO DISPLAY The maximum time in 1 50 sec between screen updates 222 ROTARY AXIS INCRMNT For Horizontal mills only This parameter sets the degrees of rotation of the A axis at an M36 or Pallet Rotate 223 AIR TC DOOR DELAY For Horizontal mills only This parameter sets the delay to open the tool changer door in milliseconds If the tool changer does not have a pneumatic door this parameter is set to zero 224 ROT AXIS ZERO OFSET This parameter shifts the zero point of A for a wheel fixture or tombstone 225 MAX ROT AXIS ALLOW For Horizontal mills with a wheel fixture only This parameter sets the maximum rotation in degrees allowed before stopping at front door 226 EDITOR CLIPBOARD This parameter assigns a program number nnnnn to the contents of the clipboard for the advanced editor 227 DISK DIR NAME
117. 3 25 5619 Front Door 14 28 0020 Window 15 59 6210 Door Handle 16 54 0030 Guide Wheel 17 25 5653 Retainer 18 20 2579 Stand off Bumper 19 20 2573 Track Front Door 20 25 5608 Saddle Back RT 21 25 5638 Saddle End Cover 22 25 5610 Saddle Front RT 23 25 5611 Saddle Front Mid 24 25 5612 Saddle Front LT 25 25 5643 Silt Plate 26 25 5640 Trough Drain 27 25 0548 Discharge Chute 28 19 8612 Screen Chip Tray 29 25 5639 Plenum Drain 30 25 5609 Saddle End Cover LT 31 25 5613 Saddle Back LT 32 25 5597B Panel Encl 33 25 5596B Panel Encl 34 25 5585B Dip Pan T C 35 25 5601C Panel Encl L R 36 25 5594B Panel Encl Top 37 25 5588B Panel Encl R Upper 38 25 5587C Panel Encl Rear Mid 39 25 5590 Panel Cbl Encl 40 25 5592B Panel Encl RT Rear 41 25 5593A Panel Encl RT Side 42 25 5591A Door Operator 43 25 5600B Panel Encl Left Side 44 25 5599B Panel Encl LT Side F 45 25 5582B Drip Pan T C Bottom 46 25 5598B Panel Encl R L 47 25 5595B Panel Encl T C Fillet 48 25 5642B Panel T C Back 49 25 5586B Support T C D Pan 50 25 5581B Retainer EC 1600 Enclosure Assembly 345 Assembly Drawings 96 0189 rev L June 2005 EC 1600 Spindle Assembly 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 1 2 1 20 0011A 50T Shaft Spindle 2 20 0001A Spindle Lock 3 30 7395 EC 1600 P Cool 4 30 7394 Plumbing Assembly 5 20 0004 50T sp
118. 4 Tube Coolant P Cool 14 52 0035 P Cool Hose 15 58 3049 Fitting Comp 1 2xNPT 3 8 Str 16 25 5366 Brkt Mounting Air Soleniod Assembly 17 25 5012 Trip Bracket Y axis 18 30 4095 TRP Soleniod Assembly 19 25 5241 Bracket Clamp TSC 20 30 6465 TSC Switch Assembly 21 25 5242 Bracket Shroud 22 36 3035 Fan Assembly Spindle 23 25 5264 Brkt Cable Carrier Y Axis 24 59 0144 Fan Guard 8 75 in 25 25 5215 Bracket Fan In Line Spindle 26 25 5213 Shroud motor In Line 27 25 5017 Cable tray Spindle Head 28 73 3055 Therm Blk 6 Pole 29 25 5216 Strap Spindle Motor Lift 30 20 2248 Plate Motor 31 20 1694A Stand Off Motor in Line 32 20 2044 Spindle Head Machined 33 20 2063 Coolant Block 34 30 6338A Oil Line Assembly Y Axis EC 400 Spindle Head Assmebly 326 Assembly Drawings 96 0189 rev L June 2005 EC 400 Top Cover 1 25 4952 Top Cover Front 2 25 4963 Brace Top Intermedite 3 32 0196 Worklight Assembly 4 25 4964 Top Cover Right 5 25 4980 Wire ChannelTop Cover 6 25 4965 Top Cover Left 7 25 4983 Splash Shield Rotating 8 25 5253 Cover Brace Top 9 25 4953 J Box Top Cover 10 25 4984 Cover Wire Channel Top 327 Assembly Drawings 96 0189 rev L June 2005 EC 400 Tool Changer Panels 328 Assembly Drawings 96 0189 rev L June 2005 1 25 4979 Panel Left Intermediate 2 25 4962 Panel TC 3 25 4975 Access Cover TC Front 4 25 5195 Access Cover TC Rear 5 25 4961 Pan TC 6 58 0671 Coolant Drain Tube 7 25 4972 Apron Left Rear 8
119. 5 2 4 Sol Ex 2 3 1 Blocked Sol Safety Valve Pressure Power On Power On Ex B Condition when machine is unclamped Note Same condition applies if table is unclamped and the machine is emergency stopped in the middle of a table index The table remains unclamped Port Plugged P 1 Sol Safety Valve Pressure Ex No Power No Power C Condition when the table is unclamped and then power is lost Main valve shuttles to clamp the table but the safety valve also loses power and blocks the exhaust port on the clamp side of the piston This prevents the clamp plate from clamping immediately The clamp plate will slowly move to its clamp position Troubleshooting 1 Failure Clamp switch wires cut Result The control see the switch as open at all times The table can index into position and clamp The control will not see the switch close therefore it assumes that the pallet is not clamped an alarm will generate Comment This is a safe condition there is no threat of injury or machine damage However the machine will not function until the switch is replaced 2 Failure The clamp status plunger rod is stuck in clamp position broken rod broken switch stuck rod The same scenario if an errant piece of metal keeps the switch tripped closed 24 Troubleshooting 96 0189 rev L June 2005 Result The clamp plate unclamps raising the pallet The machine is ready to rotate the pallet
120. 5 55545 Pump Sound Wall 25 69 1700 Prox Sensor 26 20 2532 Sensor Bracket 27 20 2527 Pinion 22T Indexer 28 20 1400 Backlash Plate 29 20 2526 Indexer Mount 30 25 5539 Shroud Support 31 20 2531 Platter Drive Mount 32 59 0695 Alpha Ip 120 33 62 0024 Servo Motor 34 25 5540 Right Shroud 35 25 5543 Bottom Shroud 348 Assembly Drawings 96 0189 rev L June 2005 EC 1600 Table Assembly Full Fouth Indexer 1 2 3 4 5 6 7 8 12 13 14 17 22 24 23 34 35 9 10 11 15 16 18 19 20 21 25 26 27 28 29 30 31 32 33 1 25 5541 Left Shroud 2 25 5542 Top Shroud 3 25 5544 Pump Cover Access 4 57 0373 Pump Cover Gasket 5 30 7398A Hydraulic Solenoid Assembly 6 32 1459 Encoder Assembly 7 52 4471 Coupling 8 20 6115 Encoder Shaft 9 20 6114B Encoder Mounting Plate 10 20 6027 Coupling Tube 11 20 6103 Ring Gear 12 30 7754 Hydraulic Brake Assembly 13 20 6113 Bearing Retainer Ring 14 51 2038 Cross Roller Bearing 15 20 2534 Encoder Shaft Plate Adaptor 16 20 6116 Encoder Shaft Plate 17 20 0973 Table Cover Center 18 20 2510A 4th Axis Platter Machined 19 69 1700 Prox Sensor 20 25 5538 Retainer Platter Seal 21 25 9817 X Axis Chip Guard 22 20 2508 Table 23 30 7410 Saddle Oil Line 24 30 7881 Brake Booster Assembly with Sensor 59 0216 Booster 58 2267 Muffler 58 0051 Connector 58 1696 Elbow 58 0315 T 52 0014 Pressure Guage 58 3658 Elbow 2x
121. 5 Z axis Cable tray 21 25 6304 Cable tray bracket 22 20 2071 Rotary motor mounting plate 23 25 5018A Receiver solenoid mount 24 62 0016 Servo motor 25 54 4505 Drive belt PGGT 5Mx15 26 20 4506 Driven pulley 310 64T 20 4229 Driven pulley lockring 27 30 6774A Rotary index solenoid assy 28 25 5027 Z axis cable carrier bracket 29 20 1991 Z axis shipping pin 30 25 4968 Rotary table side chip shield 31 35 4210 Worm shaft assembly 32 20 2045B Rotary table index machined 33 57 4282 O ring 2 248 34 20 4286 Lift piston 51 4285 Thrust washer 2 51 4286 Thrust bearing 35 57 0139 O ring 2 263 36 20 4213 Disc brake 57 2144 O ring 2 256 57 4288 Thrust bearing 37 20 4236 Spindle spacer 40 1636 SHCS 6 38 20 1998A Receiver rotary union 39 20 2344 Rotary union lower washer 40 45 0075 Steel washer 5 16 41 43 0023 HHB 5 16 18x1 pltd 42 25 5231 Front way cover Z axis 43 57 0327 Fixed way cover gasket 44 30 6336 oil line assy Z axis 45 20 0150 Ballnut housing machined 46 20 2330B Rotary axis switch arm 47 20 2473 Bar spring mount assy 48 20 2023A Ballnut spacer Z axis 49 69 1700 Proximity switch 2 341 Assembly Drawings 96 0189 rev L June 2005 EC 1600 Base Assembly 1 20 2509 Casting 2 30 6953 Lube Line Assy 3 30 0472 Bearing Assy 4 32 2133 Limit Switch 5 30 1222 Bearing Assy 6 30 3988 Coupling 7 20 0151 Motor Mount Assy 8 62 0008 Motor 9 50 9010 Linear Guides 10 24 9960a Ballscrew Assy 11 20 0150
122. 58 1671 Nipple 59 0047 Quick Exhaust Valve 25 25 5547 Booster Mounting Bracket 26 20 6102 Pinion Gear 27 20 6100 Cooling Jacket Inlet Plate 28 20 1400 Backlash Plate 29 59 2930 Harmonic Drive 50 1 30 20 2531 Platter Drive Mount 31 20 6110 Motor Shaft Spacer 32 20 6109 Motor Adaptor 33 62 0014 Motor 349 Assembly Drawings 96 0189 rev L June 2005 HS3 7R Harmonic Drive Assembly 1 20 6047 Tube Backlash Adjuster HS3R 2 20 6048 Cam Backlash Adjuster HS3R 3 20 6005 Push Block HS3R 4 20 6102 Pinion Gear HS3R 5 20 6109 Sigma Adapter HS3R 6 59 2930 Harmonic Drive 7 20 6112 Shoulder Washer HS3R 8 22 2627 Yasakawa Motor Key 9 59 2930 Harmonic Drive Assy 10 20 6108 Gearbox Adapter HS3R 11 62 0014 Yaskawa Sigma Motor 1 2 3 4 5 6 7 10 8 9 11 350 Assembly Drawings 96 0189 rev L June 2005 HS3 7R Table Assembly 1 20 6101 Machined Platter 2 20 6103 Ring Gear 3 30 7754 Brake Assy 4 51 2038 Bearing Crossroller 5 20 6113 Bearing Retainer Ring 6 20 6100 Table Machined HS3R 20 1511 Table Machined HS6R 7R 1 2 3 4 5 6 351 Assembly Drawings 96 0189 rev L June 2005 HS3 7R Encoder Assembly 20 6115 Encoder Shaft 20 6114 Encoder Mounting Plate 20 6006 Encoder Cover Plate 20 6116 Encoder Shaft Plate 20 6027 Encoder Coupler Tube 52 4471 Encoder Shaft Coupling 20 6025 Encoder Mounting Cup 32 1459 Encoder Set Screws 352 Assem
123. 5916 Thrust Washer 2x 13 25 5915 Roller Cage 14 51 0018 Bearing Roller 15 25 5900A APC Skirt 2x 16 20 2813 Stabilizer Spacer 17 25 6793 Right Clamp Shield 18 25 6794 Left Clamp Shield 19 20 2783 Drive Plate 20 25 6827 Switch Cable Cover 21 58 0779 Air Blast Tube 22 20 2726 Bulkhead 23 58 1693 LBO Fitting 24 58 0778 Clamp Tube 25 58 0777 Unclamp Tube 26 58 3087 Comp Fitting 27 58 3052 90 Comp Fitting 28 25 5899 APC Cable Strap 29 20 2719 Clamp Cylinder Cover 30 57 2986 Piston O Ring 31 20 2700 Pallet Clamp Piston 32 20 2716 Pallet Clamp Shaft 33 59 0727 Die Spring 34 20 2690 Pallet changer Base 35 20 2785 H Frame Pad 36 20 2809 Frame Button 37 59 0725 Bumper 38 20 2728 Stop Block 39 20 2727 Air Blast Ring 40 20 2582 Air Blast Nozzle 41 40 1705 FHCS 42 58 2070 Hex Fitting 43 58 0780 90 Fitting 44 20 2699 Pallet Up Plunger 45 20 3073 Clamp Switch Housing 46 32 2236 Prox Switch Unclamp 47 20 2698 Pallet Flag 48 625 x 2 Shoulder Bolt 49 59 0726 Pallet Support Spring 50 20 2715 Pallet Clamp 51 25 5903 Prox Pallet Mount 52 32 2130 Prox Home 1 5 Note The A location illustrate lifting points 319 Assembly Drawings 96 0189 rev L June 2005 EC 300 40 40 Tool changer 1 3 2 4 5 6 7 8 10 9 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 18 26 27 28 29 30 31 32 33 34 35 36 37 1 25 4
124. 6 G37 G136 was found during program restart 401 INVALID TANGENT IN GROUP 1 CORNER ROUNDING OR CHAMFERING The point or angle calculated has yielded invalid results in automatic chamfering or corner rounding This can be for one of the following reasons 1 Tangent of angle was too close to zero 2 Cosine of angle was invalid 3 Hypotenuse of calculated right triangle was shorter than side 4 Calculated point did not line on arc or line Check your geometry 402 POSSIBLE CORRUPTED FILE The parameters being loaded do not match the expected number of parameters This can be due to the loading of an older or newer parameter file than the system binary or the file is corrupted 403 TOO MANY PROGS Cannot have more than 500 programs in memory 404 RS 232 NO PROG NAME Need name in programs when receiving ALL otherwise has no way to store them 405 RS 232 ILLEGAL PROG NAME Check files being loaded Program name must be Onnnn and must be at begin ning of a block 45 Alarms 96 0189 rev L June 2005 406 RS 232 MISSING CODE Bad data was received Check your program The program will be stored but the bad data is turned into a comment 407 RS 232 INVALID CODE Check your program The program will be stored but the bad data is turned into a comment 408 RS 232 NUMBER RANGE ERROR Check your program The program will be stored but the bad data is turned into a comment 409 FILE INVALID N CODE Bad parameter or setting number Positive number must
125. 6 Is a single phase 115V protected output for the user OPERATOR S WORK LIGHT Main transformer T1 outputs 115 VAC to the work light 209 Technical Reference 96 0189 rev L June 2005 5 13 POWER TRANSFORMER ASSEMBLY T1 The power transformer assembly is used to convert three phase input power 50 60Hz to three phase 230V and 115V power Two different transformers are used depending on the input voltage range The low voltage transformer has four different input connections to allow for a range of voltages from 195 V RMS to 260 V RMS The high voltage transformer has five different input connections and will accept a range of voltages from 354V RMS to 488 V RMS The 230 V is used to power the spindle drive which also develops the 325 VDC power for the axis servo amplifiers The 115 V is used by the video monitor solenoids fans and pumps in addition to supplying power to the main LVPS used by the control electronics The transformer assembly is located in the lower right hand corner of the main cabinet Besides the high low voltage variations two different power levels are available depending on the spindle motor used The small and large transformers have power ratings of 14 KVA and 28 KVA respectively They are protected by the main circuit breaker to the levels shown in the preceding table LOW VOLT 260 244V 243 227V 226 211V 210 195V LOW VOLT LOW VOLT 260 244V 243 227V 226 211V 210 195V
126. 6 0189 rev L June 2005 295 Electrical Diagrams 96 0189 rev L June 2005 296 Electrical Diagrams 96 0189 rev L June 2005 297 Electrical Diagrams 96 0189 rev L June 2005 RELAY COIL DRIVERS K1 THROUGH K8 0VDC MOCON PCB 12VDC 12VDC P11 PIN 16 12VDC PIN 12 0VDC 12VDC 0VDC PIN 15 PIN 14 PIN 13 0VDC 12VDC 0VDC PIN 11 PIN 10 PIN 9 SPINDLE LUBE I O PCB LE 8 P1 PIN 16 GEAR BOX OIL PUMP WAY LUBE PUMP SPINDLE FAN LE 6 PIN 12 LE 7 PIN 15 PIN 14 PIN 13 PIN 11 LE 5 PIN 10 PIN 9 AUTO POWER OFF SPINDLE COOLING K8 K7 4TH AXIS PLATTER UP COOLANT ON Q8 K5 0VDC 12VDC 0VDC 12VDC PIN 8 PIN 7 PIN 6 PIN 5 12VDC 0VDC 12VDC 0VDC PIN 4 PIN 3 PIN 2 PIN 1 LE 4 PIN 8 PIN 7 LE 3 PIN 6 PIN 5 LE 2 PIN 4 PIN 3 LE 1 PIN 2 PIN 1 PC PALLET UP PC PALLET DOWN K4 K3 SERVO POWER ON TC DOOR OPEN K2 K1 510 CABLE 298 Electrical Diagrams 96 0189 rev L June 2005 299 Electrical Diagrams 96 0189 rev L June 2005 300 Electrical Diagrams 96 0189 rev L June 2005 301 Electrical Diagrams 96 0189 rev L June 2005 302 Electrical Diagrams 96 0189 rev L June 2005 303 Electrical Diagrams 96 0189 rev L June 2005 MOTOR SPIGOT M K18 SPIGOT REVERSE K17 FORWARD SPIGOT 12 VDC SINGLE PHASE REVERSIBLE CHIP CONVEYOR MOTOR M OMIT THE
127. 69 AIR BRAKE DELAY is used as the allowed time for seeking the Up switch If the switch is not detected within the allowed time alarm 925 A INDEXER IS NOT FULLY IN THE UP POSITION is generated 680 689 LEAD COMPENS SHIFT These parameters specify the amount of shift needed for proper indexing into the Lead Screw Compensation table Note that these parameters are very similar to Param 58 The difference is that these parameters hold a non zero value they take precedence over the general parameter 58 For example Param 58 LEAD COMPENS SHIFT 14 General Parameter Param 683 A LEAD COMPENS SHIFT 12 axis Parameter A Param 684 B LEAD COMPENS SHIFT 0 axis Parameter B In the above example the A axis will take its lead screw shift value from Parameter 683 since it is a non zero value but the B axis will get its shift value from Parameter 58 NOT from Parameter 684 Determining the appropriate value for lead screw compensation Example Assume Steps Per Unit on A is 2800 Parameter 47 a Take steps per unit and multiply by 360 unscaled 2800 x 360 1008000 b Apply Enc scale factor if present For example with a scale factor set to 3 we have 1008000 3 336000 c Determine the smallest number n that will hold the inequality 336000 2 n lt 256 gt 336000 2 11 lt 256 so n 11 d Therefore set Par 683 to 11 671 Indexer Down Settle Supports the indexer rotary table It specifies the amount of time in ms the mac
128. 6xSHCS Bearing Support Bearing Housing 6xSHCS EC 1600 Ballscrew and motor components Installation 1 Place the hard stop on the new ball screw so the hard stop is at the top of the column and the flange of the ball screw is mounted on the upper side of the nut housing and manually turn the ball nut up the ball screw about halfway 2 Insert the motor end of the ball screw through the upper bearing pack hole then lower the ball screw guiding the bearing support end of the screw into the bearing NOTE Correct alignment is critical to sliding the ball screw into the bearing Binding will not occur if it is guided carefully and correctly into the bearing 3 Place the bearing sleeve onto the ball screw and attach it to the top of the column with the SHCS Torque the SHCS to 30 ft lb 4 Loosely screw the locknut on the bearing plate end of the ball screw 5 Orient the ball nut so the oil line can be connected then turn the ball screw by hand to pull the ball nut flange down until it contacts the nut housing 6 Insert the SHCS that hold the ball nut to the ball nut housing but do not tighten completely 7 Loosely install the locknut on the motor end of the ball screw Mechanical Service 108 96 0189 rev L June 2005 8 Hand turn the ball screw to move the spindle motor up and down to assure free movement of the ball screw 9 Torque the SHCS that hold the ball nut to the nut housing to 30 ft lb 10 The
129. 7 Enter Debug Mode go to the POS RAW DATA page and take the actual value from the appropriate axis Enter this value into the Tool Change offset parameter 8 Restore the air pressure and zero return the axis 9 Verify that the pallet is aligned over the locators 10 Change the Parameter 209 value to 0 Mechanical Service 118 96 0189 rev L June 2005 3 11 EC 400 PALLET CHANGER Make sure the machine is turned off and the air pressure is discharged before attempting to work on this machine Refer to the assembly drawing of the APC in the back of this manual The drive mechanism for the APC is located inside the rotating door It can be accessed for troubleshooting by removing either half of the door APC disassembly requires removing the door Disassembly is a top down process 119 Mechanical Service 96 0189 rev L June 2005 Tapered Roller Bearing Bearing Locknut Shaft Cover Air Vent Tapered Roller Bearing O Ring 2 358 Hub O Ring Inside 2 377 Seal Housing Cam 3X Ball Bearings Cage Cam Shaft Clamp Bridge Cylinder Lever Shaft Mount Wired in series with Load Station door switch Operator Station Lock Switch Air Cylinder Bumper Bumper Mount Lock Pin Lock Mount Shaft Seal Pallet Pin Knob APC Shaft 4X Washers 2XTop amp 2X Bottom not shown Shoulder Screw not shown Load Station Shaft Load Station Lock Plate Lock HSG Table Bo
130. 8 Manually rotate the carousel for each tool pocket installation Re install the pocket stop and slider The carousel can be rotated by manually rotating the carousel pulley by hand 77 96 0189 rev L June 2005 Mechanical Service Carousel Motor Carousel Pulley Pulley locations and ATC movement 4 Re attach the carousel number disc with the BHCS Apply blue loctite to the BHCS and tighten 50 TAPER CAROUSEL REMOVAL AND INSTALLATION CAUTION Do not attempt to remove the carousel with the pockets installed 1 Remove sheetmetal disc covering the carousel Press lt TOOL CHANGER RESTORE gt Press lt Y gt three times to enter Tool Changer Recover Mode 2 Remove all tool changer pockets See the 50 Taper SMTC Pocket Removal and Installation in this section NOTE The carousel can be manually rotated by turning the carousel drive motor by hand while in lt E STOP gt 3 Remove the center bearing nut using Haas tool P N 1357 4 Remove the carousel using a suitable lifting device CAUTION The carousel is extremely heavy Ensure you have an appropriate lifting device and straps capable of lifting the carousel weight Installation 1 Using a suitable lifting device place the carousel onto the tool changer body 2 Use a new bearing nut and thread onto the carousel shaft Torque to 80 ft lbs 3 Install pockets into the carousel following the 50 Taper SMTC Pocket Removal and Installation section 4 Ro
131. 8 G MACRO CALL O9017 See parameter 91 for description 99 G MACRO CALL O9018 See parameter 91 for description 100 G MACRO CALL O9019 See parameter 91 for description 101 X AXIS IN POSITION LIMIT How close the motor must be to the endpoint before any move is considered com plete when not in exact stop G09 or G61 Units are encoder steps As of mill version 9 06 this parameter does not apply to feeds This parameter should be equivalent to 050 inches 102 Y AXIS IN POSITION LIMIT See Parameter 101 for description 103 Z AXIS IN POSITION LIMIT See Parameter 101 for description 104 A AXIS IN POSITION LIMIT See Parameter 101 for description 105 X AXIS MAX CURRENT Corresponds to maximum peak current provided by the amplifier 4095 30A small amp 45A Medium amp 60A large amp 106 Y AXIS MAX CURRENT See Parameter 105 for description 107 Z AXIS MAX CURRENT See Parameter 105 for description 108 A AXIS MAX CURRENT See Parameter 105 for description 109 D D GAIN FOR X Second derivative gain in servo loop 110 D D GAIN FOR Y Second derivative gain in servo loop 225 Parameters 96 0189 rev L June 2005 111 D D GAIN FOR Z Second derivative gain in servo loop 112 D D GAIN FOR A Second derivative gain in servo loop 113 X ACC DEC T CONST Acceleration time constant Units are 1 10000 seconds This parameter provides for a constant ratio between profiling lag and servo velocity at the endpoint of a rapid motion 114 Y ACC DEC T C
132. 9005 See parameter 81 for description 87 M MACRO CALL O9006 See parameter 81 for description 224 Parameters 96 0189 rev L June 2005 88 M MACRO CALL O9007 See parameter 81 for description 89 M MACRO CALL O9008 See parameter 81 for description 90 M MACRO CALL O9009 See parameter 81 for description 91 G MACRO CALL O9010 G code that will call O9010 This parameter can contain a value from 1 through 98 inclusive zero causes no call However it is best to use a value that is not already in use see current G code list Using G45 the value 45 would be entered in parameter 91 for example A program would be written to include the G45 such as G X0 G45 M30 The control would run the program until it got to the G45 It would call program O9010 run that and then return to the point that it left and continue the main program Be aware that if program O9010 contains another G45 it will call itself and keep calling until it fills the stack 4 times and then alarm out with 531 MACRO NESTING TOO DEEP Note that if G84 for example is used it would override the normal G84 Tapping Canned Cycle 92 G MACRO CALL O9011 See parameter 91 for description 93 G MACRO CALL O9012 See parameter 91 for description 94 G MACRO CALL O9013 See parameter 91 for description 95 G MACRO CALL O9014 See parameter 91 for description 96 G MACRO CALL O9015 See parameter 91 for description 97 G MACRO CALL O9016 See parameter 91 for description 9
133. 926 Auger Motor Cable Tray 15 25 5788 Right Intermediate Pan 16 25 4521 Cover Lamp Connector 20 32 0227 Mylar Reflector Lamp Assembly 25 4789 Adjust Work light Bracket 21 25 5793 Operator Door Side Z Frame 22 28 0151 Operator Door Side Window 23 25 5787 Right Chip Shield PC Wing 24 25 5789 Operator Side Lower Chip Shield 25 25 5228 Door Window Z Frame 2x 25 5800 Operator Side Top Chip Shield 17 25 5889 Operator Side Top Cover 18 25 5887 Top Center Channel 19 25 5890 Tool Changer Side Top Cover 311 Assembly Drawings 96 0189 rev L June 2005 EC 300 Rear Panels View Rotated 90 CCW 1 2 3 4 5 6 7 9 10 12 13 14 8 11 1 25 5720 Rear Header 2 25 5666 Rear Control Box Panel 3 25 5722 Control Support Mounting Bracket 4 25 5924 Control Intermediate Pan 5 25 5665 Front Control Pan 6 25 5667 Front Control Box Panel 7 25 5721 Top Panel Support Brace 8 25 5912 Control Top Panel Tray 9 25 5896 Control Box Panel Tray 10 25 5925 Rear Control Pan 11 25 5897 Rear Panel support Bracket 2x 12 25 5664 Rear Left Pan 13 25 7581 TSC Filter Bracket 14 25 5718 Rear Left Panel 312 Assembly Drawings 96 0189 rev L June 2005 EC 300 Tool Changer Panels View Rotated 90 CW 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 1 25 5881 Tool Changer Top Cover 2 25 5706 T C Front Panel 3 25 5779 T C Side
134. A loss of power to the tool changer can also cause this Check relays K9 K12 and fuse F1 on IOPCB 116 SPINDLE ORIENTATION FAULT Spindle did not orient correctly During a spindle orientation function the spindle rotated but never achieved proper orientation This can be caused by failure of encoder cables belts MOCON or vector drive 117 SPINDLE HIGH GEAR FAULT Gearbox did not shift into high gear During a change to high gear the spindle is rotated slowly while air pressure is used to move the gears but the high gear sensor was not detected in time Parameters 67 70 and 75 can adjust the time out times Check the air pressure the circuit breaker CB4 for the solenoids and the spindle drive 118 SPINDLE LOW GEAR FAULT Gearbox did not shift into low gear During a change to low gear the spindle is rotated slowly while air pressure is used to move the gears but the low gear sensor was not detected in time Parameters 67 70 and 75 can adjust the time out times Check the air pressure the circuit breaker CB4 for the solenoids and the spindle drive 119 OVERVOLTAGE Incoming line voltage is above maximum The servos will be turned off and the spindle tool changer and coolant pump will stop If this condition persists an automatic shutdown will begin after the interval specified by parameter 296 120 LOW AIR PRESSURE Air pressure dropped below 80 PSI for a period defined by Parameter 76 The LOW AIR PR alarm will appear on the screen as soon
135. ALLET CHANGER CW CCW AIR SOLENOIDS SHIELD 2 911A UNSWITCHED LEG 1 20 912A SWITCHED LEG 2 FROM MCD RELAY BOARD M25 M26 M27 20 913A SHIELD DRAIN Cable List 286 96 0189 rev L June 2005 910B 115 VAC TO SERVO FAN SHIELD 2 911B LEG 1 20 912B LEG 2 20 910C 115 VAC TO PURGE SOLENOID SHIELD 2 911C UNSWITCHED LEG 1 20 912C SWITCHED LEG 2 FROM 270 IOPCB P48 913C SHIELD DRAIN 910D 115 VAC TO PALLET ALARM SHIELD 2 911D SWITCHED LEG 1 FROM MCD RELAY BOARD M24 20 912D UNSWITCHED LEG 2 20 913D SHIELD DRAIN 930 230 VAC FOR COOLANT PUMP FROM CB3 SHIELD 2 931 LEG 1 20 932 LEG 2 20 933 SHIELD DRAIN 940 230 VAC SINGLE PHASE POWER TO COOLANT PUMP 941 LEG 1 20 942 LEG 2 20 940A 230 VAC SINGLE PHASE POWER TO THROUGH SPINDLE COOLANT PUMP 941A LEG 1 20 942A LEG 2 20 950 LOW AIR PRESSURE OIL LUBE SENSOR SHIELD 3 951 LOW AIR SIGNAL 20 952 LOW OIL LUBE SIGNAL 20 953 COMMON DATA GROUND 20 954 SHIELD DRAIN 960 LOW TRANSMISSION OIL LUBE SHIELD 2 961 LOW TRANSMISSION OIL LUBE SIGNAL 20 962 COMMON RETURN DATA GROUND 20 963 SHIELD DRAIN 970 VECTOR DRIVE OVER VOLT SENSOR 990 HOME SENSORS SHIELD 4 ALL 20 991 COMMON DATA GROUND 992 X AXIS HOME SWITCH 993 Y AXIS HOME SWITCH 994 Z AXIS HOME SWITCH 287 Cable List 96 0189 rev L June 2005 1000 SPINDLE ENCODER CABLE MoCon SIDE CONNECTION ALL 24 1000 1 LOGIC RETURN D GROUND 1000 2 ENCODER A CHAN
136. Axis way covers 2 35 25 0645 X Axis extension 36 25 0679 X Axis extension access cover 353 Assembly Drawings 96 0189 rev L June 2005 Pendant Arm Knuckle 25 6661 Knuckle Cover 25 6660 Knuckle Swivel Plate 25 6659 Pendant Arm Mount 20 7109 Wavy Washer 55 0020 Levelling Screw 40 164391 Pendant Mount 20 7110 PARAM SETNG GRAPH HELP CALC NEXT TOOL RELEASE TOOL PART ZERO SET TOOL OFFSET MEASURE MESGS ALARM DGNOS POSIT OFFSET COMDS PRGRM CONVRS DISPLAY CURNT OVERRIDES CUSOR PAGE AUX CLNT CLNT CHIP CHIP CHIP FWD STOP REV DOWN UP CLNT 7 8 9 4 1 CANCEL 5 2 0 SPACE 6 3 WRITE ENTER JOG LOCK B SHIFT E D C B A K Q W J P V I O U EOB H N T Z G M S Y F L R X 10 100 10 HAND CW STOP CCW SPINDLE CNTRL FEED FEED RATE FEED RATE FEED RATE 10 100 10 SPINDLE HAND CNTRL SPIN SPINDLE SPINDLE RAPID 5 RAPID RAPID RAPID 25 50 100 INSERT ALTER DELETE UNDO SINGLE DRY OPTION BLOCK BLOCK RUN STOP DELETE COOLNT ORIENT SPINDLE ATC ATC FWD REV 0001 001 01 1 1 1 10 100 ALL ORIGIN SINGL HOME AXES AXIS G28 SELECT SEND RECV ERASE PROG RS232 RS232 PROG EDIT MEM MDI DNC HAND ZERO LIST JOG RET PROG F1 F2
137. CCURACY BACKLASH Accuracy complaints are usually related to tooling programming or fixturing problems Eliminate these possibilities before working on the machine Poor positioning accuracy Check parameters for that axis Check for backlash in the ball screw see the following steps INITIAL PREPARATION Turn the machine ON Zero return the machine and jog the column to the approximate center of its travel in the X and Y directions Move the Z axis to its full travel forward CHECKING X AXIS 1 Set up a dial indicator and base on the mill table as shown in Fig 1 3 1 Figure 1 3 1 Dial indicator in position to check X axis 2 Set dial indicator and the Distance to go display in the HANDLE JOG mode to zero as follows Zero the dial indicator Press the MDI key on the control panel Press the HANDLE JOG key on the control panel 14 Troubleshooting 96 0189 rev L June 2005 The Distance to go display in the lower right hand corner of the screen should read X 0 Y 0 Z 0 3 Set the rate of travel to 001 on the control panel and jog the machine 010 in the positive X direction Jog back to zero 0 on the display The dial indicator should read zero 0 0001 4 Repeat Step 3 in the negative direction TOTAL DEVIATION BETWEEN THE DIAL INDICATOR AND THE CONTROL PANEL DISPLAY SHOULD NOT EXCEED 0002 An alternate method for checking backlash is to place the dial indicator as shown
138. COMP T CONST This parameter should be set to 0 276 B SCREW COMP T CONST This parameter should be set to 0 278 COMMON SWITCH 3 Parameter 278 is a collection of general purpose single bit flags used to turn some functions on and off This bit will cause the machine to use discrete outputs 21 and 26 to command the shuttle to move in and out On mills with the Air Driven Shuttle it must be set to 1 On all other mills it must be set to 0 The left and right cursor arrows are used to select the function being changed All values are 0 or 1 only The function names are 0 INVERT GEARBOX SIGS This bit allows an alternate gearbox configuration It inverts the sense of the gearbox inputs Used for 50 taper option 1 DPR SERIAL Causes the main serial inputs outputs to go through the disk video board 2 CHECK PALLET INPUT If set to 1 the discrete input specified by parameter 256 PALLET LOCK INPUT is checked prior to the execution of a spindle command If the input was high i e an open circuit alarm 180 would be generated The input is also checked while the spindle is turning and will generate the same alarm if it goes high Thus the input can now be used to stop a program after the spindle has been commanded to turn such as by a pressure switch from the user s clamp or fixture 3 CHK HIDDN MACRO VAR This bit is used on horizontal mills only 4 DISPLAY ACTUAL RPM When set to 1 displays the actual spindle speed on the Current Commands displ
139. CS 8X Lock Ring SHCS Lock Ring Double Arm Removal of the Double Arm Installation 1 Place the double arm onto output shaft Align the double arm to the home position then slide the lock ring onto the shaft 2 Reattach the lock ring to the double arm with eight 8 SHCS Tighten in a star pattern to 15 ft lbs repeat this sequence 3 times to seat the arm lock bushing Verify the slides are correctly adjusted on the double arm with the following procedure With the double arm lowered and the split tool inserted into the double arm a 0 020 feeler gauge should fit between the slide and the tool flange O D The plunger should be able to rise fully to the locked position with the gauge between the split tool and the plunger Plunger Spring Adjuster Hex Shim Washers Insert 0 020 Feeler Gauge Here Adjuster Double Arm with Cover Plate Removed Slide Tool Holder The plunger will not return reliably to the fully raised locked position when the tool is inserted if there is insufficient clearance The split tool will be excessively loose in the doublearm if there is too much clearance Mechanical Service 88 96 0189 rev L June 2005 To adjust the clearance remove the slide and the cover by removing the cover plate and lifting the slide out at an angle Be careful not to lose the spring Loosen the adjuster and correct the clearance by adding or removing shims Apply blue Locktite and retighten Grease the spring and th
140. CTION NAME APC 2 DOOR CLOSED APC 2 DOOR OPEN APC PALLET CLAMP LEFT DDOR APC 2 DOOR OPEN APC DOOR OPEN PALLET CHANGER X AXIS Y AXIS Z AXIS A1 A AXIS A2 5TH AXIS TOOL CHANGER LUBE PANEL TSC CHIP CONVEYOR MFIN CLG SPARE COOLANT FONT PANEL PALLET CHANGER SIGNAL TOOL CHANGER REMOTE BOX FRONT PANEL 660 490X X HOME LIMIT SWITCH X AXIS MOTOR POWER CABLE X ENCODER CABLE 490Y 670 Y AXIS MOTOR POWER CABLE Y HOME LIMIT SWITCH Y ENCODER CABLE 680 490Z 350A Z HOME LIMIT SWITCH Z AXIS MOTOR POWER CABLE Z ENCODER CABLE 24VDC SRVO BRAKE RELEASE 690 490A 390 A HOME LIMIT SWITCH A AXIS MOTOR POWER CABLE A ENCODER CABLE 4 th AXIS BRAKE 230 690B 490B B HOME LIMIT SWITCH B AXIS MOTOR POWER CABLE 5 th AXIS BRAKE B ENCODER CABLE M28 790 810A APC PIN CLR 1 APC PIN CLR 2 TOOL CHANGER MOTORS 420 APC 2 CLR 1 amp 2 APC 2 PAL 2 amp 1 HOME 480 APC PALLET CLAMP RIGHT DOOR WIRE NUMBER SUPER SPEED TOOL CHANGER 690B 490B FUNCTION NAME SUPER SPEED TOOL CHANGER MOTOR POWER CABLE SUPER SPEED TOOL CHANGER ENCODER CABLE EC 300 EC 400 Cable List 278 96 0189 rev L June 2005 9 CABLE LIST WIRE TERMINAL FUNCTION NAME NUMBER INCOMING POWER 195 260 VAC 353 480 VAC OPTIONAL L1 INCOMING 195 260VAC PHASE 1 TO CB1 1 L2 INCOMING 195 260VAC PHASE 2 TO CB1 2 L3 INCOMING 195 260VAC PHASE 3 T
141. DE CONNECTION 610 1 A CHANNEL 610 2 ANALOG GROUND 610 3 B CHANNEL 610 4 ANALOG GROUND 610 5 ENABLE 610 6 LOGIC GROUND 610 7 FAULT 610 8 LOGIC GROUND 610 9 NOT USED 610 10 SHIELD ANALOG GROUND 620 Y AXIS HAAS AMPLIFIER CABLE TO MOTOR CONTROLLER BOARD SAME AS 610 1 THRU 610 10 630 Z AXIS HAAS AMPLIFIER CABLE TO MOTOR CONTROLLER BOARD SAME AS 610 1 THRU 610 10 640A A AXIS HAAS AMPLIFIER CABLE TO MOTOR CONTROLLER BOARD SAME AS 610 1 THRU 610 10 640B B AXIS HAAS AMPLIFIER CABLE TO MOTOR CONTROLLER BOARD SAME AS 610 1 THRU 610 10 640C HAAS VECTOR DRIVE CURRENT COMMAND CABLE ALL 24 640C 4 FAULT 640C 5 325 VDC VOLTAGE MONITOR 640C 6 A PHASE RETURN 640C 7 B PHASE RETURN 640C 8 DIGITAL GROUND 640C 9 FAULT RETURN 640C 10 ANALOG GROUND Cable List 282 96 0189 rev L June 2005 650 230VAC THREE PHASE POWER TO SPINDLE MOTOR SHIELD 3 651 PHASE 1 652 PHASE 2 653 PHASE 3 654 SHIELD DRAIN 650A 230VAC THREE PHASE POWER CONTACTOR TO SPINDLE MOTOR WYE DELTA OPTION 651A PHASE 1 652A PHASE 2 653A PHASE 3 654A SHIELD DRAIN 650B 230VAC THREE PHASE POWER CONTACTOR TO VECTOR DRIVE WYE DELTA OPTION 651B PHASE 1 651B PHASE 2 651B PHASE 3 660 X AXIS ENCODER CABLE ALL 24 660 1 LOGIC RETURN D GROUND 660 2 ENCODER A CHANNEL 660 3 ENCODER B CHANNEL 660 4 5 VDC 660 5 ENCODER Z CHANNEL OR C 660 6 HOME LIMIT SWITCH 660 7 OVERHEAT SWITCH 660 8 ENCODER A 660 9 E
142. ED MIN LIMIT This parameter works with the AUTOFEED feature It specifies the minimum allowable feed rate override percentage that the AUTOFEED feature can use and should initially be set to 1 302 FEED ACCELERATION This parameter supports the motion control feature This is the acceleration that applies to feed motion in encoder steps per second squared For vertical mills 1 2 of the value of parameter 7 is a good starting point For horizontal mills 1000000 is a good value to start with This parameter can be further updated as necessary 303 FEED TIME CONSTANT This parameter supports the motion control feature It is the base 2 exponent of the feed time constant in milliseconds It should be set to 3 304 SPIGOT REV POS DLY This parameter is used to specify the length of a delay units are ms when moving the coolant spigot in reverse This parameter should be set to zero on all machines 240 Parameters 96 0189 rev L June 2005 305 SERVO PO BRK DLY The SRV PO Servo Power On discrete output is used to engage and disengage an axis brake This parameter is used to specify a time in milliseconds that the control should wait after activating the SRV PO output and turning off power to the servo motors via the MOCON This parameter also specifies the time to wait after deactivating the SRV PO output and reactivating the servo motors via the MOCON 306 POCKET UP DN DELAY This parameter supports the side mount tool changers It specifies the time a
143. EL See Parameter 10 for description 227 Parameters 96 0189 rev L June 2005 161 B BACK EMF See Parameter 11 for description 162 B STEPS REVOLUTION See Parameter 12 for description 163 B BACKLASH See Parameter 13 for description 164 B DEAD ZONE See Parameter 14 for description 165 B AXIS IN POSITION LIMIT Same definition as Parameter 101 166 B AXIS MAX CURRENT Same definition as Parameter 105 167 D D GAIN FOR B Second derivative gain in servo loop 168 B ACC DEC T CONST Same definition as Parameter 113 169 B PHASE OFFSET See Parameter 121 for description 170 B GRID OFFSET See Parameter 125 for description 171 B EXACT STOP DIST See Parameters 134 for description 172 B FRICTION COMPENSATION See Parameter 138 for description 173 B ACCEL FEED FORWARD Same description as Parameter 145 174 B SCREW COMP COEF This is the coefficient of heating of the ball screw and is used to decrease or shorten the screw length 175 B AIR BRAKE DELAY Delay provided for air to release from brake on B axis prior to moving Units are millisec onds NOTE The C axis parameters 176 200 are used to control the Haas Vector Drive Parameter 278 bit HAAS VECT DR must be set to 1 for these parameters to be available 176 C SWITCHES See Parameter 1 for description 177 C P GAIN See Parameter 2 for description 178 C D GAIN See Parameter 3 for description 179 C I GAIN See Parameter 4 for description 180 C SLIP GAIN The sl
144. ER COMP IN SKIP Skip G31 and G37 functions cannot be used with cutter compensation 377 NO SKIP IN GRAPH SIM Graphics mode cannot simulate skip function 378 SKIP SIGNAL FOUND Skip signal check code was included but skip was found when it was not expected 379 SKIP SIGNAL NOT FOUND Skip signal check code was included but skip was not found when it was expected 380 X Y A OR G49 NOT ALLOWED IN G37 G37 may only specify Z axis and must have tool offset defined 44 Alarms 96 0189 rev L June 2005 381 G43 G44 NOT ALLOWED IN G36 OR G136 Auto work offset probing must be done without tool offset 382 D CODE REQUIRED IN G35 A Dnn code is required in G35 in order to store the measured tool diameter 383 INCH IS NOT SELECTED G20 was specified but settings have selected metric input 384 METRIC IS NOT SELECTED G21 was specified but settings have selected inches 385 INVALID L P OR R CODE IN G10 G10 was used to changes offsets but L P or R code is missing or invalid 386 INVALID ADDRESS FORMAT An address A Z was used improperly 387 CUTTER COMP NOT ALLOWED WITH G103 If block buffering has been limited Cutter Compensation cannot be used 388 CUTTER COMP NOT ALLOWED WITH G10 Coordinates cannot be altered while Cutter Comp is active Move the G10 outside of Cutter Comp enablement 389 G17 G18 G19 ILLEGAL IN G68 Planes of rotation cannot be changed while rotation is enabled 390 NO SPINDLE SPEED S code has not been encountered Add a
145. ER SUPPLY ASSEMBLY All power to the control passes through the power supply assembly It is located on the upper right corner of the control cabinet MAIN CIRCUIT BREAKER CB1 Circuit breaker CB1 is rated at 40 amps 20 for High Voltage option and is used to protect the spindle drive and to shut off all power to the control The locking On Off handle on the outside of the control cabinet will shut this breaker off when it is unlocked A trip of this breaker indicates a SERIOUS overload problem and should not be reset without investigating the cause of the trip The full circuit breaker rating corresponds to as much as 15 horsepower Circuit breaker CB 1 rating HP Rating 195 260VAC 354 488 VAC 20 15 40Amp 20 Amp 40 30 80 Amp 40Amp 208 Technical Reference 96 0189 rev L June 2005 MAIN CONTACTOR K1 Main contactor K1 is used to turn the control on and off The POWER ON switch applies power to the coil of K1 and after it is energized auxiliary contacts on K1 continues to apply power to the coil The POWER OFF switch on the front panel will always remove power from this contactor When the main contactor is off the only power used by the control is supplied through two amp fuses to the circuit that activates the contactor An overvoltage or lightning strike will blow these fuses and shut off the main contactor The power to operate the main contactor is supplied from a 24V AC control transformer that is primary fused at amp
146. Frame Screw Screws Retainer Lens Lens Lens CHIP AUGER During normal operation most chips are discharged from the machine at the discharge tube However very small chips may flow through the drain and collect in the coolant tank strainer To prevent drain blockage clean this strainer regularly Should the drain become clogged and cause coolant to collect in the pan stop the machine loosen the chips blocking the drain and allow the coolant to drain Empty the coolant tank strainer then resume operation 254 96 0189 rev L June 2005 SPINDLE AIR PRESSURE Verify Spindle air pressure using the gauge located behind the air regulator panel VF VR and VS mills should be set to 17 psi EC series and HS Series should be set to 25psi Adjust if necessary 15K Spindle The air pressure for the 15K Spindle is 20 psi The 15K Spindle requires higher pressure to slightly reduce the amount of oil and speed the delivery of the oil to the bearings TSC MAINTENANCE The TSC pump is a precision gear pump and will wear out faster and lose pressure if abrasive particles are present in the coolant Check the dirt indicator on the 100 micron mesh filter with the TSC system running and no tool in the spindle Change the element when the indicator reaches the zred zone Clean the pump intake filter when indicator is in the red zone Reset indicator with button All intake filters can be cleaned with a wire brush After changing
147. G DATA ERROR Possible corrupted program Save all programs to disk delete all then reload 251 PROG DATA STRUCT ERROR Possible corrupted program Save all programs to disk delete all then reload 252 MEMORY OVERFLOW Possible corrupted program Save all programs to disk delete all then reload 253 ELECTRONICS OVERHEAT The control box temperature has exceeded 135 degrees F 60 deg C This can be caused by an electronics problem high room temperature or clogged air filter 254 SPINDLE MOTOR OVERHEAT Motor driving spindle is too hot The spindle motor temperature sensor sensed a high temperature for greater than 1 5 seconds 255 NO TOOL IN SPINDLE There is an invalid tool number in the spindle entry of the POCKET TOOL table The spindle entry cannot be 0 and must be listed in the body of the table If there is no tool in the spindle enter the number for an empty pocket into the spindle entry If there is a tool number in the spindle entry make sure that it is in the body of the table and that the pocket is empty 256 CURRENT TOOL UNKNOWN Current tool information has been lost This is most likely due to re initialization It is likely that the next commanded tool change will result in a collision between the spindle and a tool in a pocket To eliminate the possibility of a crash perform Tool Changer Restore Do not use Power Up Restart as this will cause the machine to try to return a tool to the carousel 257 PROG DATA ERROR Possible cor
148. H DIST This parameter sets the finish tolerance for determining the end point of a rigid tapping operation Units are encoder counts 145 X ACCEL FEED FORWARD 146 Y ACCEL FEED FORWARD 147 Z ACCEL FEED FORWARD 148 A ACCEL FEED FORWARD These parameters set the feed forward gain for the axis servo They have no units 149 PRECHARGE DELAY This parameter sets the delay time from precharge to tool release Units are milliseconds 150 MAX SP RPM LOW GEAR Max spindle RPM in low gear 151 B SWITCHES See Parameter 1 for description 152 B P GAIN See Parameter 2 for description 153 B D GAIN See Parameter 3 for description 154 B I GAIN See Parameter 4 for description 155 B RATIO STEPS UNIT See Parameter 47 for description 156 B MAX TRAVEL STEPS See Parameter 6 for description Normally this parameter would not apply to the A axis however this parameter is used on mills with a gimbaled spindle 5 axes mills On a VR series mill this parameter is used to limit the amount of angular movement of the spindle A and B axes The A and B axes are limited in movement to a distance between negative MAX TRAVEL and positive TOOL CHANGE OFFSET On 5 axes mills A and B axes ROT TRVL LIM must be set to 1 MAX TRAVEL and TOOL CHANGE OFFSET must be calibrated and set correctly 157 B ACCELERATION See Parameter 7 for description 158 B MAX SPEED See Parameter 8 for description 159 B MAX ERROR See Parameter 9 for description 160 B FUSE LEV
149. HIS IS A LEFT HAND THREAD d Return the Coolant Union with all pipe thread connectors and black coolant hose intact to Haas Automation for warranty Removal of any of the pipe connectors from the union will void any claims for warranty 4 Disconnect the air line at the lube air panel 5 Disconnect the clamp unclamp cables quick disconnect and the assembly s solenoid wiring located on the solenoid bracket 6 Remove the three tool release air hoses 7 Use a strap and overhead lifting device to hold the TRP in position The TRP is heavy so secure properly with the strap Mechanical Service 140 96 0189 rev L June 2005 Rear View TRP Lifting Strap TRP in Position Motor and Transmission TRP shown in position and as it is lowered 8 Remove the four shoulder screws holding the tool release piston assembly to the head casting 9 Lower the TRP to remove it from the machine TRP DISASSEMBLY 1 Loosen the shaft clamp and remove It may be necessary to use a punch and mallet to break the clamp loose 2 Remove the switch trip and compression spring 3 Remove the 50T upper spacer 4 Push the TRP shaft down 5 Remove the 8 bolts holding the TRP assembly together 6 Separate and remove the upper half of the housing 7 Remove the upper TRP piston 8 Remove the lower half of the TRP housing 9 Remove the TRP lower spacer 10 Remove the lower TRP 50T piston 11 Remove the TRP sub
150. HRESHOLD units are an analog to digital value Parameter 731 PWR FAULT MAX TIME units are millisecond 20 If the Power Failure Detection Module is not installed parameters 730 and 731 should both be set to zero 733 APC AIR BLAST RELAY Defines the output relay that turns on the air blast on the EC 300 and MDC 500 Set to 39 for the Mill Drill Center and EC 300 or zero for all other mills 249 Parameters 96 0189 rev L June 2005 734 INPUT MASK Used for the Office Mills 0 TOOL CHANGER IN 16 SPARE 1 TOOL CHANGER OUT 17 SPARE 2 TOOL 1 IN POSITION 18 SPARE 3 LOW TSC PRESSURE 19 SPARE 4 TOOL IN POSITION 20 LOW TRANS OIL PRESS 5 SPINDLE HIGH GEAR 21 APC DOOR 6 SPINDLE LOW GEAR 22 APC PIN CLEAR 1 7 EMERGENCY STOP 23 APC PIN CLEAR 2 8 DOOR SAFETY SWITCH 24 TOOL UNCLAMP REMOTE 9 M CODE FINISH 25 SPARE 10 OVERVOLTAGE 26 APC PALLET 2 HOME 11 LOW AIR PRESSURE 27 APC PALLET 1 HOME 12 LOW LUBE PRESSURE 28 GROUND FAULT 13 REGEN OVERHEAT 29 G31 BLOCK SKIP 14 DRAWBAR OPEN 30 SPIGOT POSITION 15 DRAWBAR CLOSED 31 CONVEYR OVERCURRENT BALL SCREW COMPENSATION Separate ball screw compensation is provided for each of the X Y and Z axes The operator entered compen sation values are spaced at 0 5 inch intervals within the machine coordinate system The compensation values are entered in inches with a resolution of 0 0001 inch The operator entered values are used to interpolate into a table of 256 entries The spacing between two ent
151. HT WIRING BEACON 115 VAC TO LCD LVPS 115 VAC TO WORK LIGHT SWITCH FUNCTION NAME FRONT PANEL 90A 740 750 720 280 90B WIRE NUMBER 770 EMERGENCY STOP INPUT CABLE 1050 DOOR SWITCH WIRING THRU SUPPORT ARM FRONT PANEL SUPPORT ARM FLEXIBLE CABLE CONDUIT 490X 660 WIRE NUMBER HOME LIMIT SWITCH X ENCODER CABLE X AXIS MOTOR POWER CABLE FUNCTION NAME WIRE NUMBER FUNCTION NAME WIRE NUMBER FUNCTION NAME WIRE NUMBER FUNCTION NAME WIRE NUMBER FUNCTION NAME WIRE NUMBER FUNCTION NAME WIRE NUMBER 820 810A 810 FUNCTION NAME TOOL CHANGER STATUS TOOL CHANGER SHUTTLE MOTOR TOOL CHANGER TURRET MOTOR WIRE NUMBER 990 960 300 FUNCTION NAME X Y Z HOME SENSORS LOW LUB 115VAC TO OILER WIRE NUMBER 130 940A FUNCTION NAME TSC OVER TEMP 230 VAC 3PH TO TSC COOLANT PUMP WIRE NUMBER 140 FUNCTION NAME 230VAC 3PH POWER TO CHIP CONVEYOR MOTOR WIRE NUMBER 730B 100 FUNCTION NAME SP DRIVE LOAD COOLANT LEVEL GAUGE SENSOR M FIN WIRE NUMBER 940 FUNCTION NAME 230 VAC TO COOLANT PUMP WIRE NUMBER 770B 710 410 240 FUNCTION NAME EMERGANCY STOP INPUT CABLE APC 1 PALLET READY 1 APC 1 PALLET READY 2 APC CE DOOR OPEN APC PAL HOME MD PAL UP APC PAL 1 HOME PAL DOWN WIRE NUMBER 880B 810 770B 450 FUNCTION NAME TRANSMISSION HIGH LOW GEAR SOLENOIDS APC MOTOR EMERGANCY STOP INPUT CABLE APC 2 CE DOOR OPEN WIRE NUMBER 460 430 310 250 FUN
152. Haas Technical Publications Manual_Archive_Cover_Page Rev A June 6 2013 This content is for illustrative purposes Historic machine Service Manuals are posted here to provide information for Haas machine owners Publications are intended for use only with machines built at the time of original publication As machine designs change the content of these publications can become obsolete You should not do mechanical or electrical machine repairs or service procedures unless you are qualified and knowledgeable about the processes Only authorized personnel with the proper training and certification should do many repair procedures HAAS SERVICE AND OPERATOR MANUAL ARCHIVE WARNING Some mechanical and electrical service procedures can be extremely dangerous or life threatening Know your skill level and abilities All information herein is provided as a courtesy for Haas machine owners for reference and illustrative purposes only Haas Automation cannot be held responsible for repairs you perform Only those services and repairs that are provided by authorized Haas Factory Outlet distributors are guaranteed Only an authorized Haas Factory Outlet distributor should service or repair a Haas machine that is protected by the original factory warranty Servicing by any other party automatically voids the factory warranty Horizontal Service Manual 96 0189 RevL English June 2005 Troubleshooting 1 96 0189
153. ID PALLET CHANGER TYPE Parameter 605 has an invalid pallet changer type 956 APC LIFT FRAME UP TIMEOUT The pallet changer was commanded to lift but the up position switch was not contacted before the timeout period The primary cause of this alarm is insufficient air pressure or air volume Also verify the pallet is unclamped and there are no obstructing objects Check pallet up switch and wiring for damage switch connections for positive electrical contact and the lifting mechanism for proper operation Verify parameter 321 is correct After determining and correcting the problem press Tool Changer Restore to enter pallet changer recovery recover the pallet changer and then continue operation 58 Alarms 96 0189 rev L June 2005 957 APC SWITCH FAULT An illegal switch condition was detected The pallet clamp switch did not function correctly Use M17 and M18 commands to verify the input switch input relay 26 changes state when the pallet clamps and unclamps Check switch adjustment and check wiring for damage or unplugged connectors The polarity of the clamp switch may be wrong Parameter 734 is used to invert input switch polarity 958 TOOL OFS WEAR HAS BEEN CHANGED When tool offsets have been changed alarm 958 will be added to the alarm history along with the date and time Note that this is not a resetable alarm it is for information purposes only 959 NON INDEXER POSITION The position commanded for the A axis incremental indexer is a non
154. IGNAL 825 COMMON RETURN DATA GROUND 826 SHIELD DRAIN 830 VECTOR DRIVE OVERHEAT THERMOSTAT SHIELD 2 831 OVERHEAT SIGNAL 20 832 OVERHEAT RETURN D GROUND 20 833 SHIELD DRAIN 285 Cable List 96 0189 rev L June 2005 850 SERIAL PORT 1 INTERFACE CABLE 16 WIRE RIBBON 24 33 0510 850A SERIAL PORT 2 INTERFACE CABLE 16 WIRE RIBBON 24 33 0510 AUXILIARY PORT TO ROTARY CONTROLLER 860 5V 12V 12V Gnd FROM MAIN POWER SUPPLY ALL 18 861 5 VOLTS 862 LOGIC POWER RETURN 863 LOGIC POWER RETURN 864 12 VOLTS 865 12 VOLTS 860A 12 VDC POWER TO M CODE RELAY BOARD SHIELD 2 861 12 VOLTS 20 865 LOGIC POWER RETURN D GROUND 20 863 SHIELD DRAIN 860C 12 VDC POWER TO MONITOR FAN SHIELD 2 861C 12 VOLTS 20 862C LOGIC POWER RETURN 20 863C SHIELD DRAIN 880A 115 VAC TO SPINDLE HEAD SOLENOIDS SHIELD 6 ALL 24 881 WYE DELTA SWITCH COMMAND 882 TOOL UNCLAMP 883 LOW GEAR 884 HIGH GEAR 885 115 VAC COMMON 886 SHIELD DRAIN 887 PRECHARGE 890 SPINDLE HEAD INPUT STATUS SWITCHES SHIELD 6 ALL 24 891 HIGH GEAR SIGNAL 892 LOW GEAR SIGNAL 893 TOOL UNCLAMPED SIGNAL 894 TOOL CLAMPED SIGNAL 895 SPARE 896 COMMON DATA GROUND 897 SHIELD DRAIN 900 LOW THROUGH SPINDLE COOLANT STATUS SHIELD 2 901 LOW COOLANT SIGNAL 20 902 RETURN DATA GROUND 20 910 115 VAC CIRCUIT BREAKER CB4 TO SOLENOIDS SHIELD 2 911 LEG 1 20 912 LEG 2 20 913 SHIELD DRAIN 910A 115 VAC TO P
155. INTAKE FILTER ASSEMBLY CHECK VALVE ASSEMBLY 100 MESH 2 3 TOP OF SPINDLE MOTOR 1 SIDE OF MACHINE AND COOLANT TANK 3 TOP OF SPINDLE MOTOR 1 REAR OF MACHINE amp COOLANT TANK VF LOCATION EC 1600 EC 2000 LOCATION 2 SIDE OF SPINDLE MOTOR Mechanical Service 134 96 0189 rev L June 2005 3 16 HS3 7R AIR VALVE ASSEMBLY S N 51003 AND BEFORE The Air Valve Assembly has three main components 3 Way Air Valve High Pressure Regulator Low Pressure Regulator THEORY OF OPERATION The Air Valve Assembly actuates the Rotary Table brake Supplied air flows though the high pressure regulator 70 PSI to supply the high side of the Brake Valve Pressure Booster This supplies 12 1 hydraulic pressure boost to pull down on the Brake Assembly When the Brake Ring is released a valve switches the supplied air into the low side of the Pressure Booster This action returns the Pressure Booster piston to its original position and refills the hydraulic cylinder from the reservoir This is a closed hydraulic system A 70 20 PSI pressure differential is used to prevent air leaking into the Pressure Booster ASSEMBLY HYDRAULIC CYLINDER 1 Turn the hydraulic cylinder so that the two ports are facing up Remove the two caps The hydraulic cylinder is shipped with oil take caution to avoid spillage CAUTION Do not press the hydraulic cylinder piston in Hydraulic oil will escape from the open port 2 Using the correct hydrau
156. If it moves at 100 jog the Z axis in the negative direction one increment at a time Press the TOOL RELEASE button and check for movement between increments until the block is tight NOTE The increments jogged in the Z negative direction are the amount of shim that must be added to the tool release piston Refer to the TRP Shims section If the block is tight at 110 move the Z axis in the positive direction one increment at a time Press the TOOL RELEASE button and check movement between increments until the block is loose NOTE The increments jogged in the Z positive direction is the amount of shim that must be removed from the tool release piston Refer to the TRP Shims section TRP SHIMS The drawbar uses a 1 piece shim which can be added or removed without having to remove the TRP assembly Once the shims have been adjusted the TRP is reinstalled and the final torque on the bolts is 35 ft lb Tool release piston assembly 73 Mechanical Service 96 0189 rev L June 2005 NOTE Shims may need to be added or removed when spindle cartridge tool release piston assembly or drawbar is replaced If none have been replaced skip this section 1 Check the condition of the tool release bolt and the draw bar Repair or replace these items before setting the drawbar height 2 To add or subtract shims loosen the bolts that secure the retaining plate 3 Add or subtract required shim washers See previous sec
157. L 1 Remove the axis motor in accordance with Axis Motor Removal Installation section 2 Completely loosen the two SHCS on the two coupling clamp rings and remove the coupling Mechanical Service 100 96 0189 rev L June 2005 Motor Ccoupling Ccomponents INSTALLATION 1 Slide the new coupling onto the motor shaft until the coupling half is flush to the end of the shaft NOTE The slot in the locking collar must be positioned 45 degrees between the bolt hole pattern of the coupler If improperly aligned the coupler will not have enough clamping force on the ball screw or motor shaft 2 Tighten the two SHCS on the coupling s clamp ring Before tightening add one drop of blue Loctite to each screw 3 Reinstall the axis motor 101 96 0189 rev L June 2005 Mechanical Service 3 8 BEARING SLEEVE Please read this section in its entirety before attempting to remove or replace the bearing sleeve Removal 1 POWER ON the machine Zero return all axes and put the machine in HANDLE JOG mode 2 Remove the rear enclosure panel 3 Jog the axis away from the bearing support Y Axis Bearing Support Install the shipping bolts in the column to secure the Jog the Y axis to the bottom of its travel 4 POWER OFF the machine 5 Remove the hardstop bracket from bearing support end 6 Remove the locknut 7 Manually screw the column over in order to access the motor This is not possible when repairing t
158. L June 2005 8 PCBS CABLE LOCATIONS AND BOARD DIAGRAMS Shown below are three types of commonly used cable connectors They are shown as seen when plugged into the pc board These diagrams are to aid in locating the pins for trouble shooting Note The numbering sequence is the same regardless of the number of pins Cable Locations 262 96 0189 rev L June 2005 PROC PLUG CABLE SIGNAL NAME TO LOCATION PLUG J1 ADDRESS ADDRESS BUSS VIDEO J2 DATA DATA BUSS MOTIF PCB J3 860 LOW VOLTAGE POWER SUPPLY PCB J6 N A REPLACEMENT BAT CONNECTION PORT 1 850 SERIAL PORT 1 KEY INTERFACE PORT 2 850A SERIAL PORT 2 SERIAL PORT 2 MICRO PROCESSOR PCB CABLE CONNECTIONS 263 Cable Locations 96 0189 rev L June 2005 BRUSHLESS SERVO AMPLIFIER POWER TO SERVO MOTOR 335VDC FROM HAAS VECTOR DRIVE LOW VOLTAGE POWER INPUT SERVO DRIVE CURRENT COMMAND FROM MOCON BLOWN FUSE INDICATOR Cable Locations 264 96 0189 rev L June 2005 BRUSHLESS SERVO AMPLIFIER CABLE CONNECTIONS MOCON PLUG CABLE SIGNAL NAME TO LOCATION PLUG X AXIS AMP P 570 LOW VOLTAGE L V POWER SUPPLY TB A B C MOTOR DRIVE X SERVO MOTOR P 610 X DRIVE SIGNAL MOCON PCB P2 TB HV HV 335VDC SPINDLE DRIVE Y AXIS AMP P 580 LOW VOLTAGE L V POWER SUPPLY TB A B C MOTOR DRIVE Y SERVO MOTOR P
159. LOSED MOTOR M LAMP LED OPTO ISOLATOR TRANSFORMER CAPACITOR SOLENOID RESISTOR FU2 FUSE CIRCUIT BREAKER COIL DIODE GROUND CIRCUIT BREAKER SINGLE MULTI VARISTOR RELAY SINGLE POLE DOUBLE THROW RELAY OPEN RELAY CLOSED PUSH BUTTON SWITCH NORMALLY OPEN NORMALLY CLOSED PUSH BUTTON SWITCH NEON BULB W RESISTOR 308 Assembly Drawings 96 0189 rev L June 2005 ASSEMBLY DRAWINGS AND PARTS LISTS 309 Assembly Drawings 96 0189 rev L June 2005 EC 300 Front Panels 1 25 5682 Tool Trays Panel 2 25 5683 Intermediate J Box Top Cover 3 25 5681 Intermediate Top Cover 4 25 5678 Front Right Panel 5 59 0123 Sanders K 18 Wire Clip 6 25 0440 Tool Tray 2x 7 25 6182 Front Table 8 25 5740 Front Right Pan 9 59 0278 Knob Head 3 8 16 x 1 1 4 Dog Point Screw 10 20 1341 Tool holder Block 11 25 0798 Tool Holder Bracket 12 58 1671 Nipple 1 8 NPT x2 58 3618 Street Elbow 90 degree 13 25 5412 Nozzle Holder Bracket 14 25 1257 Front Panel Switch Box 15 25 5741 Front Center Pan 16 25 5739 Front Left Pan 17 25 1292 Door Handle 18 25 5809 Center Front Panel 19 30 7148 Front Door Assembly 21 25 5679 Front Left Panel 22 25 0563 Tool Box Assembly 23 25 5738 Left Intermediate Pan 24 25 5786 Left Chip Shield Pan 25 25 5742 Center Bottom Pan 26 25 5784 Front Left Chip Shield Pan 27 25 5785 Front Right Chip Shield Pan 28 25 5806 Operator Door Tunnel
160. MAX ERROR See Parameter 9 for description 24 Y FUSE LEVEL See Parameter 10 for description 25 Y TORQUE PRELOAD See Parameter 11 for description 26 Y STEPS REVOLUTION See Parameter 12 for description 27 Y BACKLASH See Parameter 13 for description 28 Y DEAD ZONE See Parameter 14 for description 29 Z SWITCHES See Parameter 1 for description 30 Z P GAIN See Parameter 2 for description 31 Z D GAIN See Parameter 3 for description 32 Z I GAIN See Parameter 4 for description 33 Z RATIO STEPS UNIT See Parameter 5 for description 34 Z MAX TRAVEL STEPS See Parameter 6 for description 35 Z ACCELERATION See Parameter 7 for description 36 Z MAX SPEED See Parameter 8 for description 37 Z MAX ERROR See Parameter 9 for description 38 Z FUSE LEVEL See Parameter 10 for description 220 Parameters 96 0189 rev L June 2005 39 Z TORQUE PRELOAD See Parameter 11 for description 40 Z STEPS REVOLUTION See Parameter 12 for description 41 Z BACKLASH See Parameter 13 for description 42 Z DEAD ZONE See Parameter 14 for description 43 A SWITCHES See Parameter 1 for description AND make sure that this parameter is set to enable the fourth axis before you try to enable the fourth axis from settings 44 A P GAIN See Parameter 2 for description 45 A D GAIN See Parameter 3 for description 46 A I GAIN See Parameter 4 for description 47 A RATIO STEPS UNIT This parameter defines the number of encoder steps requ
161. MISSED PAL 3 Pallet 3 did not complete its move from the APC to the receiver in the allowable time Pallet change sequence was halted because receiver switch was not activated Pallet is either unclamped or not on the receiver Ensure the pallet is correctly located on receiver against hard stop then run M18 to clamp the pallet After correcting the condition run an M50 to continue machining 56 Alarms 96 0189 rev L June 2005 921 APC LOAD SWITCH MISSED PAL 4 Pallet 4 did not complete its move from the APC to the receiver in the allowable time Pallet change sequence was halted because receiver switch was not activated Pallet is either unclamped or not on the receiver Ensure the pallet is correctly located on receiver against hard stop then run M18 to clamp the pallet After correcting the condition run an M50 to continue machining 922 APC TABLE NOT DECLARED Software calling invalid tables Software Error Call your dealer 923 A INDEXER IS NOT AT THE PROPER INCREMENTAL POSITION The indexer has moved to a position that cannot be seated 924 B INDEXER IS NOT AT THE PROPER INCREMENTAL POSITION The indexer has moved to a position that cannot be seated 925 A INDEXER IS NOT FULLY IN THE UP POSITION The indexer is still seated It is not completely in the up position and cannot be rotated Reset then rezero the indexer 926 B INDEXER IS NOT FULLY IN THE UP POSITION The indexer is still seated It is not completely in the up position and c
162. NCODER B 660 10 ENCODER Z OR C 660 11 X HALL A NOT USED 660 12 X HALL B NOT USED 660 13 X HALL C NOT USED 660 14 X HALL D NOT USED 660 15 SHIELD DRAIN 660 16 NOT USED 670 Y AXIS ENCODER CABLE SAME AS 660 1 THRU 660 16 680 Z AXIS ENCODER CABLE SAME AS 660 1 THRU 660 16 690A A AXIS ENCODER CABLE SAME AS 660 1 THRU 660 16 690B B AXIS ENCODER CABLE SAME AS 660 1 THRU 660 16 690C C AXIS ENCODER CABLE SAME AS 660 1 THRU 660 16 700 KEYBOARD CABLE 34 WIRE RIBBON WITH IDC FROM VIDEO P4 TO KBIF P1 283 Cable List 96 0189 rev L June 2005 710 P COOL BF COLLET OPEN BF COLLET CLOSE 711 SPARE 712 SPARE 713 SPARE 714 SPARE 715 SPARE 720 ANALOG SIGNAL FROM MOCON TO SPINDLE DRIVE TO LOAD MONITOR 721 0 TO 10 VOLTS SPEED COMMAND 722 COMMON 723 SHIELD DRAIN 740 POWER ON OFF CABLE TO FRONT PANEL SHIELD 4 741 POWER ON SWITCH LEG 1 24 VAC 20 742 POWER ON SWITCH LEG 2 20 N O 743 POWER OFF SWITCH LEG 1 24 VAC 20 744 POWER OFF SWITCH LEG 2 20 N C 745 SHIELD DRAIN 750 JOG CRANK DATA CABLE REM JOG SIDE CONNECTION ALL 24 750 1 LOGIC RETURN D GROUND 0 VDC 750 2 ENCODER A CHANNEL 750 3 ENCODER B CHANNEL 750 4 5 VDC 750 5 JUMPER TO 750 1 0 VDC 750 6 X AXIS 750 7 Y AXIS 750 8 ENCODER A CHANNEL 750 9 ENCODER B CHANNEL 750 10 JUMPER TO 750 4 5 VDC 750 11 Z AXIS 750 12 A AXIS 750 13 X 10 750 14 X 1 750 15 SHIELD DRAIN 750 16 NOT USED
163. NEL 1000 3 ENCODER B CHANNEL 1000 4 5 VDC 1000 5 ENCODER Z CHANNEL 1000 6 NOT USED 1000 7 SPINDLE MOTOR OVERHEAT SENSOR 1000 8 ENCODER A CHANNEL 1000 9 ENCODER B CHANNEL 1000 10 ENCODER Z CHANNEL 1000 11 NOT USED 1000 12 NOT USED 1000 13 NOT USED 1000 14 NOT USED 1000 15 SHIELD DRAIN 1000 16 NOT USED 1010 AUX FRONT PANEL CABLE HS 1R RP SHIELD 6 ALL 24 1011 COMMON FOR CYCLE START AND FEED HOLD RETURN 1012 CYCLE START 1013 PART READY 1014 COMMON FOR PALLET ROTATE AND PART READY 1015 PALLET ROTATE 1016 FEED HOLD 1017 SHIELD DRAIN 1030 SPINDLE LOAD RESISTOR SHIELD 2 1031 REGEN LOAD RESISTOR FOR SPINDLE DRIVE 18 1032 REGEN LOAD RESISTOR FOR SPINDLE DRIVE 18 1040 115 VAC TO MIKRON DOOR INTERLOCK SWITCH SHIELD 2 1041 LEG 1 20 1042 LEG 2 20 1043 SHIELD DRAIN 1050 DOOR SWITCH INPUT SHIELD 2 1051 DOOR SWITCH SIGNAL 20 1052 DOOR SWITCH RETURN D GROUND 20 1053 SHIELD DRAIN 1060 SPARE GROUND FAULT DETECTION SENSE INPUT 1070 PROBE INPUT OPTION SHIELD 2 1071 PROBE SIGNAL 20 1072 LOGIC COMMON 20 1073 SHIELD DRAIN 1070A PROBE OUTPUT MCD RELAY BOARD M22 OPTION SHIELD 2 1071A UNSWITCHED LEG 1 20 1072A SWITCHED LEG 2 20 1073A SHIELD DRAIN 288 Electrical Diagrams 96 0189 rev L June 2005 ELECTRICAL WIRING DIAGRAMS 289 Electrical Diagrams 96 0189 rev L June 2005 290 Electrical Diagrams 96 0189 rev L June 2005 291 Electrical Diagrams
164. O CB1 3 71 PROTECTED 195 260VAC CB1 4 TO K1 1 72 PROTECTED 195 260VAC CB1 5 TO K1 2 73 PROTECTED 195 260VAC CB1 6 TO K1 3 74 195 260VAC FROM K1 4 TO XFORMER T1 75 195 260VAC FROM K1 5 TO XFORMER T1 76 195 260VAC FROM K1 6 TO XFORMER T1 77 230VAC PHASE 1 FROM XFORMER T1 TO SPINDLE DRIVE CHIP CONV 78 230VAC PHASE 2 FROM XFORMER T1 TO SPINDLE DRIVE CHIP CONV 79 230VAC PHASE 3 FROM XFORMER T1 TO SPINDLE DRIVE CHIP CONV 90 115 VAC FROM TB2 CB2 OUTPUT TO IOPCB P33 SHIELD 3 91 115 VAC FROM TB2 1 TO IOPCB P33 PIN 1 20 92 115 VAC FROM TB2 2 TO IOPCB P33 PIN 2 20 93 115 VAC FROM TB2 3 TO IOPCB P33 PIN 3 20 94 SHIELD DRAIN 115 VAC FROM XFORMER T1 TO TB1 CB2 INPUT 94 STEPPED DOWN 115 VAC FROM XFORMER T1 14 95 STEPPED DOWN 115 VAC FROM XFORMER T1 14 96 STEPPED DOWN 115 VAC FROM XFORMER T1 14 90A 115 VAC TO CRT SHIELD 2 91A LEG 1 16 92A LEG 2 16 93A SHIELD DRAIN 90B 115 VAC CABINET DOOR FAN 91B LEG 1 16 92B LEG 2 16 93B SHIELD DRAIN 90C 115 VAC TO CB4 SHIELD 2 91C LEG 1 20 92C LEG 2 20 93C SHIELD DRAIN 100 M FUNCTION INPUT SHIELD 2 101 SIGNAL 20 102 COMMON 20 103 SHIELD DRAIN 279 Cable List 96 0189 rev L June 2005 100A M FUNCTION OUTPUT M21 MCD RELAY BOARD M21 SHIELD 2 101A UNSWITCHED LEG 1 20 102A SWITCHED LEG 2 20 103A SHIELD DRAIN 110 SPARE 115 VAC SERVO POWER 140 230VAC 3PH POWER TO CHIP CONVEYOR MOTOR 141 PHASE A 230VAC 142
165. ONST See Parameter 113 for description 115 Z ACC DEC T CONST See Parameter 113 for description 116 A ACC DEC T CONST See Parameter 113 for description 117 LUB CYCLE TIME If this is set nonzero it is the cycle time for the lube pump and the Lube pressure switch option is checked for cycling in this time It is in units of 1 50 seconds 118 SPINDLE REV TIME Time in milliseconds to reverse spindle motor 119 SPINDLE DECEL DELAY Time in milliseconds to decelerate spindle motor 120 SPINDLE ACC DECEL Accel decel time constant in 200ths of a step ms ms for spindle motor 121 X PHASE OFFSET The motor phase offset for X motor This is arbitrary units 122 Y PHASE OFFSET See Parameter 121 for description 123 Z PHASE OFFSET See Parameter 121 for description 124 A PHASE OFFSET See Parameter 121 for description 125 X GRID OFFSET This parameter shifts the effective position of the encoder Z pulse It can correct for a positioning error of the motor or home switch 126 Y GRID OFFSET See Parameter 125 for description 127 Z GRID OFFSET See Parameter 125 for description 128 A GRID OFFSET See Parameter 125 for description 129 GEAR CH SETTLE TIME Gear change settle time This is the number of one millisecond samples that the gear status must be stable before considered in gear 130 GEAR STROKE DELAY This parameter controls the delay time to the gear change solenoids when performing a gear change 131 MAX SPINDLE RPM This is the maxim
166. OUSEL OR PRESS WRITE TO CONTINUE WITH AUTOMATIC RECOVERY cnc waits for write before continuing Y move to next pocket N TOOL CHANGE RECOVERY COMPLETE PRESS Y TO CONTINUE PLEASE UPDATE POCKET amp TOOL PAGE offset page with pockets displayed SIDEMOUNT MILL TOOL RECOVERY SCREEN TEXT UPPER CASE ACTIONS DECISIONS LOWER CASE S SITUATION M NEXT MODE THE TOOL MAY FALL DURING THE TOOL RECOVERY PROCESS PLACE SOMETHING SOFT UNDER TOOL TO CATCH IT DO NOT USE YOUR HANDS TO CATCH THE TOOL PRESS Y TO CONTINUE THE PROCESS cnc waits for Y before continuing carousel between pockets 26 Troubleshooting 96 0189 rev L June 2005 1 6 THROUGH THE SPINDLE COOLANT NOTE Abrasive swarf from grinding or ceramic machining operations will cause heavy wear of TSC coolant pump coolant tip and drawbar This is not covered by warranty on new machines Notify HAAS Service Department if machine is being used for this application COOLANT OVERFLOW Check the alarm history to determine the cause of the problem before any action is taken Coolant pouring out of spindle head Check the customer s tooling for through holes in the pull stud holder and tool Check the purge and drain lines connected to the seal housing are intact if not replace Check the TSC coolant union If failure is found replace the coolant union Check pre charge pressure in accordance with TSC Precharge
167. P50T 1 M24 X 3 Threads JMTBA Standard MAS 403 P50T 1 CT40T Pullstud One Identification Groove BT 40T Two Identificaiton Grooves 199 Technical Reference 96 0189 rev L June 2005 Tool holders and pull studs must be in good condition and tightened together with wrenches or they may stick in the spindle taper Clean the tool tapers with a lightly oiled rag to leave a film to prevent rusting Tools that make a loud bang when being released indicate a problem and should be checked before serious damage occurs When the TOOL RELEASE button on the keypad is pressed the tool should be pushed out of the spindle by a small amount approximately 07 This is an indication that the pull stud is correctly touching the release mechanism Air Pressure Low air pressure or insufficient volume will reduce the pressure applied to the tool unclamp piston and will slow down tool change time or will not release the tool The air pressure is now checked prior to moving the carousel on a mill with a side mount tool changer and alarm 120 LOW AIR PRESSURE is generated if such a problem exists Operation of the tool changer can also be interrupted by problems with the tool clamp unclamp and the spindle orientation mechanism Problems with them can be caused by low air pressure or a blown solenoid circuit breaker CB2 An inadequate air supply will cause tool changer faults Follow these guidelines Minimum air pressure to the machine is 100psi Observe t
168. Pallet Toe Clamp Rotary Table 7 Remove the 3 toe clamps from the sides of the HRT 210 rotary tables and remove rotary tables with a lift 8 Remove 2 two dowel pins 2 per pallet that are seated in non threaded holes in the pallet for proper orientation of the rotary tables Do not lose these pins The Pallet Table assembly must be rotated approximately 30 away from the home position to access the 5 8 shoulder bolts underneath 30 0 Spring Shoulder Bolt Mechanical Service 114 96 0189 rev L June 2005 9 Remove the pallet changer tables by unbolting the 4 5 8 shoulder bolts between the pallet changer and the frame support After removing the shoulder bolts the pallet is loose on the pallet support springs and can be lifted off using 2 eye bolts The table weighs aprox 160 lbs each Pallet Support Spring Splash Shield Clam Shell Bracket Shoulder Bolt Frame Support 10 Remove the 2 Splash Shields along with the Bracket Clam Shell located under and around the table area NOTE Air pressure must stay connected throughout this process Do not initiate a pallet change under any circumstance and only rotate assembly by hand Frame Support Removal Remove the Splash Shields the Bracket Shell and disconnect the Home Switch The frame support can be removed with the Servo Motor and Flange Plate still connected The frame sup ports weigh approximately 195 lbs and should be lift
169. Panel 4 25 6682 Removal Tool 40T Holder 5 25 9248 Plate Window Handle 6 25 5885 T C Access Panel 7 32 0097 Remote Switch Box 8 T C Access Window 9 25 9262 Wash Handle Holding Bracket 10 25 5927 T C Header Panel 11 25 5777 Top Bulkhead 12 25 5778 Mounting Bulkhead 13 25 5709 T C Rear Panel 14 25 6730 Separator Return Line Bracket 15 25 5705 T C Rear Pan 16 25 5707 T C Front Pan 17 25 5804 T C Top Chip Shield 18 25 5716 T C Front Chip Shield 19 25 5957 T C Access Bottom Bulkhead 20 25 5706 T C Front Panel 21 25 5776 Lower Bulkhead 22 26 0155 Nylon Strip Brush 2x 23 25 5956 T C Access Top Bulkhead 313 Assembly Drawings 96 0189 rev L June 2005 EC 300 Column and Frame Panels 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 1 59 0706 Shade Roller 70 5 x 21 2x 2 25 5833 Shade Roller Left Frame 3 25 5837 Top Column Clamp Wiper 26 0173 Top Column Wiper Felt 4 25 5834 Shade Roller Top Frame 5 25 5832 Shade Roller Right Frame 6 30 7214 Column Frame Roller Assembly 7 25 5773 Shade Roller Frame Brace 2x 8 25 5767 Right Corner Seal 9 25 5765 Saddle Cover Front Seal 10 25 5766 Wiper Backing Plate 25 0169 Saddle Wiper Felt 11 25 5768 Left Corner Seal 12 25 5836 Column Felt Wiper Clamp 2x 26 0172 Column Felt Wiper 13 25 5826 Column Top Cover 14 25 5825 Column Top Side Cover 15 25 5831 Gordillo Top Br
170. R P M D Depth of cut d diameter of cutter I P M Feed table travel in inches per minute K Constant cubic inches per minute per HPc Power required to remove 1 cubic inch per minute HPc Horsepower at the cutter F P R Feed per revolution R P M Revolutions per minute T Number of teeth in cutter W Width of cut in inches 217 Parameters 96 0189 rev L June 2005 6 PARAMETERS Parameters are seldom modified values that change the operation of the machine These include servo motor types gear ratios speeds stored stroke limits ball screw compensations motor control delays and macro call selections These are all rarely changed by the user and should be protected from being changed by the parameter lock setting If you need to change parameters contact HAAS or your dealer Parameters are protected from being changed by Setting 7 The Settings page lists some parameters that the user may need to change during normal operation and these are simply called Settings Under normal conditions the parameter displays should not be modified A complete list of the parameters is provided here The PAGE UP PAGE DOWN up and down cursor keys and the jog handle can be used to scroll through the parameter display screens in the control The left and right cursor keys are used to scroll through the bits in a single parameter PARAMETER LIST 1 X SWITCHES Parameter 1 is a collection of single bit flags used to turn servo r
171. RC ERROR Offsets lost maybe by low battery Check for a low battery and low battery alarm 205 PROGRAMS CRC ERROR Users program lost maybe by low battery Check for a low battery and low battery alarm 206 INTERNAL PROG ERROR Possible corrupted program Save all programs to disk delete all then reload Check for a low battery and low battery alarm 207 QUEUE ADVANCE ERROR Cycle power on the machine If the alarm reoccurs call your dealer and report the sequence of events that lead to the alarm 208 QUEUE ALLOCATION ERROR Cycle power on the machine If the alarm reoccurs call your dealer and report the sequence of events that lead to the alarm 209 QUEUE CUTTER COMP ERROR Cycle power on the machine If the alarm reoccurs call your dealer and report the sequence of events that lead to the alarm 210 INSUFFICIENT MEMORY Not enough memory to store users program Check the space available in the LIST PROG mode and possibly delete some programs 211 ODD PROG BLOCK Possible corrupted program Save all programs to disk delete all then reload 212 PROG INTEGRITY ERROR Possible corrupted program Save all programs to disk delete all then reload Check for a low battery and low battery alarm 213 PROGRAM RAM CRC ERROR Electronics fault possibly with main processor 214 NO OF PROGRAMS CHANGED Indicates that the number of programs disagrees with the internal variable that keeps count of the loaded programs Possible processor board problem
172. ROTATE ARM FWD OR REV TOOL RELEASE TOGGLE TOOL UN CLAMP UP OR DOWN ARROW MOVES PKT UP OR DOWN ORIENT SPINDLE SPINDLE ORIENTATION NOTE IF YOU WANT TO MOVE THE SPINDLE UP OR DOWN THE ARM MUST BE AT ORIGIN AND YOU MUST EXIT TL CHANGER RECOVERY ARE YOU FINISHED USING COMMANDS Y cnc waits for Y before continuing orient spindle pressed N REMOVE ALL TOOLS FROM ARM AND SPINDLE USE TOOL RELEASE BUTTON WHILE HOLDING TOOL TO REMOVE ANY TOOL FROM SPINDLE DEPRESS TOOL CLAMP RELEASE STUD ON ARM WHILE HOLDING TOOL AND SLIDE TOOL OUT NOTE THERE IS A TOOL CLAMP RELEASE STUD FOR EACH END OF ARM ARE ALL THE TOOLS REMOVED Y cnc waits for Y before continuing Y ABOUT TO ORIENT THE SPINDLE CAUTION THIS MAY DAMAGE THE TOOL ARM IF SPINDLE INTERFERES WITH ITS MOTION PRESS O TO ORIENT N TO CANCEL N ALARMS EXIST THEY MUST BE CLEARED PRESS Y TO CONTINUE THEN RESET TO CLEAR ALARMS THEN RETRY N arm at origin Y N N or O orient spindle N O arm at origin Y AT ORIGIN CONTINUE TO PKT RESTORE Y The atc fwd rev can still move arm at this time cnc waits for Y before continuing carousel between pockets Y N RESTORING POCKETS PLEASE WAIT CHECK CURRENT CAROUSEL POCKET ENTER CURRENT POCKET NUMBER THEN PRESS THE ENTER KEY USE ATC FWD REV TO ROTATE ARM TO ORIGIN PRESS LEFT OR RIGHT ARROW KEY TO MOVE CAR
173. RP 5 Plug in the clamp and unclamp switches 6 Set the main air regulator to 85 psi NOTE Tool Push Out Adjustment and Setting TRP Switches must be completed TOOL PUSH OUT ADJUSTMENT 1 Put tool holder in spindle 2 Plug the spindle taper air blast 3 Place an angle plate on the machine table Place a clean aluminum block between the angle plate and the tool holder 4 Jog the Z axis towards the plate until the tool holder is about 030 from the aluminum block Switch the jog increments to 001 and jog the Z axis towards the plate one increment at a time until the tool holder just presses the block firmly against the angle plate This is the zero point 5 Plug the spindle taper air blast 145 Mechanical Service 96 0189 rev L June 2005 Figure 3 2 10 Fork shim location 6 The Tool Push out adjustment is 0 060 0 010 Add or remove shims from the tool release fork to make adjustments The shims come in 0 010 and 0 018 thicknesses Jog away from the plate 0 060 Press and hold the tool release button and feel for movement in the aluminum block If the block is tight when the button is pressed shims may have to be ADDED to the tool release fork If the block is loose when the button is pressed shims may have to be REMOVED from the tool release fork This is the opposite of 40 taper adjustment If the aluminum block is tight at 0 060 release the button and jog the Z Axis up 0 001
174. Retighten the set screw 4 Check the tension of the shade Repeat this process as needed for proper tension one revolution at a time Do not overtighten the spring EC 300 Y AXIS WAY COVER Upper Way Cover Removal 1 Handle jog the X axis to center of travel Handle jog the Y axis down fully 2 POWER OFF the machine 3 Remove the twenty six 26 FHCS that attach the vertical guides to the way cover 5 Remove the six 6 BHCS that the attach the upper way cover to the spindle head and the lower way cover Lower Y Axis Waycovers Upper Y Axis Waycovers 6X BHCS 4X BHCS 20X 1 4 20 UNC x 1 1 4 SS FHCS 4X Lockwasher P Cool Assembly Waycover Guide Rails 2X Holding Bar Holding Bar Y Axis Waycovers 5X Guide Bar Front Bar 6X Spacer 2X Guide Rail 6X 1 4 20 UNC x 2 1 2 SS FHCS Mechanical Service 62 96 0189 rev L June 2005 Installation 1 Install the four SHCS at the top of the way cover Slide the way cover up and down to ensure that it moves freely 2 Slide the way cover down until the bottom flange goes under the spindle head cover and fasten it with four 4 BHCS 3 Fasten the left and right vertical guides using twenty six 26 FHCS Lower Y Axis Way Cover Removal 1 Handle jog the X axis to center of travel Handle jog the Y axis up fully 2 POWER OFF the machine 3 Remove the twenty six 26 SHCS that attach the left and right vertical guides and remove
175. S232 When a parameter file has been loaded from RS 232 alarm 902 will be added to the alarm history along with the date and time Note that this is not a resetable alarm it is for information purposes only 903 CNC MACHINE POWERED UP When the machine is powered up alarm 903 will be added to the alarm history along with the date and time Note that this is not a resetable alarm it is for information purposes only 904 ATC AXIS VISIBLE The tool changer axis must be invisible for tool change operations with the HS tool changers Set Parameter 462 bit 18 INVIS AXIS to 1 This will make the tool changer axis invisible and tool changes will be allowed 55 Alarms 96 0189 rev L June 2005 905 NO P CODE IN M14 M15 M36 In M14 M15 M36 must put pallet number in a P code 906 INVALID P CODE IN M14 M15 M36 OR M50 The P code must be the pallet number of a valid pallet without a decimal point and must be a valid integer number 907 APC UNLOAD SWITCH MISSED PAL 3 Pallet 3 did not return from the receiver to the APC in the allowable amount of time This can be caused by the chain switch block missing the limit switch or from another mechanical problem such as clutch slippage 908 APC UNLOAD SWITCH MISSED PAL 4 Pallet 4 did not return from the receiver to the APC in the allowable amount of time This can be caused by the chain switch block missing the limit switch or from another mechanical problem such as clutch slippage 909 APC PROGRAM NO
176. SE WIRES FOR 3 PHASE MOTOR OPTIONAL B F D C G P8 E CHIP K35 REVERSE CONVEYOR CHIP CONVEYOR GROUND CIRCUIT FU3 FU2 ON CONVEYOR CHIP Q4 Q3 THREE PHASE 210 VAC IN CHIP CONVEYOR AND SPIGOT MOTORS OVERCURRENT DETECTION 4 5 3 2 1 6 140 IOPCB THREE PHASE 230 VAC FROM ENA REV FROM IOPCB 140A P79 SIGNAL 12 VDC ENA REV 140A HOPT A PCBA VECTOR DRIVE 140D 140C LEFT CHIPC RIGHT CHIPC CB 230V 5 AMPS 79 78 M RED BLK ORG BLU GRN WHT 10 7 6 3 2 1 PIN J BOX CONTROL 10 PIN CONN RIGHT CHIPC 230 VAC 1PH M GRN WHT ORG BLU 10 7 6 3 J BOX CONTROL 10 PIN CONN BLK RED 2 1 PIN 230 VAC 1PH LEFT CHIPC GRN WHT ORG BLU BLK RED WHT GRN BLU ORG RED BLK 304 Electrical Diagrams 96 0189 rev L June 2005 305 Electrical Diagrams 96 0189 rev L June 2005 306 Electrical Diagrams 96 0189 rev L June 2005 Processor Stack Servo Amplifiers TC Motor arm TC Carousel From Home Switches Tool Changer X Y Chip Auger Chip Auger Chip Auger Jog Handle A Z VECTOR DRIVE Control Pendent Floppy LCD I O PCB 160VDC 230VAC MicroProc Video Mocon Z Y X A HV HV DC PC P C EC 400 Block Diagram 307 Electrical Diagrams 96 0189 rev L June 2005 ELECTRICAL SYMBOLS LIMIT SWITCH OPEN LIGHT EMITTING DIODE LIMIT SWITCH C
177. Switch 4 Mark the spot where the bit changes to 1 and secure the switch with a hose clamp 5 Reconnect the main air supply and take the machine off of E stop 6 Run the tool changer door and check for speed 7 Adjust the speed at the solenoid valve on the lube panel 8 Check the action of the spring damper that stops the tool changer door when it opens The tension can be adjusted by turning the adjustment screw on the back of the spring EC 400 TOOL CHANGER DOOR REPLACEMENT This procedure describes the installation of the complete door assembly It may not be necessary to start the procedure from the beginning Remove the damaged or inoperative parts and then rebuild the toolchanger door assembly Installation and Alignment Linear Guides and Air Cylinder 1 Push the top of the linear guide towards main panel wall and tighten top bolt Push the bottom of the linear guide towards panel wall and lightly tighten bottom bolt Securely tighten the remaining bolts and then tighten the top and bottom bolts Install linear guide trucks and grease using fittings 2 Grease shoulder bolt and slide through panel bracket spacer idler assembly second spacer and washer Thread the bolt into the pemnut and tighten Mechanical Service 84 96 0189 rev L June 2005 3 Push air cylinder towards linear guide rail while tightening bolts 4 Thread amp tighten onto cylinder rod end Tool Changer Doors 5 Grease main pane
178. T LISTED There is no program name in the Pallet Schedule Table for the loaded pallet To run a program for the loaded pallet enter the program name into the Program Name column of the Pallet Schedule Table for the pallet you want to operate on or remove the M48 from the subprogram you want to use Verify that the program and the pallet are compatible 910 APC PROGRAM CONFLICT The subprogram you are trying to run is not assigned to the loaded pallet Another program is assigned to this pallet in the Pallet Schedule Table Either enter the program name that you want to run into the Program Name column of the Pallet Status Table or remove the M48 from the subprogram you want to use Verify that the subprogram and the pallet are compatible 911 APC PAL LOAD UNLOAD AT ZERO One or more of the pallets on the Automatic Pallet Changer has a load or unload position set to zero This indicates that the APC set up procedure was incomplete Establish the correct load and unload positions for all pallets and enter the positions in the appropriate settings See operator s manual for the APC model and its correct setting numbers 912 APC NO P CODE OR Q CODE FOR M46 M46 must have a P code and a Q code The P code must be a line number in the current program The Q code is the number of the pallet if loaded that will cause a jump to the program line number 913 APC NO P CODE OR Q CODE FOR M49 M49 must have a Q code The P code is the pallet number The Q code is
179. TION PRECHARGE REGULATOR ASSY PRA 40 Taper AT BOTTOM REAR OF SPINDLE HEAD REAR OF GEAR BOX SPINDLE MOTOR ASSEMBLY ON TOOL RELEASE PISTON ASSEMBLY SIDE OF GEAR BOX SPINDLE MOTOR ASSEMBLY REAR OF MACHINE amp COOLANT TANK ASSEMBLY DIRT INDICATOR 100 MICRON FILTER DIRT INDICATOR INTAKE FILTER TSC FILTER ASSEMBLY INTAKE FILTER ASSEMBLY PRECHARGE REGULATOR ASSY PURGE VALVE ASSEMBLY INTAKE FILTER 100 MESH TSC FILTER 100 MICRON SOLENOID VALVE PURGE 2 POSITION 3 WAY SP RET 2 POSITION 3 WAY SP RET SOLENOID VALVE TOOL RELEASE CHECK VALVE ASSY TSC 2 POSITION 3 WAY SP RET SOLENOID VALVE PRECHARGE SET AT 3 6 4 4 PSI PRECHARGE REGULATOR PRESSURE SWITCH LOCATION VMC 3 4 5 1 2 V1 SV3 SV2 SV1 SHUTTLE VALVE PVA PS PRA R1 SET AT 40 PSI P1 G2 G1 FA1 FA2 F2 TSC PUMP CVA F1 CV CHECK VALVE 50 Taper TRSA V2 V3 V1 SV2 SV1 S1 P1 FA2 G2 G1 FA1 F2 F1 CVA SOLENOID VALVE TOOL RELEASE 2 POSITION 3 WAY SP RET 2 POSITION 4 WAY SP RET TOOL RELEASE SOLENOID ASSEMBLY SHUTTLE VALVE PURGE CHECK VALVE COOLANT CHECK VALVE SOLENOID VALVE PURGE 300 PSI MAX PRESSURE SWITCH 40 PSI TSCHP PUMP SUCTION GAGE INTAKE FILTER USE 20 MICRON FILTER ELEMENT TSC FILTER 20 MICRON FILTER GAGE TSC FILTER TSCHP FILTER ASSEMBLY INTAKE FILTER ASSEMBLY
180. The servo motors must be on to check backlash by this method 5 If backlash is found refer to Backlash Possible Causes in this section CHECKING Z AXIS 1 Set up a dial indicator and base on the mill table as shown in Fig 1 3 3 Figure 1 3 3 Dial indicator in position to check Z axis 2 Set dial indicator and the Distance to go display in the HANDLE JOG mode to zero as follows Zero the dial indicator Press the MDI key on the control panel Press the HANDLE JOG key on the control panel The Distance to go display in the lower right hand corner of the screen should read X 0 Y 0 Z 0 3 Set the rate of travel to 001 on the control panel and jog the machine 010 in the positive Z direction Jog back to zero 0 on the display The dial indicator should read zero 0 0001 4 Repeat Step 3 in the negative direction An alternate method for checking backlash is to place the dial indicator as shown in Fig 1 3 3 and manually push the Z Axis forward and back while listening for a clunk The dial indicator should return to zero after releasing the axis NOTE The servo motors must be on to check backlash by this method 5 If backlash is found refer to Backlash Possible Causes in this section BACKLASH POSSIBLE CAUSES If backlash is found in the system check for the following possible causes 16 Troubleshooting 96 0189 rev L June 2005 Loose SHCS attaching the b
181. This ensures that the only circuit powered when the machine is turned off is this transformer and only low voltage is present at the front panel on off switches LOW VOLTAGE POWER SUPPLY The low voltage power supply provides 5V DC 12V DC and 12V DC to all of the logic sections of the control It operates from 115V AC nominal input power It will continue to operate correctly over a 90V AC to 133V AC range POWER PCB PSUP The low voltage power distribution and high voltage fuses and circuit breakers are mounted on a circuit board called the POWER PCB POWER UP LOW VOLTAGE CONTROL TRANSFORMER T5 The low voltage control transformer T5 supplies power to the coil of the main contactor K1 It guarantees that the maximum voltage leaving the Power Supply assembly when power is off is 12V AC to earth ground It is connected via P5 to the POWER PCB SECONDARY CIRCUIT BREAKERS The following circuit breakers are located on the Power supply assembly CB2 Controls the 115 V power from the main transformer to the servo transformers and if tripped will turn off the servo motors and air solenoids CB2 could be blown by a severe servo overload CB3 Controls the power to coolant pump only It can be blown by an overload of the coolant pump motor or a short in the wiring to the motor CB5 Controls power to the TSC coolant pump only It can be tripped by an overload of the TSC coolant pump motor or a short in the wiring to the motor CB
182. ULT Encoder marker pulse count failure This alarm usually indicates that the Z Fault encoder has been damaged and encoder position data is unreliable This can also be caused by loose scale connectors 282 A AXIS LINEAR SCALE Z FAULT Encoder marker pulse count failure This alarm usually indicates that the Z Fault encoder has been damaged and encoder position data is unreliable This can also be caused by loose encoder connectors 283 X AXIS LINEAR SCALE Z CH MISSING Broken wires or encoder contamination All servos are turned off This Z Channel Missing can also be caused by loose scale connectors 284 Y AXIS LINEAR SCALE Z CH MISSING Broken wires or encoder contamination All servos are turned off This Z Channel Missing can also be caused by loose encoder connectors 285 Z AXIS LINEAR SCALE Z CH MISSING Broken wires or encoder contamination All servos are turned off This Z Channel Missing can also be caused by loose encoder connectors 286 A AXIS LINEAR SCALE Z CH MISSING Broken wires or encoder contamination All servos are turned off This Z Channel Missing can also be caused by loose encoder connectors 287 X AXIS LINEAR SCALE CABLE FAULT Cable from X axis scale does not have valid differential signals 288 Y AXIS LINEAR SCALE CABLE FAULT Cable from Y axis scale does not have valid differential signals 289 Z AXIS LINEAR SCALE CABLE FAULT Cable from Z axis scale does not have valid differential signals 290 A AXIS LINEAR SCALE CABLE
183. VER REMOVAL Left Right Way Cover Removal 1 Jog the X axis to the center of travel and POWER OFF the machine 2 To remove the desired way cover remove the SHCS that fasten the way covers to the table and remove the SHCS that fasten the way covers to the outside casting Y AXIS WAY COVER REMOVAL Removal Top 1 Jog the X axis to the center of travel and the Y axis all the way down 2 POWER OFF the machine 3 Remove the BHCS that fasten the waycover to the spindle head and the vertical guides to the column 5 Remove the top waycover Install the way cover in the reverse order above however make sure that all necessary gaskets and sealants are replaced and repaired as necessary Removal Lower 1 Jog the X axis to the center of travel and the Y axis all the way up 2 POWER OFF the machine 3 Remove the three 3 BHCS that fasten the waycover to the spindle head Mechanical Service 60 96 0189 rev L June 2005 4 Remove the seven 7 BHCS on each side that fasten the vertical guides to the column 5 Remove the lower waycover Install the way cover in the reverse order above however make sure that all necessary gaskets and sealants are replaced and repaired as necessary Z AXIS WAY COVER Right Way Cover Removal 1 Jog the Z axis receiver all the way in the Z direction away from the spindle 2 POWER OFF the machine 3 Remove the 14 BHCS that fasten the front of the waycover
184. Y STOP as this will leave the tool changer in an abnormal position that takes special action to correct KEYBOARD BEEPER There is a beeper inside the control panel that is used as an audible response to pressing keyboard buttons and as a warning beeper The beeper is a 2 3 kHz signal that sounds for about 0 1 seconds when any keypad key CYCLE START or FEED HOLD is pressed The beeper also sounds for longer periods when an auto shut down is about to occur and when the BEEP AT M30 setting is selected If the beeper is not audible when buttons are pressed the problem could be in the keypad keyboard interface PCB or in the beeper Check that the problem occurs with more than one button 205 Technical Reference 96 0189 rev L June 2005 5 9 MICROPROCESSOR ASSEMBLY The microprocessor assembly is in the rear cabinet at the top left position It contains three large boards They are microprocessor the keyboard and the MOCON All three boards of the processor assembly receive power from the low voltage power supply The three PCB s are interconnected by a local buss on dual 50 pin connec tors At power on some diagnostic tests are performed on the processor assembly and any problems found will generate alarms 157 or 158 In addition while the control is operating it continually tests itself and a self test failure will generate Alarm 152 MICROPROCESSOR PCB 68ECO30 The Microprocessor PCB contains the 68ECO30 processor running at 40
185. Z axis spindle position value 3 Enter TCR mode Press the DOWN ARROW command a tool pocket down Manually insert a tool into the tool pocket Plane4 Setting Parameter 64 indicator reference measurement 4 Place a 0 0005 indicator with an extended arm base on to the machine table Indicate the bottom of the tool with the indicator to the nearest 0 001 Record the measurement 5 Remove indicator from the table and the tool holder from the tool pocket Insert the tool into the spindle head position Place the measurement indicator under the spindle head 93 96 0189 rev L June 2005 Mechanical Service 6 Enter DEBUG Jog handle the Z axis up or down until the end of the tool is at the same height as the measured value found when the tool was placed in the tool pocket Record the Z axis spindle height value 7 Take the difference in the spindle height values found in DEBUG mode and add the encoder count value to the original value for PARAMETER 64 setting Example Difference in Z axis encoder counts Old Z axis Tool Change Setting New Z axis Tool Setting 20681 861699 882380 8 Enter PARAMETERS page UNLOCK settings and write new setting value for Parameter 64 LOCK parameter settings 9 Perform a tool change and observe for misalignment Adjust the PARAMETER 64 setting if neces sary SERVO TOOL CHANGER OFFSETS Invisible Axis Explanation The SMTC uses an invisible axis to control the double arm
186. a decimal R code can be used such as R180 53 Note that the P and R codes only work on a vector drive machine 22 ENABLE MACRO Enables macro functions 23 INVERT SKIP Invert sense of skip to active low closed 24 HANDLE CURSOR Enable use of jog handle to move cursor 25 NEGATIVE WRK OFFSET Selects use of work offsets in negative direction 26 TRANS OIL LOW PRESS Enables transmission low oil pressure detection 27 QUICK CODE Enables conversational programming 28 OILER ON OFF Enables oiler power when servos or spindle is in motion 29 OVERVOLT INPUT N CInverts sense of over voltage signal 222 Parameters 96 0189 rev L June 2005 30 SPINDLE ENCODER 2 This parameter bit enables a second encoder that is mounted on the spindle motor and wired into the C axis input of the Mocon It is required to control the vector algorithm on a belted machine when the belts slip at high load When two encoders are present the first is mounted on the spindle or output of the transmission and is wired to the spindle input on the MOCON Most mills use a single encoder that is mounted on either the spindle transmission output or spindle motor but always connected to the spindle input on the Mocon 31 DOOR STOP SPINDLE Enables functions to stop spindle and manual operations at door switch 58 LEAD COMPENS SHIFT Shift factor when applying lead screw compensation Lead screw compensation is based on a table of 256 offsets each 127 encode
187. a test of the entire system should be performed This will identify leaks and allow for the system to be bled while it is still easily accessible Set the air valve assembly and the hydraulic cylinder on top of the table or other high work surface Set the pressure booster assembly onto the floor 1 Identify the low pressure tubing line coming from the low pressure side of the pressure booster Connect this tubing line to the low pressure regulator of the air valve assembly 2 Identify the high pressure tubing line coming from the high pressure side of the pressure booster Connect this tubing line to the high pressure regulator of the air valve assembly 3 Connect the tubing line from the air port of the hydraulic cylinder to the unregulated source on the air valve assembly 4 Attach a supplied air line to the air valve assembly Supplied air should be set to 85 psi Using the appropriate regulator adjuster on the air valve assembly set the low pressure regulator to 20 psi Make sure that the swivel elbow connected to the hydraulic cylinder is at the highest point of the entire assembly Caution During the following steps spillage of hydraulic oil may occur Wear eye protection and have sufficient rags on hand to clean up any purged oil 5 Set the high pressure regulator to approximately 5 10 psi Remember that the pressure booster will still provide 12 1 pressure boost 6 Loosen the connection between the hydraulic hose and t
188. acket 16 25 5823 Column Right Cover 17 25 5827 Gordillo Right Guide 18 25 5829 Bottom Chip Cover Plate 19 20 2615 Bottom Plate Bar 2x 20 25 5830 Bottom Gordillo Cover 21 59 0714 Y Axis Gordillo 2x 22 25 5911 Y Axis Waycover Center Cover 23 25 5828 Gordillo Left Guide 24 25 5824 Column Left Cover 314 Assembly Drawings 96 0189 rev L June 2005 EC 300 Base Assembly 1 50 9011 Linear Guide truck 2 50 0017 Linear Guide 35mm truck 3 20 2587 Saddle Casting 4 58 3600 3 8 Nipple 5 20 7008 Nut Housing 6 25 7267 Prox Switch Bracket 7 25 5780 Y Axis Trip Bracket 8 25 5919 Cable Carrier Bracket 9 20 2593 Prox Switch 10 20 0150 Nut Housing 11 30 7140 Base Lube Assembly 12 30 7138 Saddle Lube Assembly 13 25 5953 Chip Shield 14 20 2687 ATC Mount 15 62 0014 Servo Motor 16 25 9203 Motor Mount Cover Plate 17 20 2733 X Axis Bumper 18 30 3107 Ballscrew Assembly 19 20 2593 X Axis Ship Block 20 20 2676 Ballscrew Bumper 21 20 0152 Bearing Housing 22 50 9011 Linear Housing 23 58 1680 Parker Fitting 24 58 0097 90 Fitting 25 57 9265 Chip Conv Bracket 26 32 6626 Chip Conv Motor 27 25 5669 Auger Box 28 57 0360 Box Gasket 29 20 2586 Base Casting 30 57 9265 Conveyor Gasket 31 20 2592 Chip Auger 32 25 5670 Auger Box Cover 33 25 5673 Strainer Base 34 58 0807 Coolant Nozzle Base 1 2 3 4 5 6 7 8 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
189. ad The fuse function built into the MOCON has been overloaded due to a lot of motor accel decels or hitting a hard stop with the axis This safety function protects the amplifier and motor so find the cause and correct it If the current program is the cause change the program If the axis hits a hard stop the travel limits may be set wrong Phasing Error The MOCON did not receive the proper phasing information from the motors DO NOT RESET the machine if this alarm occurs Power the machine down and back up If the problem persists it is probably a broken wire or faulty MOCON connectors This problem could also be related to the Low Voltage Power Supply Check to see if the LVPS is functioning properly Servo Error Too Large This alarms occurs when the difference between the commanded axis position and the actual position becomes larger than the maximum that is set in the parameter This condition occurs when the amplifier is blown is not receiving the commands or the 320 volt power source is dead If the MOCON is not sending the correct commands to the amplifier it is probably due to a broken wire or a PHASING ERROR that was generated Axis Z Fault or Z Channel Missing During a self test the number of encoder counts was found to be incorrect This is usually caused by a noisy environment and not a bad encoder Check all shields and grounds on the encoder cables and the motor leads that come into the amplifiers An a
190. age measured at pins 2 and 3 of the Vector Drive 7 VDC 8 Electrical power must be phased properly to avoid damage to your equipment The Power Supply Assembly PC board incorporates a Phase Detect circuit with neon indicators shown below When the orange neon is lit NE5 the phasing is incorrect If the green neon is lit NE6 the phasing is correct If both neon indicators are lit then you have a loose wire Adjust phasing by swapping L1 and L2 of the incoming power lines at the main circuit breaker PHASE DETECT PHASE DETECT PASS FAIL NE6 NE5 WARNING ALL POWER MUST BE TURNED OFF AT THE SOURCE PRIOR TO ADJUSTING PHASING 9 Turn off the power rotate the shaft that engages the handle on the panel door counterclockwise until it snaps into the OFF position Also set the main switch handle on the panel door to OFF Both the handle and the switch must be set to OFF before the door can be closed Close the door lock the latches and turn the power back on 10 Remove the key from the control cabinet and give it to the shop manager INSTALLATION PROCEDURE FOR EXTERNAL 480V TRANSFORMER Introduction The external transformer adds to overall machine reliability and performance however it does require extra wiring and a place to locate it The external transformer provides electrostatically shielded isolation This type of transformer acts to isolate all common mode line transients and improve EMI conducted emissio
191. all nut to the nut housing Tighten the SHCS as described in Mechanical Service section Loose SHCS attaching the nut housing to the column head or saddle depending on the axis Tighten the SHCS as described in Mechanical Service Loose clamp nut on the bearing sleeve Tighten the SHCS on the clamp nut Loose motor coupling Tighten as described in Mechanical Service Broken or loose flex plates on the motor coupling NOTE The coupling cannot be serviced in the field and must be replaced as a unit if it is found to be defective Loose SHCS attaching the bearing sleeve to the motor housing or top of column Tighten as described in Ball Screw section Defective thrust bearings in the bearing sleeve Replace the bearing sleeve as outlined in Bearing Sleeve section Loose SHCS attaching the axis motor to the motor housing If the SHCS are found to be loose inspect the motor for damage If none is found tighten as described in Axis Motor section If damage is found replace the motor Incorrect backlash compensation number in Parameter 13 27 or 41 Worn ball screw EC 400 A Axis Backlash Adjustment Full Forth 1 indexer instructions are different see the instructions at the end of this section 1 Remove all parts and fixtures from the platter 2 Check and record backlash near the outer edge of the platter face using approximately 15 20 ft lbs The factory specification is 0 00
192. ange it to 999999 266 X SWITCHES Parameter 266 is a collection of single bit flags used to turn servo related functions on and off The left and right cursor arrows are used to select the function being changed All values are 0 or 1 only The function names are 0 X LIN SCALE EN Used to enable linear scales for the X axis 1 X INVRT LN SCL Used to invert the X axis linear scale 2 DSBL SCALE Z Used to disable the linear scale Z test 3 X ZERO AXIS TC Used to return axis to the position specified by the TOOL CHANGE OFFSET parameter prior to a tool change On mills with a gimbaled spindle this bit must be set to 1 on the A and B axes parameter 269 and 270 and 0 on all other axes 4 X 2ND HOME BTN Used to move axis to coordinate specified in Work Offset G129 5 X NEG COMP DIR Used to negate the direction of thermal compensation 6 X DELAY AXIS 0 Used with an APL to ensure X axis is zeroed before A axis of APL 7 X MAX TRAVEL INP This bit is set to 1 on five axes machines This bit indicates that there is a switch visible through MOCON that detects if the axis has rotated all the way round It is used to tell the control to skip the first zero switch when zeroing so it can unwrap the cables 9 X TEMP SENSOR This performs Ball Screw Thermal Compensation via a temperature sensor attached to the ball nut When this bit is set to 1 the feature is activated for that axis Note that this feature can only be used when temperature sensors are
193. anger is installed on the machine Note that if this parameter is set to zero the control will automatically reset it based upon the parameters which previously specified the tool changer type The following types are recognized 1 Generic Geneva or umbrella type This is the default 2 Horizontal type using W axis 3 Horizontal type using B axis 4 Horizontal type using TT axis 5 Generic Vertical Side Mount Tool Changer VSMTC 6 Super2 VSMTC using TT axis 7 Chain Type 8 Mori Side Mount Tool Changer 9 Manual Tool Changer 248 Parameters 96 0189 rev L June 2005 711 Pocket Up Settle This parameter supports the vertical mill side mount tool changer It specifies the amount of time in 50ths of a second that the carousel is to wait after a tool change before it is allowed to move It should be set to 20 on all mills 715 Color Message Used to change the color of the text messages displayed at the bottom of an LCD monitor Any value from 0 to 255 can be used The following are some suggestions Black 0 Brown 3 4 11 12 19 20 Red 5 6 13 143 Orange 7 15 23 Yellow 30 31 39 55 63 Pink 95 103 111 119 159 167 175 183 Purple 67 75 77 83 140 141 198 215 Blue 64 88 210 248 Green 24 40 56 104 120 716 Color CMD Position Used to change the color of the positions text displayed on the Current Commands page on an LCD monitor See color values listed for parameter 715 717 Color CMD G Code Use
194. annot be rotated Reset then rezero the indexer 927 ILLEGAL G1 CODE FOR ROTARY INDEXER The rotary indexer only does rapid G0 motion Feed G1 motion is not allowed 937 INPUT LINE POWER FAULT This alarm works with the Power Failure Detection Module This alarm will be generated whenever incoming power to the machine falls below reference voltage value in parameter 730 and duration of time in parameter 731 Cycle the power to continue 938 LANGUAGES LOADED Foreign languages were recently loaded into the control 939 LANGUAGES FAILED TO LOAD Foreign languages fails to be loaded into the control Languages either exceeded total flash memory or not enough flash memory available Try deleting a language from disk 940 SIDE MOUNT CAROUSEL ERROR This alarm is generated by the tool changer if the carousel motor is still running when the tool pocket is unlocked and lowered prior to a tool change If the carousel does not start to rotate after the allowed time specified by parameter 60 TURRET START DELAY or does not stop rotating after the allowed time specified by parameter 61 TURRET STOP DELAY 941 POCKET TOOL TABLE ERROR This alarm is generated by the tool changer if the tool specified by the program is not found in the POCKET TOOL table or the searched pocket is out of range 942 CAROUSEL POSITION TIMEOUT This alarm is generated by the tool changer if the tool carousel has not moved after the allowed time or has not stopped after the allowed time spe
195. ap the cables 9 Y TEMP SENSOR This performs Ball Screw Thermal Compensation via a temperature sensor attached to the ball nut When this bit is set to 1 the feature is activated for that axis Note that this feature can only be used when temperature sensors are installed The following parameters must be set appropriately 201 132 133 XYZ SCREW COMP COEF 8000000 272 273 274 XYZ SCREW COMP T CONST 28000 351 TEMP PROBE OFFSET 450000 16 SCALE Z HIST For HAAS diagnostic use only 268 Z SWITCHES Parameter 268 is a collection of single bit flags used to turn servo related functions on and off The left and right cursor arrows are used to select the function being changed All values are 0 or 1 only The function names are 0 Z LIN SCALE EN Used to enable linear scales for the Z axis 1 Z INVRT LN SCL Used to invert the Z axis linear scale 2 DSBL SCALE Z Used to disable the linear scale Z test 3 Z ZERO AXIS TC Used to return axis to the position specified by the TOOL CHANGER OFFSET parameter prior to a tool change On mills with a gimbaled spindle this bit must be set to 1 on the A and B axes parameter 269 and 270 and 0 on all other axes 4 Z 2ND HOME BTN Used to move axis to coordinate specified in Work Offset G129 5 Z NEG COMP DIR Used to negate the direction of thermal compensation 6 Z DELAY AXIS 0 Used with an APL to ensure Z axis is zeroed before A axis of APL 7 Z MAX TRAVEL INP This bit is set to 1 on five axes
196. ard MAS 403 1982 This pull stud is characterized by a long shaft and a 45 shoulder under the head Do not use the short shaft or pull studs with a sharp right angle 90 head as they will not work and will cause serious damage A B C A B E C D E D CT BT A B C D E 40T 40T 45T 50T 40T 40T 50T 50T Kit Kit Kit Kit Kit Kit Kit Kit 45 o 0 172 Thru 1 104 20 7595 TSC 22 7171 TSC 20 7594 TSC 22 0075 TSC 20 7165 non TSC 22 7170 non TSC 20 7164 non TSC 22 0039 non TSC 1 104 45 o TPS24CT PS24CT TPS24CT50 PS24CT50 TPS24BT PS24BT TPS24E50 PS24E50 45 o 0 990 0 172 Thru 45 o 0 990 45 o 0 31 1 780 1 386 45 o 1 780 1 386 45 o 1 780 1 386 0 31 45 o 1 780 1 386 2 69 2 57 2 48 65 M16X2 M24X3 1 75 3 26 3 35 83 82 2 25 4 00 3 94 91 2 75 2 50 44 1 75 44 2 75 5 8 11 1 8 4 00 3 87 A B C D E 45T 50T CAT V Flange MAS 403 M24 X 3 Threads JMTBA Standard MAS 403 P50T 1 M16 X 2 Threads JMTBA Standard MAS 403 P40T 1 M16 X 2 Threads JMTBA Standard MAS 403 P40T 1 5 8 11 Inch Threads JMTBA Standard MAS 403 P40T 1 5 8 11 Inch Threads JMTBA Standard MAS 403 P40T 1 1 8 Inch Threads JMTBA Standard MAS 403 P50T 1 1 8 Inch Threads JMTBA Standard MAS 403
197. are a number of ways to verify the problem The following procedure will verify thermal growth of the X axis ballscrew in a machine that has not been warmed up 1 Home the machine In MDI mode press POSIT and PAGE DOWN to the OPER page Troubleshooting 7 96 0189 rev L June 2005 2 Jog to an offset location on the table example X 15 0 Y 8 0 Select the X axis and press the ORIGIN key to zero it Select the Y axis and zero it 3 Press the OFSET key then scroll down to G110 or any unused offset Cursor to X and press PART ZERO SET twice This will set X0 Y0 at this position 4 Enter the following program It will start at the new zero position rapid 10 inches in the X direction feed the final 25 inches at 10 inches min and then repeat the X movement G00 G110 X0 Y0 X10 0 G01 X10 25 F10 M99 5 In order to set up the indicator run the program in SINGLE BLOCK mode and stop it when X is at 10 25 Set the magnetic base on the table with the indicator tip touching the spindle housing in the X axis and zero it 6 Exit SINGLE BLOCK mode and run the program for a few minutes Enter SINGLE BLOCK mode again stop the program when X is at 10 25 and take a final reading on the indicator If the problem is thermal growth the indicator will show a difference in the X position NOTE Ensure the indicator setup is correct as described in Accuracy section Errors in setup are common and often incorrectly appear t
198. asurement would be to take an indicator on a magnetic base extended 10 inches between the table and spindle housing and observe the reading of the indicator A reading of more than 001 would indicate excessive vibration The two common sources of noise are the spindle and axis drives Most complaints about vibration accuracy and finish can be attributed to incorrect machining practices such as poor quality or damaged tooling incorrect speeds or feeds or poor fixturing Before concluding that the machine is not working properly ensure that good machining practices are being observed These symptoms will not occur individually Ex A machine with backlash may vibrate heavily yielding a bad finish Put all of the symptoms together to arrive at an accurate picture of the problem Machine vibrates while jogging the axis with the hand wheel The HAAS control uses very high gain accelerations curves This vibration as you jog is simply the servos quickly trying to follow the handle divisions If this is a problem try using a smaller division on the handle You will notice the vibration more at individual clicks than when you are turning the handle faster This is normal The machine vibrates excessively in a cut This can be caused by a number of factors as machining practices come into play Generally speaking the least rigid element of a cut is the tool because it is the smallest part Any cutter will vibrate if pushed beyond its tensile strength In or
199. at fasten the waycover to the receiver and remove it through the door at the control pendant 3 Disconnect the reservoir at the rotary indexer end and plug the end of the hose 4 Remove the drain plug on the opposite side of the rotary indexer Replug the hole when the oil has drained 5 Remove the air escape hole plug on the side of the platter 6 Fill the rotary table until oil begins to escape from the air escape hole and plug it 7 Replace the reservoir hose and the way covers Command the receiver 180 to 0 repeatedly for fifteen minutes The reservoir will drop in level as it continues to replace the oil Add oil as needed to the reservoir to just below the full line Side View Front View Oil Reservoir Rotary Indexer 1 or 45 1 Remove the drain plug located on the left side of the rotary indexer Replace the plug when the oil has drained 2 Remove the air vent plug located to the upper right of the drain hole 3 Fill the rotary indexer at the oil fill hole shown in the illustration Replace the plug when oil begins to seep from the air vent 260 96 0189 rev L June 2005 4 Command a 180 to 0 rotation for fifteen minutes This will remove air remaining in the system The rotary indexer is full when the oil level is half way on the site glass Fill as needed 5 Replace the waycover Oil Fill Sight Glass Oil Fill Oil Drain Air Vent EC 400 Rotary Indexer 261 Cable Locations 96 0189 rev
200. ative number in the TT axis Parameter 487 not the B axis 12 Return the axis to Invisible set parameter 462 to 1 and cycle power 13 Zero return the TT axis The double arm should be in the middle of the home position 95 96 0189 rev L June 2005 Mechanical Service 3 7 AXIS MOTORS Please read this section in its entirety before attempting to remove or replace the axis motors X AXIS MOTOR X Axis Motor Key 4X SHCS 4X BHCS Coupling Coupling Housing Cover X Axis Motor and Ball Screw Assembly EC 300 Coupling X Axis Motor Cover Plate Coupling Housing 4X BHCS 4X SHCS Key Proximity Sensor Wiring Top View X Axis Motor and Ball Screw Assembly EC 400 Removal 1 Power ON the machine Zero return all axes and put machine in HANDLE JOG mode 2 Jog the Y axis to the bottom of its travel Jog the X axis away from the motor 3 Remove the rear enclosure panel 4 POWER OFF the machine 5 On the top of the motor housing remove the four BHCS and remove the coupling housing cover 6 Loosen the SHCS on the motor coupling 7 Disconnect all wiring from the motor and remove Be careful of the proximity sensor wires when lifting out the motor Mechanical Service 96 96 0189 rev L June 2005 8 Remove the SHCS motor mounting bolts and remove the motor from the coupling housing Installation 1 Inspect the motor coupling and replace it if required Visually inspect th
201. ay K6 is for the coolant pump 230V AC It is a plug in type and is double pole Relays K9 through K12 are also plug in types for controlling the drawbar motors The Input Output Assembly consists of a single printed circuit board called the IOPCB 203 Technical Reference 96 0189 rev L June 2005 5 7 TWO SPEED GEAR TRANSMISSION EC 1600 HS 3 4 6 7 The spindle head contains a two speed gear transmission The spindle motor is directly coupled to the trans mission and the transmission is cog belt coupled to the spindle GEAR BOX LUBRICATION The transmission requires 5 quarts of Mobil DTE 25 oil The level should be checked monthly with a dipstick 5 quarts 43 4 deep The gear box uses an oil sump and is cooled by gear oil GEAR BOX AIR SOLENOIDS There is a double solenoid valve controlling air to the gear box This solenoid sends air to select either the high gear or the low gear When power is removed from the solenoids the valve remains in its last state Air is always required to ensure the gears are held in either high or low gear Circuit breaker CB4 will interrupt power to these solenoids Power is left on the solenoid which is commanded last GEAR BOX SENSE SWITCHES There are two switches in the gear box used to sense the position of the gears One switch indicates HIGH by opening and the other indicates LOW by opening Between gears both switches are closed indicating a between gear condition The diagnostic display shows
202. ay page 5 TSC PURGE ENABLE Enables purge output on TSC option 237 Parameters 96 0189 rev L June 2005 6 SINGLE CLAMP SWITCH This parameter enables the control to rely up on a single switch to detect the clamp position of the Side Mount Tool Changer arm When this bit is set to zero both the upper and the lower switches are used to detect the arm position When it is set to one only the lower switch will be used This means that the control will not wait until the upper switch is tripped to conclude that the tool is clamped so subsequent operations can begin immediately This increases tool change speed 7 SPINDLE DRIVE LOCK This bit must be set to 1 if machine is equipped with a non Haas vector spindle drive This bit must be set to 1 if the machine has a 50 taper spindle or a non Haas vector drive 8 UNUSED 9 CONCURENT SPINDLE When set to 1 the spindle will be commanded to start concurrently with other commands in the same block In the following example with this bit set to 1 the spindle will start at the same time as the rapid move G0 X 1 S7500 M3 10 HS3 HYDRAULIC TL CH This parameter bit is used with the 38 tool SMTC on the HS 3 When this is set to zero the mill will behave normally When it is set to 1 the control will recognize that the toolchanger is a 38 Tool SMTC 11 HAAS VECTOR DRIVE This bit must be set to 1 if machine is equipped with a HAAS vector spindle drive When set to 1 voltage to the Haas vector drive is
203. be wired one to one It cannot be a Null Modem cable which inverts pins 2 and 3 To check cable type use a cable tester to check that communication lines are correct The controller is DCE Data Communication Equipment This means that it transmits on the RXD line pin 3 and receives on the TXD line pin 2 The RS 232 connector on most PC s is wired for DTE Data Terminal Equipment so no special jumpers should be required The Down Line DB 25 connector is only used when more than one controller is to be used The first controller s down line connector goes to the second controller s up line connector etc The RS 232 interface sends and receives seven data bits even parity and two stop bits The interface must be set correctly The data rate can be between 110 and 19200 bits per second When using RS 232 it is important to make sure that Parameters 26 RS 232 Speed and 33 X on X off Enable are set to the same value in the controller and PC If Parameter 33 is set to on the controller uses X on and X off codes to control reception so be sure your computer is able to process these It also drops CTS pin 5 at the same time it sends X off and restores CTS when is sends X on The RTS line pin 4 can be used to start stop transmission by the controller or the X on X off codes can be used The DSR line pin 6 is activated at power on of the controller and the DTR line pin 20 from the PC is not used If Parameter 33 is 0 the CTS line can s
204. bly Drawings 96 0189 rev L June 2005 HS 3 Sheet Metal and Parts List 0 21 23 24 25 26 27 28 30 31 32 33 34 36 35 35 29 22 1 2 3 6 9 15 16 17 18 19 19 2 4 5 11 10 12 13 8 7 36 34 14 1 25 0528 Back panel sheet metal 2 25 0163 Y Axis bellows top edge cover 3 59 0268 Y Axis upper bellows 4 25 6017 Y Axis splash cover 5 25 6051 Door enclosure 6 25 6017 Y Axis chip guard 7 25 6057 Conduit enclosure 8 25 6026 Head cover right 9 25 6025 Head cover left 10 25 6057 Conduit enclosure access plate 11 25 6571 L bracket 12 25 0446 Center bottom sheet metal 13 25 6052 Door 14 59 0267A Y Axis lower bellows 15 22 6056 Fence panel 6 16 25 0626 Left table gutter 17 25 0630 Front table cover 18 25 6003 Access cover 2 19 25 0627 Right table gutter 20 25 0448 Z Axis chip conveyor tray left 21 25 0449 Z Axis chip conveyor tray right 22 25 6043 Z Axis chip conveyor brace 6 23 57 0085 Z Axis chip conveyor tray gasket 2 24 25 6054 X Axis splash guard 25 25 0450 X Axis chip conveyor tray left 26 25 0548 Chip conveyor chute 27 57 0086 X Axis chip conveyor tray gasket 28 25 0451 X Axis chip conveyor tray middle 29 25 0452 X Axis chip conveyor tray right 30 57 0087 Center Trough Gasket 31 25 6008 Z Axis way covers 32 25 6063 X Axis chip conveyor brace 4 33 25 0447 Z Axis way cover end support 34 25 6007 X
205. bly straight out Mark the orientation of the plate first as it must be reassembled exactly as it was NOTE If the Servo Motor has been removed the Grid Offset has to be re calculated in order to assure that there is no mis allignment after re assembling the motor Refer to the Pallet Changer Grid Offset section of this manual NOTE Power off before disconnecting anything and unscrew the power cables for the Rotary Tables from J box 6 The power wires are located on top of the machine for the two rotary tables and are routed through the table to the top of the machine via the center compartment within the rotating doors 113 Mechanical Service 96 0189 rev L June 2005 NOTE There are 2 power lines and 2 air lines one pair connected to each table There is also an oil line that splits to each table Remove the cable cover on the rotating door and pull the cables through Disconnect the power cables from the J box remove the lubrication line and disconnect and crimp air lines leading to the rotary tables with a zip tie There is a silk screen on the outside of the J box that illustrates wire routing J Box Junctions Air Solenoids for Clamp Unclamp and Air Blast Electrical to Servo Motor Air Oil and Electrical to Rotary 1 Oil Manifold Air Oil and Electrical to Rotary 2 Electrical From Control Cabinet Oil Reservoir Air Pallet 1 Pallet 2 J Box Servo Motor Control Cabinet Dowel Pin
206. bolt with the cylinder fully retracted 12 Unscrew the rod one full turn and tighten the jam nut The air cylinder should reach the end of its travel before the cams do 13 Attach the rod end to the cylinder lever using the shoulder screw with one washer on each side of the rod end 14 Torque both of the shoulder screws to 100 ft lbs 15 Reinstall and adjust the H frame up switch 16 Reinstall the airlines and the cylinder shield 17 After completion run a sample program to test for proper operation Mechanical Service 124 96 0189 rev L June 2005 EC 400 ROTARY INDEXER AIR DIAGRAM Top View Front View Air In Safety Solenoid Assembly Lift Purge Solenoid Assembly Air in From Air Doubler 140 PSI Clamp Solenoid Assembly Platter Air Purge Clamp Solenoid Assembly Lift Clamp Air in From Air Doubler 140 PSI Lift Solenoid 80 PSI Safety Solenoid RECEIVER REPLACEMENT The following instructions detail the procedure for leveling and verification of the receiver geometry Machine level must be verified before replacing the receiver and check the receiver geometry for reference before it is removed Receiver Pallet Verification Leveling The machine must be level with absolutely no twist in the Z axis Clean the pallet and precision level of all debris The level can also be placed on top of the pallet clamp plate with the pallet off of the machine Center the X and Z axes Posit
207. bow Coil the Tubing and mark with masking tape See Figure 9 Use wire ties to secure the Tubing lines to follow the Hydraulic Hose out 174 Mechanical Service 96 0189 rev L June 2005 PRESSURE BOOSTER ASSEMBLY BENCH TEST Prior to installation of the Pressure Booster Assembly a test of the entire system should be performed This will identify leaks and allow for the system to be bled while it is still easily accessible Set the Air Valve Assembly and the Hydraulic Cylinder on top of the Table or other high work surface Set the Pressure Booster Assembly onto the floor 1 Identify the low pressure Tubing line coming from the low pressure side of the Pressure Booster Connect this Tubing line to the Low Pressure Regulator of the Air Valve Assembly 2 Identify the high pressure Tubing line coming from the high pressure side of the Pressure Booster Connect this Tubing line to the High Pressure Regulator of the Air Valve Assembly 3 Connect the Tubing line from the air port of the Hydraulic Cylinder to the unregulated source on the Air Valve Assembly 4 Attach a supplied air line to the Air Valve Assembly Supplied air should be set to 85 PSI 5 Using the appropriate regulator adjuster on the Air Valve Assembly set the Low Pressure regulator to 20 PSI 6 Make sure that the Swivel Elbow connected to the Hydraulic Cylinder is at the highest point of the entire assembly CAUTION During the following Steps spillage of hyd
208. cal stop A short in the motor or a short of one motor lead to ground can also cause it 163 Z AXIS DRIVE FAULT Current in Z servo motor beyond limit Possibly caused by a stalled or overloaded motor The servos are turned off This can be caused by running the axis into a mechanical stop A short in the motor or a short of one motor lead to ground can also cause it 164 A AXIS DRIVE FAULT Current in A servo motor beyond limit Possibly caused by a stalled or overloaded motor The servos are turned off This can be caused by running the axis into a mechanical stop A short in the motor or a short of one motor lead to ground can also cause it 165 X ZERO RET MARGIN TOO SMALL This alarm will occur if the home limit switches move or are misadjusted This alarm indicates that the zero return position may not be consistent from one zero return to the next The encoder Z channel signal must occur between 1 8 and 7 8 revolution of where the home switch releases This will not turn the servos off but will stop the zero return operation 166 Y ZERO RET MARGIN TOO SMALL This alarm will occur if the home limit switches move or are misadjusted This alarm indicates that the zero return position may not be consistent from one zero return to the next The encoder Z channel signal must occur between 1 8 and 7 8 revolution of where the home switch releases This will not turn the servos off but will stop the zero return operation 167 Z ZERO RET MARGIN TOO SMALL Thi
209. ce it NOTE Carefully inspect the spindle shaft for galling or burrs inside the spindle shaft where the end of the drawbar rides If it is damaged the spindle must be replaced 9 Install the drawbar 10 Reinstall the tool release piston 3 5 TOOL CLAMP UNCLAMP SWITCH ADJUSTMENT TOOLS REQUIRED Right angle plate Machined aluminum block 2 x4 x4 TOOL CLAMP UNCLAMP SWITCH ADJUSTMENT INITIAL PREPARATION 1 Remove the rear enclosure panel 2 Secure the right angle plate in place on the table 3 Place the machined block of aluminum against the right angle plate Mechanical Service 72 96 0189 rev L June 2005 4 POWER ON the machine 5 Insert an empty tool holder into the spindle taper 6 Go to HANDLE JOG mode Choose Z axis and set the jog increments to 01 7 Jog the Z axis in the negative direction until the tool holder is approximately 03 from the block At this point stop jogging and press the TOOL RELEASE button top left The tool holder will come out of the taper NOTE Do not jog too far in the negative direction This will cause overcurrent in the Z axis SETTING TRP HEIGHT 1 Press the MDI key and turn the jog handle to zero 0 2 Press HANDLE JOG and set the increments to 01 Jog the Z axis in the positive direction 100 3 Press and hold the TOOL RELEASE button and try to move the block by hand The block should be tight at 100 and loose at 110
210. ches sec sec it would be 269 blocks per second Note also that an important equation 7 above is the relationship between radius of curvature r chordal error e and block length l If you have a radius or curvature close to 1 4 inch and your maximum chordal error is 0 00005 inch the recommended block length is 0 01 inch This shows that it is not always required to use very short blocks 216 Technical Reference 96 0189 rev L June 2005 5 22 FORMULAS TO FIND TO FIND S F M TO FIND THE SFM OF A CUTTER OR WORKPIECE EXAMPLE To find the SFM of a cutter rotating at 600 RPM with a diameter of 10 inches SFM 262 x d x RPM 12 3 1416 x d x RPM R P M TO FIND THE RPM OF A CUTTER OR WORKPIECE EXAMPLE To find the RPM of a cutter rotating at 150 SFM with a diameter of 8 inches SFM 3 1416 x d d 12 x SFM 3 82 x SFM I P M TO FIND THE FEED table travel in inches per minute EXAMPLE To find the feed of a 10 tooth cutter rotating at 200 RPM with a feed per tooth of 0 012 IPM F P T x T x RPM F P R TO FIND THE FEED PER REVOLUTION in inches OF A CUTTER EXAMPLE To find the feed per revolution of a cutter rotating at 200 RPM with a table travel of 22 inches per minute F P R R P M I P M F P T TO FIND THE FEED PER TOOTH OF A CUTTER EXAMPLE To find the feed per tooth of a cutter rotating at 200 RPM with a table travel of 22 inches per minute F P T I P M T x
211. cified by parameter 60 TURRET START DELAY and parameter 61 TURRET STOP DELAY respectively 943 UNPROCESSED QUEUE CELL IN TOOL CHANGE There is an unknown command generated in the Tool change Please save your current program to disk and notify your dealer 944 INDEXER OUT OF POSITION The A axis indexer is out of position Jog the A axis to within 1 degree of a clamping position before you run a program 945 APC LIFT FRAME DOWN TIMEOUT The pallet changer was commanded to lower but the down position switch was not contacted before the timeout period Check for foreign objects under the lift frame Verify there is an adequate supply of air pressure and air volume Verify that parameter 320 is correct Check air solenoids for sticking and air release ports for clogging Check pallet down position switch and wiring for damage switch connections for positive electrical contact and the lifting mechanism for proper operation After determining the cause and correcting the problem press TOOL CHANGER RESTORE to enter pallet changer recovery recover the pallet changer and then continue operation 57 Alarms 96 0189 rev L June 2005 946 APC PALLET CLAMP TIMEOUT The pallet in the mill did not clamp in the time allowed Check for foreign objects under the pallet and between the pallet and the clamp plate Verify there is an adequate supply of air pressure and air volume Check air solenoids for sticking and air release ports for clogging Check the pallet cla
212. clamp nut against the bearing sleeve at the motor end to 50 ft lbs EC 400 The ball screw lock nut on the bearing pack end should be torqued to 50 ft lb 10 ft lb for the bearing support end With a T handle wrench hand tighten the clamp nut screw and mark with yellow paint Remove the shaft lock EC 300 Loosen the clamp screw and bearing lock nut and tighten to 4 IN lbs against the bearing Retighten the clamp screw EC 400 EC 1600 Loosen the clamp screw and the bearing lock nut and tighten to 10 ft lbs against the bearing Retighten the clamp screw 11 Replace the bearing support end hard stop 12 POWER ON the machine 13 Rotate the ballscrew by hand to assure free movement 14 Jog the X axis to the left end of travel and check for free movement 15 Replace the rear enclosure panel Y AXIS BALL SCREW Removal 1 Power ON the machine zero return all axes and select handle jog mode 2 Rest the Spindle on a sufficient block Power OFF the machine and remove the axis motor in accordance with Y Axis Motor Removal 3 EC 300 Remove the right side spindle head cover Mechanical Service 106 96 0189 rev L June 2005 Bumper Bumper Bracket 4X BHCS Bearing Locknut 4X SHCS Support Bearing Housing 2X Dowel Pin Bearing Locknut Y Axis Ballscrew Coupling Housing Cover Coupling 5X SHCS Bumper Ball Screw Nut Housing Plane5 Plane6 Plane5 Bumpe
213. closer to the operator so the next tool can be manually installed On an HS 3 the X axis is on the table and there is no advantage to moving it Setting this bit to one will save time 3 EXTRA LARGE TOOLS This parameter enables the user to specify that large tools are considered to be extra large and allow the Tool Pocket table to get set up as shown below This parameter bit should be set to 1 on all mills with the 50 Taper Side Mount Tool Changer It will enable the control to recognize tools that occupy three pockets An example of a tool pocket table with extra large tools 1 2 L 3 4 5 L 6 Note that when this parameter bit is set to 1 the following tool pocket configuration is not allowed see alarm 422 L L 4 HIGH SPD MACHINING This parameter bit enables the High Speed Machining feature This parameter requires an unlock code in order to set the bit to 1 This option requires the Floating Point Co Processor and Floating Point software If this option is turned on when non floating point software is installed the High Speed option will have no effect 5 FAEMAT SPINDLE This bit controls the tool clamp and unclamp sequence for different spindles This bit should be set to 1 when the mill has a Faemat spindle installed Otherwise the bit should be set to 0 This improvement is intended primarily for the VB 1 bridge mill 6 MANUAL TOOL CHANGER This parameter must be set to 1 when a TM 1 has no tool changer
214. cted by first correcting any mechanical problem pressing RESET until the alarms are clear selecting ZERO RET mode and selecting AUTO ALL AXES Some mes sages are displayed while editing to tell the operator what is wrong but these are not alarms See the editing topic for those errors The following alarm list shows the alarm numbers the text displayed along with the alarm and a detailed description of the alarm what can cause it when it can happen and how to correct it 101 COMM FAILURE WITH MOCON MOCON MEMORY FAULT During a self test of communications between the MOCON and main processor the main processor does not respond and one of them is possibly bad Check cable connections and boards This alarm could also be caused by a memory fault which was detected on the MOCON 102 SERVOS OFF Indicates that the servo motors are off the tool changer is disabled the coolant pump is off and the spindle motor is stopped Caused by EMERGENCY STOP motor fault or power failure 103 X SERVO ERROR TOO LARGE Too much load or speed on X axis motor The difference between the motor position and the commanded position has exceeded Parameter 9 X axis Max Error The motor may also be stalled disconnected or the driver failed The servos will be turned off and a RESET must be done to restart This alarm can be caused by problems with the driver motor or the slide being run into the mechanical stops 104 Y SERVO ERROR TOO LARGE Too much load or speed
215. ction is reversed while in a gear change 79 SPINDLE STEPS REV Sets the number of spindle encoder steps per revolution of the spindle This number takes into account the pulley ratio between transmission and spindle plus transmission and encoder 80 MAX SPIN DELAY TIME The maximum delay time control will wait for spindle to get to commanded speed or to get to zero speed Units are milliseconds 81 M MACRO CALL O9000 M code that will call O9000 This parameter can contain a value from 1 through 98 inclusive zero causes no call However it is best to use a value that is not already in use see current M code list Using M37 the value 37 would be entered in parameter 81 for example A program would be written to include the M37 such as G X0 M37 M30 The control would run the program until it got to the M37 It would call program O9000 run that and then return to the point that it left and continue the main program Be aware that if program O9000 contains another M37 it will call itself and keep calling until it fills the stack 9 times and then alarm out with 307 SUBROUTINE NESTING TOO DEEP Note that if M33 for example is used it would override the normal M33 Conveyor Stop function 82 M MACRO CALL O9001 See parameter 81 for description 83 M MACRO CALL O9002 See parameter 81 for description 84 M MACRO CALL O9003 See parameter 81 for description 85 M MACRO CALL O9004 See parameter 81 for description 86 M MACRO CALL O
216. ctivated by pressing Origin If an item is active the remaining hours will be displayed a deactivated item will display instead The maintenance item time is adjusted by using the left and right arrows Pressing the Origin key will reinstate the default time Items are tracked either by the time accumulated while power is on ON TIME or by cycle start time CS TIME When the time reaches zero the message Maintenance Due is displayed at the bottom of the screen a negative number of hours indicates the hours past due This message is not an alarm and does not interfere with machine operation in any way After the necessary maintenance has been performed the operator can select that item on the Scheduled Maintenance screen press the Origin button to deactivate it then press Origin again to reactivate it with the default number of hours remaining WINDOWS GUARDING Polycarbonate windows and guarding can be weakened by exposure to cutting liquids and chemicals that contain amines It is possible to loose up to 10 of the remaining strength annually If degradation is suspected window replacement should occur at no more than a two year interval Windows and guarding should be replaced if damaged or severely scratched Replace dam aged windows immediately WORKLIGHT There are threetype of worklights for the Haas mills Turn off power to the machine at the main breaker before doing any work on the mill Glass
217. d and come back in to the same Z axis axis position and note the indicator reading For a full 4th rotary it is not necessary to move off the pad because pop up on the rotary will only be 0003 Rotate until all 4 locating pads have been indicated The specification is 0003 00762mm or less Receiver Removal Installation Removal Home the A axis before starting the removal procedure 1 Remove the pallet from the receiver 2 Remove the screws from the front and rear Z axis waycovers and slide them away from the rotary base 3 Disconnect the air supply from the machine and bump up parameter 76 to 999999 4 Remove the single bolt securing the switch plate assembly and the switch plate assembly Set safely aside 5 For reference label the 3 rotating union hoses This will help when replacing them 6 Remove the one bolt at the bottom of the rotating union The rotary union is now loose and is pulled straight down to remove Note that there are shim washers between the large fender washer and the bottom of the receiver shaft Receiver To Base Bolts Switch Bracket Bolt Rotating Union Rotating Union Bolt Mechanical Service 126 96 0189 rev L June 2005 7 Remove the 8 bolts securing the receiver to the rotary platter The receiver is now ready to be removed from the machine 8 Working through the operator door use lifting equipment to remove the receiver The receiver clamp plate has 1 2 13 tapped holes in it
218. d for a 5 axis machine 207 Technical Reference 96 0189 rev L June 2005 5 10 HAAS VECTOR DRIVE The Haas vector drive is a current amplifier controlled by the MOCON software using the C axis output The vector drive parameters are a part of the machine parameters and are accessible through the Haas front panel The spindle encoder is used for the closed loop control and spindle orientation as well as rigid tapping if the option is available Spindle speed is very accurate since this is a closed loop control and the torque output at low speeds is to non vector drive spindles 5 11 RESISTOR ASSEMBLY The Resistor Assembly is located on top of the control cabinet It contains the servo and spindle drive regen load resistors SPINDLE DRIVE REGEN RESISTOR A resistor bank is used by the spindle drive to dissipate excess power caused by the regenerative effects of decelerating the spindle motor If the spindle motor is accelerated and decelerated again in rapid succession repeatedly this resistor will get hot In addition if the line voltage into the control is above 255V this resistor will begin to heat This resistor is overtemp protected at 1000 C At that temperature an alarm is generated and the control will begin an automatic shutdown If the resistor is removed from the circuit an alarm may subse quently occur because of an overvoltage condition inside the spindle drive A functional resistor will have a reading of 8 ohms 5 12 POW
219. d off This can be caused by running the axis into a mechanical stop A short in the motor or a short of one motor lead to ground can also cause it 194 B ZERO RET MARGIN TOO SMALL This alarm will occur if the home limit switches move or are misadjusted This alarm indicates that the zero return position may not be consistent from one zero return to the next The encoder Z channel signal must occur between 1 8 and 7 8 revolution of where the home switch releases This will not turn the servos off but will stop the zero return operation 195 B CABLE FAULT Cable from B axis encoder does not have valid differential signals 196 COOLANT SPIGOT FAILURE Spigot failed to achieve commanded location after two 2 attempts 197 MISC SOFTWARE ERROR This alarm indicates an error in the control software Call your dealer 198 PRECHARGE FAILURE During TSC operation the precharge failed for greater than 0 1 seconds It will shut off the feed spindle and pump all at once Check all airlines and the air supply pressure Also check 3 phase power phasing 199 NEGATIVE RPM A negative spindle RPM was sensed 201 PARAMETER CRC ERROR Parameters lost maybe by low battery Check for a low battery and low battery alarm 202 SETTING CRC ERROR Settings lost maybe by low battery Check for a low battery and low battery alarm 203 LEAD SCREW CRC ERROR Lead screw compensation tables lost maybe by low battery Check for low battery and low battery alarm 204 OFFSET C
220. d to change the color of the active G and M code text displayed on the Current Com mands page on an LCD monitor See color values listed for parameter 715 718 Color CMD Axes Load Used to change the color of the axis load text displayed on the Current Commands page on an LCD monitor See color values listed for parameter 715 719 Color CMD Bold Text Used to change the color of the large feed and speed text displayed on the Current Com mands page on an LCD monitor See color values listed for parameter 715 720 Coor Override Used to change the color of the spindle and axis override text displayed on the Current Com mands page on an LCD monitor See color values listed for parameter 715 721 RUNNING RELAY Supports the Machine Data Collection feature which specifies an output relay that will be turned on when the machine is in RUNNING mode Note that this only works when it is set to 32 or larger and specifies an actual relay and when parameter 315 bit 26 STATUS RELYS is set to zero Note also that if SINGLE BLOCK is activated while the machine is running the relay may not turn off at the end of the current block 727 APC CHAIN MIN TIME Defines the time to wait BEFORE some switch fault checks are to begin It should be set to 3000 on all APC mills and zero on all others The units are milliseconds 730 PWR FAULT THRESHOLD 731 PWR FAULT MAX TIME Parameter 730 and 731 support the optional Power Failure Detect Module Parameter 730 PWR FAULT T
221. de entered at the keyboard Warning only 421 NO VALID POCKETS Pocket Table is full of dashes 422 POCKET TABLE ERROR If the machine has a 50 taper spindle there must be 2 dashes between L s L s must be surrounded by dashes 423 X SCALE SCREW MISMATCH Scale induced correction exceeds one motor revolution 424 Y SCALE SCREW MISMATCH Scale induced correction exceeds one motor revolution 425 Z SCALE SCREW MISMATCH Scale induced correction exceeds one motor revolution 426 A SCALE SCREW MISMATCH Scale induced correction exceeds one motor revolution 427 INTERRUPT OVERRUN The control detected an interrupt overrun condition An interrupt occurred before the previous interrupt was completed Call your dealer 429 DISK DIR INSUFFICIENT MEMORY CNC memory was almost full when an attempt was made to read the directory 430 FILE UNEXPECTED END OF INPUT Ending sign not found Check your program An ASCII EOF code was found in the input data before program receive was complete This is a decimal code 26 46 Alarms 96 0189 rev L June 2005 431 FILE NO PROG NAME Need name in programs when receiving ALL otherwise has no way to store them 432 FILE ILLEGAL PROG NAME Check files being loaded Program must be Onnnn and must be at the beginning of a block 433 FILE EMPTY PROG Check your program Between and there was no program found 434 FILE LOAD INSUFFICIENT MEMORY Program received does not fit Check the space available in the LIST
222. der to eliminate the machine as the source of the problem you need to check the spindle and the backlash of the axes as described in the following sections Once machining practices have been eliminated as the source of vibration observe the machine in both operation and cutting air Move the axes individually without the spindle turning and then turn the spindle without moving the axes Isolate whether the vibration comes from the spindle head or from an axis Isolate the source of vibration per Spindle Servo Motors Ball Screws and Gearbox and Spindle Motor sections ACCURACY Before you complain of an accuracy problem please make sure you follow these simple do s and don ts Ensure that the machine has been sufficiently warmed up before cutting parts This will eliminate mispositioning errors caused by thermal growth of the ballscrews see Thermal Growth section Don t ever use a wiggler test indicator for linear dimensions They measure in an arc and have sine cosine errors over larger distances Don t use magnetic bases as accurate test stops The high accel decel of the axis can cause them to move Don t attach magnetic base to the sheet metal of the machine Don t mount the magnetic base on the spindle dogs Don t check for accuracy repeatability using an indicator with a long extension Ensure that test indicators and stops are absolutely rigid and mounted to machined casti
223. djust and repeat steps 2 8 if necessary This step is not necessary for In Line Drive machines Checking with the 0 04 shim assures that the switch is not backed off too far If switch is all the way in this check is not needed CAUTION Remove the tool holder from the spindle before performing the CLAMP switch adjustment Failure to remove it could result in damage to the tool holder the mill table or cause severe personal injury Spindle Cartridge Assembly Drawbar Shim Tool Release Piston Shim 75 96 0189 rev L June 2005 Mechanical Service 3 6 40 TAPER CAROUSEL SIDE MOUNT TOOL CHANGER 40 TAPER CAROUSEL REMOVAL AND INSTALLATION 1 13 12 11 10 9 8 7 6 5 4 3 2 23 22 21 20 19 18 17 16 15 14 24 Carousel Number Disc Tool Pockets Carousel Carousel Cover Carousel Housing Assembly ATC Assembly Base EC 300 Side Mount Tool Changer Assembly 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 21 Load Position ATC Cover 3 Pieces Carousel Number Disc Carousel Tool Pockets Carousel Carousel Housing Assembly ATC Assembly Mounting Bracket Carousel Shaft Nut Pocket Retaining Screw EC 400 Side Mount Tool Changer Assembly Special Tools Required
224. ds 321 RP DRAWBAR UP TIME This is the time required for the drawbar to move up Units are milliseconds 327 X SCALES PER INCH This parameter is used on machines equipped with linear scales This parameter should be set to 25 400 on mills fitted with linear scales On all other mills they should be set to zero 328 Y SCALES PER INCH This parameter is used on machines equipped with linear scales This parameter should be set to 25 400 on mills fitted with linear scales On all other mills they should be set to zero 329 Z SCALES PER INCH This parameter is used on machines equipped with linear scales This parameter should be set to 25 400 on mills fitted with linear scales On all other mills they should be set to zero 330 A SCALES PER INCH This parameter is used on machines equipped with linear scales This parameter should be set to 0 on mills with or without linear scales 331 B SCALES PER INCH This parameter is used on machines equipped with linear scales This parameter should be set to 0 on mills with or without linear scales 333 X SCALES PER REV This parameter is used on machines equipped with linear scales This parameter should be set to 50 000 on mills fitted with linear scales On all other mills they should be set to zero 334 Y SCALES PER REV This parameter is used on machines equipped with linear scales This parameter should be set to 50 000 on mills fitted with linear scales On all other mills they should be set to zero
225. e G47 must have P0 for text engraving or P1 for sequential serial number 314 SUBPROGRAM NOT IN MEMORY Check that a subroutine is in memory or that a macro is defined 315 INVALID P CODE IN M97 M98 G47 M99 The P code must be the name of a program stored in memory without a decimal point for M98 and must be a valid N number for M99 If G47 command then P must be a 0 for text engraving 1 for sequential serial numbers or ASCII value between 32 and 126 316 X OVER TRAVEL RANGE Commanded X axis move would exceed the allowed machine range Machine coordi nates are in the negative direction This condition indicates either an error in the user s program or improper offsets 317 Y OVER TRAVEL RANGE Commanded Y axis move would exceed the allowed machine range Machine coordi nates are in the negative direction This condition indicates either an error in the user s program or improper offsets 318 Z OVER TRAVEL RANGE Commanded Z axis move would exceed the allowed machine range Machine coordi nates are in the negative direction This condition indicates either an error in the user s program or improper offsets 319 A OVER TRAVEL RANGE Commanded A axis move would exceed the allowed machine range Machine coordi nates are in the negative direction This condition indicates either an error in the user s program or improper offsets 320 NO FEED RATE Must have a valid F code for interpolation functions 321 AUTO OFF ALARM Occurs in debug mod
226. e If the alarm reoccurs call your dealer and report the sequence of events that lead to the alarm 506 OPERAND STACK ERROR The macro expression operand stack pointer is in error Cycle power on the machine If the alarm reoccurs call your dealer and report the sequence of events that lead to the alarm 507 TOO FEW OPERANDS ON STACK An expression operand found too few operands on the expression stack Cycle power on the machine If the alarm reoccurs call your dealer and report the sequence of events that lead to the alarm 508 DIVISION BY ZERO A division in a macro expression attempted to divide by zero Re configure expression 509 ILLEGAL MACRO VARIABLE USE See MACROS section for valid variables 510 ILLEGAL OPERATOR OR FUNCTION USE See MACROS section for valid operators 511 UNBALANCED RIGHT BRACKETS Number of right brackets not equal to the number of left brackets 512 ILLEGAL ASSIGNMENT USE Attempted to write to a read only macro variable 513 VARIABLE REFERENCE NOT ALLOWED WITH N OR O Alphabetic addresses N and O cannot be combined with macro variables Do not declare N 1 etc 514 ILLEGAL MACRO ADDRESS REFERENCE Alphabetic addresses N and O cannot be combined with macro variables Do not declare N 1 etc 47 Alarms 96 0189 rev L June 2005 515 TOO MANY CONDITIONALS IN A BLOCK Only one conditional expression is allowed in any WHILE or IF THEN block 516 ILLEGAL CONDITIONAL OR NO THEN A conditional expression was found outs
227. e Assembly 3 Attach a supplied air line to the Air Valve Assembly Supplied air is preset to 45 PSI 4 Using the appropriate regulator adjuster on the Air Valve Assembly set the Low Pressure regulator to 20 PSI CAUTION During the following Steps spillage of hydraulic oil may occur Wear eye protection and have sufficient rags on hand to clean up any leaked oil 5 Set the High Pressure regulator to approximately 5 10 PSI Remember that the Pressure Booster will still provide 40 1 pressure boost 6 Apply air pressure to the Pressure Booster by pressing the yellow pin button on the Air Valve Assembly Do not activate the Pressure Booster for more than five seconds at a time 7 If any air leaks have been noticed during this operation take appropriate measures to fix them before installing the assembly INSTALLATION PRESSURE BOOSTER Position the Pressure Booster and Air Valve assemblies near the working areas 1 Thread the 3 4 NPT Elbow new part into the Fill Port machined into the right side of the Table The Elbow must be installed from the inside Orient the Elbow so that it points down 2 Thread a Hose Barb into the Elbow Tighten with a 1 1 16 socket 3 Lift the Pressure Booster Assembly into the cavity machined underneath the right front of the Table See the Figure on the following page for the approximate location Route the Hydraulic Hose and High and Low Pressure Tubing through the mouse hole Secu
228. e Door Open spare P10 100 External M Fin P11 970 Vector Drive Over Volt VD J1 P12 950 Low Air Oil P13 960 Low Air Lube P14 830 Regen Overheat T1 34 3080T Q1 U30 P60 TB1 P62 P64 P54 P57 P58 P59 K11 K12 K10 K9 K7 Q17 Q30 Q13 Q31 Q14 Q28 Q15 Q29 Q16 Q27 Q10 Q18 Q22 Q21 Q20 Q19 Q23 P31 P33 P32 P34 P35 P36 P37 Q5 Q4 Q3 LE31 FU1 K32 M21 M22 M23 M25 M24 U59 U1 U2 U3 U4 U5 U6 U7 U38 U56 U51 U50 U53 U44 R42 P22 P23 P24 P25 P26 P27 P28 P29 P30 P21 P20 P19 P18 P17 P16 P15 P14 P13 P12 P11 P10 P8 P7 P6 P4 P3 P2 P1 U35 U8 U60 R119 R122 Q39 Q40 LE41 Q35 Q6 Q12 Q24 Q9 FU2 Q14 Q15 Q16 Q10 K33 K34 K35 K36 K37 P5 P9 P38 P39 D10 D1 R3 DISP1 DISP2 DISP3 D12 D27 D11 D26 U61 R126 RI27 P66 P67 P68 P69 U68 U32 U47 U12 U9 U11 U 29 U31 U 25 U 26 U 27 U 28 U52 U15 U16 U17 U18 U10 U36 U37 U46 U13 P65 C45 U57 C46 NE1 U34 U35 Q37 P70 U21 U20 U14 U64 U67 U22 U62 U63 U19 U49 U23 U24 K38 CR5 J10 Q38 U65 U66 UR6 UR2 Q34 Q26 Q25 Q33 Q32 J9 TB2 P71 U54 D22 D20 D19 D18 D17 R4 P40 P41
229. e VIDEO KEYBOARD beneath the MOCON board with the standoffs 7 Reconnect all leads previously removed to their proper connections VIDEO KEYBOARD NOTE Refer to Cable Locations for a diagram of this board 8 Remove the MOCON board as described in Steps 1 5 9 Disconnect all leads to the Video Keyboard Ensure all cables are properly labeled for reconnect ing later The following illustration shows all cable numbers and the locations on the Video Keyboard Electrical Service 188 96 0189 rev L June 2005 10 After all cables have been disconnected unscrew the standoffs taking care to hold the board in place until all standoffs have been removed NOTE If the PROCESSOR board needs replacing please skip the next step 11 Replace the Video Keyboard attaching it to the PROCESSOR board beneath the Video Keyboard with the standoffs 12 Reconnect all leads previously removed to their proper connections PROCESSOR BOARD NOTE Refer to Cable Locations for a diagram of this board 13 Remove the MOCON board as described in Steps 1 7 and the Video Keyboard as described in Steps 8 9 14 Disconnect all leads to the Processor board Ensure all cables are properly labeled for reconnect ing later The following illustration shows all cable numbers and the locations on the Processor board 15 After all cables have been disconnected unscrew the standoffs taking care to hold the board in plac
230. e backlash in the drive assembly Mechanical Service 80 96 0189 rev L June 2005 Radial Alignment of Double Arm to Carousel 1 Rotate the cam box pulley counter clockwise to raise the double arm into the split tool Visually check the centerline alignment of the split tool to the centerline of the tool pocket 2 In order to adjust the radial alignment of the split tool to the double arm loosen the lock ring SHCS and adjust the double arm 3 If the double arm is not aligned in the Y axis with the centerline of the split tool loosen the four cam box SHCS and insert a pry bar between the slots Adjust the cam box until the centerline of the split tool is aligned with the centerline of the tool pocket 4 Torque the cam box SHCS to 80 ft lbs Carousel Double Arm Finger Center Cam Box Movement Double Arm Radial Alignment Tool Release Button 2 Tool Pocket Center Double Arm Cam Box Double Arm Alignment front view Checking Parallelism of Double arm to Table 13 Rotate the cam box pulley clockwise to lower the double arm Remove the split tool from the double arm 14 Rotate the cam box pulley counter clockwise to retract the double arm back to its home position 15 Remove the air supply line from the rear of the machine Switch the inlet and outlet airlines back to their original positions at the back of the ATC assembly Reattach the air supply line the tool pocket holder should retract to its home
231. e coolant Coolant is also carried out with the parts A proper coolant mixture is between 6 and 7 To top off coolant only more coolant or deionized water should be used Be sure that the concentration is still within the range A refractometer can be used to check the concentra tion Coolant should be replaced at regular intervals A schedule should be set and held to This will avoid a build up of machine oil It will also ensure that coolant with the proper concentration and lubricity will be replaced 256 96 0189 rev L June 2005 LUBRICATION SYSTEM All machine lubrication is supplied by the external lubrication system Current lube level is visible in the reservoir Add oil as necessary to maintain proper oil level Warning Do not add lube above the high line marked on the reservoir Do not allow the lube level to go below the low line marked on the reservoir as machine damage could result Oil Fill To High Mark Oil Reservoir Oil Pump Pressure Gauge Air Filter Regulator Hose Barb Shop Air Air Nozzle Air Line MAX MIN Oil Filter Spindle Air Oil Pressure Gauge Rear View External Lubrication System Lube Oil Filter The way lube oil filter element is a 25 micron porous metal filter 94 3059 It is recommended that the filter should be replaced annually or every 2000 hours of machine operation The filter element is housed in the filter body which is located in the oil pump reservoir interna
232. e current limiting resistors After correcting the condition run an M50 to continue machining 650 RP PALLET NOT ENGAGING RP MAIN DRAWBAR This alarm occurs when the Pull Stud cannot properly engage the Ball Pull Collet If this happens the Ball Pull Collet has been pushed down into the Collet Housing and pallet clamping is not possible Check alignment of the H frame with the adjustable Hard Stops Check the Pallet Pull Studs and the RP Main Drawbar Ball Collet for damage or obstruction Remove any debris that may have entered the Collet Check that the six balls in the collet float within the holes If lift to the H frame has been lost following a collet jammed condition orientation of the pallet is not guarantied Check orientation of the pallet as well Zeroing of the A Axis is not safe if lift has been lost It may be necessary to remove workpiece from the pallet After correcting the condition run an M50 to continue machining 651 Z AXIS IS NOT ZEROED The Z axis has not been zeroed In order to continue Tool Change Recovery the Z axis must be zeroed Once the Z axis has been zeroed continue with Tool Change Recovery 652 U ZERO RET MARGIN TOO SMALL This alarm will occur if the home limit switches move or are misadjusted This alarm indicates that the zero return position may not be consistent from one zero return to the next The encoder Z channel signal must occur between 1 8 and 7 8 revolution of where the home switch releases This will
233. e flex plates to ensure they are parallel to the coupling halves Slide the new coupling onto the motor shaft until the coupling half is flush to the end of the shaft NOTE The slot in the locking collar must be positioned 45 degrees between the bolt hole pattern of the coupler If improperly aligned the coupler will not have enough clamping force on the ball screw or motor shaft Refer to the diagram in coupling replacement section 2 Reconnect all wiring to the motor 3 Align the key on the motor shaft Slide the motor into the coupling housing inserting the end of the ball screw into the motor coupling 4 Reinstall and tighten down the four SHCS that hold the motor to the coupling housing 5 Tighten the SHCS on the motor coupling at the ball screw Place a drop of blue Loctite on the screw before inserting 6 Replace the housing cover and fasten the BHCS 7 Replace the rear enclosure panel 8 Check for backlash in the X axis ball screw Troubleshooting section or noisy operation 9 Set grid offset Caution Work offsets will change Y AXIS MOTOR Removal 1 Power ON the machine Zero return all axes and put machine in HANDLE JOG mode 2 Remove the rear enclosure panel 97 96 0189 rev L June 2005 Mechanical Service 3 Jog the X axis until the Y axis motor can be easily accessed from the rear 4 Install the column shipping bolts if available or place a block of wood on the column cas
234. e in determining the limits So if this parameter is set to 3 then in the above example the rotary will be allowed to go up to 15 degrees due to encoder scaling Similar results will be achieved when the SCALE FACT X bit is set to 1 based on SCALE X LO and SCALE X HI bits 0 To deactivate this feature on any axis the PLUS TRAVEL LIMIT should be set to zero 621 Y Axis Plus Travel Limit See Parameter 620 622 Z Axis Plus Travel Limit See Parameter 620 623 A Axis Plus Travel Limit See Parameter 620 624 B Axis Plus Travel Limit See Parameter 620 629 Sp Axis Plus Travel Limit See Parameter 620 626 U Axis Plus Travel Limit See Parameter 620 627 V Axis Plus Travel Limit See Parameter 620 628 W Axis Plus Travel Limit See Parameter 620 630 Tt Axis Plus Travel Limit See Parameter 620 644 X Axis Indexer Increment Note that only parameters 647 and 648 for the A and B axes are intended to be used and only on Horizontal Mills fitted with a Rotary Indexer The Rotary Indexer is a device that holds a part to be ma chined and rotates in one degree increments It can rotate only in rapid motion G00 it cannot rotate in a feed motion G01 It can be jogged by pressing a jog button or with a jog handle Before it can be rotated air is applied to lift the indexer from its clamped position The message A UNCLMP for example will appear at the bottom of the screen and remain as long as the rotary indexer is in the up position When the commanded
235. e motor end of the ball screw two or three turns but do not tighten 6 Loosen all of the SHCS on the bearing sleeve approximately 1 4 turn then torque to 15 ft lb This ensures the ball screw is installed and runs parallel and flat to the linear guides and the saddle 7 Tighten the ball screw against the clamp nuts as follows Tighten the clamp nut on the motor housing end of the ball screw to 15 ft lb Tighten the SHCS on the clamp nut Place a spanner nut over the clamp nut on the support bearing end of the ball screw and slowly tighten to 4 inch lb Remove the spanner nut Tighten the SHCS on the clamp nut with Loctite and mark it with yellow marking paint 8 Reinstall and tighten the hard stop on the bearing support 9 Reinstall the axis motor as described in the specific axis motor installation section 10 Check for backlash in the ball screw see the Troubleshooting section or noisy operation 11 Set the grid offset 103 96 0189 rev L June 2005 Mechanical Service 3 9 BALL SCREW Please read this section in its entirety before attempting to remove or replace the ball screws TOOLS REQUIRED Torque wrench Spanner nut X AXIS BALL SCREW 4X BHCS 2X SHCS 2X SHCS 6X SHCS 4X SHCS Coupling Housing Cover Coupling Motor Bumper Support Bumper Bearing Locknut Bearing Locknut Support Bearing Housing X Axis Ballscrew EC 300 X Axis Ballscrew Coupli
236. e only 322 SUB PROG WITHOUT M99 Add an M99 code to the end of program called as a subroutine 323 ATM CRC ERROR Advanced Tool Management ATM variables lost maybe by low battery Check for a low battery and low battery alarm 324 DELAY TIME RANGE ERROR P code in G04 is greater than or equal to 1000 seconds over 999999 milliseconds This alarm can also be generated by entering an invalid M95 time format 325 QUEUE FULL Cycle power on the machine If the alarm reoccurs call your dealer and report the sequence of events that lead to the alarm 42 Alarms 96 0189 rev L June 2005 326 G04 WITHOUT P CODE Put a Pn n for seconds or a Pn for milliseconds 327 NO LOOP FOR M CODE EXCEPT M97 98 L code not used here Remove L Code 328 INVALID TOOL NUMBER Tool number must be between 1 and the value in Parameter 65 329 UNDEFINED M CODE That M code is not defined and is not a macro call 330 UNDEFINED MACRO CALL Macro name O90nn not in memory A macro call definition is in parameters and was accessed by user program but that macro was not loaded into memory 331 RANGE ERROR Number too large 332 H AND T NOT MATCHED This alarm is generated when Setting 15 is turned ON and an H code number in a running program does not match the tool number in the spindle Correct the Hn codes select the right tool or turn off Setting 15 333 X AXIS DISABLED Parameter has disabled this axis 334 Y AXIS DISABLED Parameter has disabled this axis 335 Z
237. e pallet changer to operate Set the parameter bit INVIS AXIS to one for the axis that the pallet changer is installed on 950 APC ILLEGAL SWITCH CONDITION LIFT FRAME The pallet changer lift frame switches indicate that the pallet changer lift frame is up and down at the same time Verify there is an adequate supply of air pressure and air volume Check the adjustment of the lift frame position switches and for debris on the switches Check switch electrical connections and wiring This may be a false alarm if the pallet changer was out of position by 90 degrees 20 when a pallet change was in progress After correcting the cause press Tool Changer Restore to enter pallet changer recovery recover the pallet changer and then continue operation 951 APC ILLEGAL SWITCH CONDITION PALLET CLAMP The pallet changer clamp switches indicate that the pallet changer is clamped and unclamped at the same time Check the adjustment of the pallet clamp switches and for debris on the switches Check switch electrical connections and wiring After correcting the cause press Tool Changer Restore to enter pallet changer recovery recover the pallet changer and then continue operation 952 APC MISLOCATED LIFT FRAME The pallet changer lift frame is not in the expected position The lift frame was either down when expected to be up or up when expected to be down For example the lift frame must be up while rotating The lift frame must be down when a pallet change
238. e slide assembly and reinstall them both Reattach the cover plate and recheck the clearance Both ends of the double arm are separately adjusted 3 Re align the double arm to the spindle and tool pocket Refer to double arm alignment instructions in the previous ATC alignment section 40 TAPER SMTC POCKET REMOVAL AND INSTALLATION Removal 1 Turn the machine on and rotate the carousel to the pocket you want to change Remove the sheetmetal in order to gain access to pocket limit switches Remove the sheetmetal disc covering the carousel 2 Press lt Tool Changer Restore gt Press lt Y gt three times 3 Remove the four SHCS that hold the pocket stop Remove the shoulder bolt from the back of the pocket slide Carousel Cam Follower Groove Tool Pocket Stop 4X SHCS Tool Pocket NOTE The machine must be in Tool Changer Recovery Mode to perform the next step 4 Press lt v gt to retract the air cylinder shaft Manually lower the pocket and remove the pocket retaining screw See the following figure 89 96 0189 rev L June 2005 Mechanical Service Tool Pocket Load Position Tool Pocket Mounting FHCS Carousel Slider Position Pocket Orientation Tabs Pocket Stop 5 Remove the tool changer pocket by carefully maneuvering the pocket out of the carousel taking care not to drop the pocket slide NOTE If the carousel is to be replaced skip to the Carousel Removal and Installation secti
239. e stalled disconnected or the driver failed The servos will be turned off and a RESET must be done to restart This alarm can be caused by problems with the driver motor or the slide being run into the mechanical stops 612 U SERVO OVERLOAD Excessive load on U axis motor This can occur if the load on the motor over a period of several seconds or even minutes is large enough to exceed the continuous rating of the motor The servos will be turned off when this occurs This can be caused by running into the mechanical stops It can also be caused by anything that causes a very high load on the motors 49 Alarms 96 0189 rev L June 2005 613 COMMAND NOT ALLOWED IN CUTTER COMP At least one command in the highlighted block cannot be executed while cutter compensation is active Block Delete characters and M codes such as M06 M46 M50 and M96 are not allowed Your program must have a G40 and a cutter compensation exit move before these can be commanded 614 V SERVO OVERLOAD Excessive load on V axis motor This can occur if the load on the motor over a period of several seconds or even minutes is large enough to exceed the continuous rating of the motor The servos will be turned off when this occurs This can be caused by running into the mechanical stops It can also be caused by anything that causes a very high load on the motors 615 W SERVO OVERLOAD Excessive load on W axis motor This can occur if the load on the motor over a period of
240. e the fuse Haas p n 93 1089 If the fuse blows again the amplifier may be damaged in which case the amplifier needs to be replaced The POWER PCB contains three amp fuses located at the top right FU1 FU2 FU3 If the machine is subject to a severe overvoltage or a lightning strike these fuses will blow and turn off all of the power Replace these fuses only with the same type and ratings FU 4 5 and 5A protect the chip conveyor FU6 is only used with 3 phase motors Size Fuse Name Type Rating Voltage Location amps 5mm FU1 FU3 Slo Blo 250V PSUP pcb upper right 1 4 F1 Ultra fast 15 250V Amplifier X Y Z A B 5mm FU4 5 Fast blow 5A 250V PSUP bottom right corner 211 Technical Reference 96 0189 rev L June 2005 5 15 SPARE USER M CODE INTERFACE The M code interface uses outputs M21 25 and one discrete input circuit M codes M21 through M25 will activate relays labeled M21 25 These relay contacts are isolated from all other circuits and may switch up to 120V AC at three amps The relays are SPDT WARNING Power circuits and inductive loads must have snubber protection The M FIN circuit is a normally open circuit that is made active by bringing it to ground The one M FIN applies to all of the user M codes The timing of a user M function must begin with all circuits inactive that is all circuits open The timing is as follows The Diagnostic Data display page may be used to observe the state of these s
241. e until all standoffs have been removed 16 Replace the Processor board attaching it to the electrical cabinet beneath the Processor board with the standoffs 17 Reconnect all leads previously removed to their proper connections I O BOARD NOTE Refer to Cable Locations for a diagram of this board 1 Follow all precautions noted previously before working in the electrical cabinet 2 Turn the main switch upper right of electrical cabinet to the off position 3 Using a large flat tip screwdriver loosen the three screws on the cabinet door and then open the door enough to safely work on the electrical panel 4 Disconnect all leads to the Input Output board and move aside for removal Ensure all cables are properly labeled for reconnecting later The following illustration shows all cable numbers and the locations on the I O board 5 Remove the board by first removing the twelve screws that fasten it to the cabinet Take care to hold the board in place until all screws have been removed 6 Replace the I O board attaching it to the cabinet with the twelve screws previously removed 7 Reconnect all leads to the I O board at this time 189 Electrical Service 96 0189 rev L June 2005 POWER amp LOW VOLTAGE SUPPLY POWER BOARD NOTE Refer to Cable Locations for a diagram of this board 1 Follow all precautions noted previously before working in the electrical cabinet 2 Turn the main switch u
242. e up Use a C clamp to press the keys together to seat them against the drawbar Torque the 5 16 18 retaining bolts to 30 ft lb 71 Mechanical Service 96 0189 rev L June 2005 Verify the operation of the spindle by running it If there is excessive vibration loosen the bolts to the spindle cartridge and spindle head Run the spindle at 1000 rpm and snug the bolts Stop the spindle and tighten the bolts DRAWBAR REPLACEMENT 50 TAPER 1 Remove the head covers Refer to the Head Covers Removal Installation section 2 Remove the tool release piston Refer to the 50 Taper Spindle TRP Removal section 3 Remove the TSC extension tube if the machine is equipped with Through the Spindle Coolant option Refer to the TSC section 4 Remove the six bolts holding the spindle cap to the machine 5 Remove the drawbar 6 Thoroughly coat the replacement drawbar with grease including the end of the shaft where the four holding balls are located CAUTION Excess grease may cause the drawbar to hydraulic lock preventing the full stroke of the drawbar 7 If machine is equipped with Through the Spindle Coolant option grease the O rings 8 Insert six new balls in the replacement drawbar and insert into the spindle shaft Be sure that as the shaft is installed the balls do not fall out of the bores in the drawbar CAUTION Insert the drawbar gently so the O rings are not damaged DO NOT use a hammer to for
243. e was an M17 or M18 commanded in program restart These commands are illegal in program restart 347 INVALID OR MISSING E CODE All 5 axis canned cycles require the depth to be specified using a positive E code 348 MOTION NOT ALLOWED IN G93 MODE This alarm is generated if the mill is in Inverse Time Feed mode and a G12 G13 G70 G71 G72 G150 or any Group 9 motion command is issued 349 PROG STOP WITHOUT CANCELING CUTTER COMP An X Y cutter compensation exit move is required before a program stop 350 CUTTER COMP LOOK AHEAD ERROR There are too many non movement blocks between motions when cutter compensation is being used Remove some intervening blocks 351 INVALID P CODE In a block with G103 Block Lookahead Limit a value between 0 and 15 must be used for the P code 43 Alarms 96 0189 rev L June 2005 352 AUX AXIS POWER OFF Aux C U V or W axis indicate servo off Check auxiliary axes Status from control was OFF 353 AUX AXIS NO HOME A ZERO RET has not been done yet on the aux axes Check auxiliary axes 354 AUX AXIS DISCONNECTED Aux axes not responding Check auxiliary axes and RS 232 connections 355 AUX AXIS POSITION MISMATCH Mismatch between machine and aux axes position Check aux axes and interfaces Make sure no manual inputs occur to aux axes 356 AUX AXIS TRAVEL LIMIT Aux axes are attempting to travel past their limits 357 AUX AXIS DISABLED Aux axes are disabled 358 MULTIPLE AUX AXIS Can only move one auxilia
244. ed and the proper parameters are set If this switch is set but bit 19 is not then the winding switching will only be done when the spindle is at rest depending on the target speed of the spindle 19 DEL Y SWITCH ON FLY This bit enables switching on the fly as the spindle motor is accelerating or decelerating through the switch point If bit 18 is not set this switch will be ignored 20 5 AX TOFS X This bit is used with the G143 modal 5 axes tool length compensation on machines with a Gimbaled Spindle If it is set to 1 this means that when the corresponding rotary axes is moved the sign of the X Position must be inverted Normally this bit should be set to 0 21 5 AX TOFS Y This bit is used with the G143 modal 5 axes tool length compensation on machines with a Gimbaled Spindle If it is set to 1 this means that when the corresponding rotary axes is moved the sign of the Y Position must be inverted Normally this bit should be set to 0 22 B C 5 AXES This bit is used with the G142 modal 5 axes tool length compensation on machines with a Gimbaled Spindle The B axis normally moves the A axis but if this is not true this bit can be set to change which is the inner axis Normally this bit should be set to 0 238 Parameters 96 0189 rev L June 2005 23 TL CHGR DOOR SWITCH Horizontal tool carousel door configuration This bit specifies the Horizontal Mill tool carousel door configuration If it is set to 0 this indicates the conf
245. ed out carefully To service the Pallet Clamp Piston assembly the entire pallet changer assembly must be removed 1 Remove all front interior sheet metal pieces attached to the Pallet Changer in addition to steps 6 9 NOTE If enough lift capacity is available 2 000 lbs on an extended arm the rotary tables pallets and frame support may stay in place otherwise they must be removed described in steps 6 10 and Frame Support Removal Lifting Apparatus 2 Disconnect the Rotary Table power cables remove the air lines located on the lower left of the Pallet Changer base and remove the 7 bolts that attach the piston to the shaft NOTE Mark the air lines for proper re assembly 3 Disconnect the pallet clamp switch and remove the 10 5 8 16 socket head bolts holding the Pallet Changer base to the main base casting 115 Mechanical Service 96 0189 rev L June 2005 4 Bolt in lifting tools and lift out Disconnect the un clamp air fitting on the bottom side of the Piston Cover Plate Remove the Piston Cover the Pallet Clamp Piston and P C Shaft to service the assembly To service the Thrust Bearing assembly see Frame Support Removal and steps 1 10 in the Pallet Changer Disassembly section and remove the support frame which will expose the thrust bearings and thrust washers Note The weight of the table rests on the thrust bearing Lifting Points Drive Plate Thrust Washer Roller Cage Thrust
246. ed to zero and the tool change is performed 5 The Y axis is moved to the position specified by parameter 254 6 The air door is commanded to close 7 There is a delay specified by parameter 223 to allow the door to close fully 233 Parameters 96 0189 rev L June 2005 255 CONVEYOR TIMEOUT The number of minutes the conveyor will operate without any motion or keyboard action After this time the conveyor will automatically shut off Note that this parameter value will cause the conveyor to turn off even if the intermittent feature is functioning Note also that if this parameter is set to zero the chip conveyor will shut off immediately i e pressing CHIP FWD or CHIP REV will not turn it on 256 PALLET LOCK INPUTThe setting for EC300 must be 26 the EC400 must be 32 and the MDC1 must be 27 or alarm 180 will occur when the spindle is turned on 257 SPINDL ORIENT OFSETIf the machine is equipped with a spindle vector drive as set in bit 7 of Parameter 278 this bit sets the spindle orientation offset The offset is the number of encoder steps between the Z pulse and the correct spindle orientation position It is used to orient the spindle properly anytime it needs to be locked such as prior to a tool change or orient spindle command 258 COLD SPINDLE TEMPThe first time Cycle Start is pressed after the machine has been turned on the control will compare the microprocessor temperature in degrees Fahrenheit against the value of this paramete
247. egal transition of count pulses in jog handle encoder This alarm usually indicates that the encoder has been damaged and encoder position data is unreliable This can also be caused by loose connectors 232 SPINDLE TRANSITION FAULT Illegal transition of count pulses in spindle encoder This alarm usually indicates that the encoder has been damaged and encoder position data is unreliable This can also be caused by loose connectors at the MOCON 233 JOG HANDLE CABLE FAULT Cable from jog handle encoder does not have valid differential signals 234 SPINDLE CABLE FAULT Cable from spindle encoder does not have valid differential signals 235 SPINDLE Z FAULT Encoder marker pulse count failure This alarm usually indicates that the encoder has been damaged and encoder position data is unreliable This can also be caused by loose encoder connectors 38 Alarms 96 0189 rev L June 2005 236 SPINDLE MOTOR OVERLOAD The spindle motor is overloaded 237 SPINDLE FOLLOWING ERROR The error between the commanded spindle speed and the actual speed has exceeded the maximum allowable as set in Parameter 184 238 AUTOMATIC DOOR FAULT The automatic door was commanded to operate but did not complete the operation The door was 1 Commanded to close but failed to contact the closed switch in the time allowed 2 Commanded to open but failed to contact the opened switch not all doors have an opened switch in the time allowed or 3 Com manded to open but did no
248. egreasers or solvents to clean Ball Screws or their components Do not use water based cleaners as they may cause rust 4 Jog the ball nut to the other end of its travel If metal flakes are now present on the screw threads you may have wear issues 5 Re lubricate screw threads before returning the machine to service DRIVE FAULT OVERCURRENT Y axis motor overcurrent Alarm not cleared Check Y axis parameters Check the ball screw for binding Check motor and cable for shorts Check amplifier 20 Troubleshooting 96 0189 rev L June 2005 1 4 PALLET CHANGER EC 400 PALLET CHANGER OVERVIEW When the automatic pallet changer APC is at rest the pallet is clamped the pallet at the load station is at home position and the APC door is closed The H frame Down solenoid is on the safety solenoid is on and the H frame is down with the H frame lock pin engaged in the bumper mount The APC servo has been zero returned using the APC home sensor When a pallet change is commanded the following events occur in this order 1 H frame down switch is checked to verify down status 2 Z axis rapids if necessary to a position specified by the grid offset amp parameter 64 3 A axis rapids if necessary to position specified by grid offset amp parameter 224 this may involve a raise amp lower of the pallet 4 The lifting and lowering of the A axis platter is monitored by a sensor assembly located
249. elated functions on and off The left and right cursor arrows are used to select the function being changed All values are 0 or 1 only The function names are 0 REV ENCODER Used to reverse the direction of encoder data 1 REV POWER Used to reverse direction of power to motor 2 REV PHASING Used to reverse motor phasing 3 DISABLED Used to disable the X axis 4 Z CH ONLY With A only indicates that no home switch 5 AIR BRAKE With A only indicates that air brake is used 6 DISABLE Z T Disables encoder Z test for testing only 7 SERVO HIST Graph of servo error for diagnostics only 8 INV HOME SW Inverted home switch N C switch 9 INV Z CH Inverted Z channel normally high 10 CIRC WRAP With A only causes 360 wrap to return to 0 11 NO I IN BRAK With A only removes I feedback when brake is active 12 LOW PASS 1X Adds 1 term to low pass filter 13 LOW PASS 2X Adds two terms to low pass filter 14 OVER TEMP NC Selects a normally closed overheat sensor in motor 15 CABLE TEST Enables test of encoder signals and cabling 16 Z TEST HIST History plot of Z channel test data 17 SCALE FACT X If set to 1 the scale ratio is interpreted as divided by X where X depends on bits SCALE X LO and SCALE XHI 18 INVIS AXIS Used to create an invisible axis 19 ALM ON LM SW Rotary alarms at the limit switch 20 CK TRAVL LIM A Rotary travel limits are used On mills with the Gimbaled Spindle used on the VR series m
250. elt is on the transmission shaft properly 3 Tension the encoder belt to 2 10 lb 4 Install the TRP 139 Mechanical Service 96 0189 rev L June 2005 3 18 50 TAPER SPINDLE TRP REMOVAL 1 For TSC equipped machines place a tool holder in the spindle 2 Remove the screws that hold the lower Y axis way cover from the head and lower the way cover 3 For TSC equipped machines the coolant union and extension tube must be removed before proceeding They both have left handed threads CAUTION Do not remove pipe connectors from the coolant union Removing any pipe connector from the union will void your warranty on the union Use wrenches only on the SAE hose connector and the bottom nut of the Coolant Union See arrows below Left Hand Threads SAE Hose Connector a Loosen the SAE hose connector at the Check Valve Assembly with a wrench right arrow in diagram Do not use a wrench on the pipe connector attached to the Coolant Union the Union will be damaged and the Warranty voided b Carefully cut off the clear plastic Drain Hose at the side of the Coolant Union It is safest to use scissors or snips Cut it close to the connector since the hose will be re used on the replacement union Do not cut the Black coolant hose Note If you are not replacing the Union leave the Drain Hose attached to the union c Remove the coolant union from the Extension Tube bottom arrow in diagram using two wrenches 7 8 and 15 16 T
251. enoid assembly is located Four solenoid valves are used to provide the responses required for the pallet change operation LUBRICATION SUPPLY LINES An oil supply line from the lube air panel on the right side of the machine attaches to the lube tube adaptor It provides lubrication to the rotary table drawbar which carries oil mist from the air blast plug up the center of the main drawbar to the drawbar and pallet nut 5 20 DIAGNOSTIC DATA The ALARM MSGS display is the most important source of diagnostic data At any time after the machine completes its power up sequence it will either perform a requested function or stop with an alarm Refer to the Alarms section for a complete list of alarms their possible causes and some corrective action If there is an electronics problem the controller may not complete the power up sequence and the CRT will remain blank In this case there are two sources of diagnostic data these are the audible beeper and the LED s on the processor PCB If the audible beeper is alternating a second beep there is a problem with the main control program stored in EPROM s on the processor PCB If any of the processor electronics cannot be accessed correctly the LED s on the processor PCB will or will not be lit If the machine powers up but has a fault in one of its power supplies it may not be possible to flag an alarm condition If this happens all motors will be kept off and the top left corner of the
252. ents unauthorized use of the 5th B axis It can only be set to 1 with a magic code When it is set to zero it revents the user from altering setting 78 and prevents the user from zeroing the parameter 151 DISABLED bit When this parameter bit is changed to zero setting 78 will be returned to OFF and the parameter 151 DISABLED bit will be set to 1 Note that when parameter 209 HORIZONTAL is set to 1 setting 78 is unavailable and not displayed because the B axis is used for the tool changer 16 TOOL CAGE DOOR Supports the machines fitted with the side mount tool changer cage door When a machine has a cage door this parameter must be set to 1 On all other machines it must be set to zero 17 VIBRATION SENSOR This parameter enables the vibration sensor When it is set to 1 the output from the sensor will be converted to Gs and displayed on the Current Commands Tool Load screen When this parameter is set to zero NO SENSOR will be displayed instead 18 HIGH Z TOOL CHANGER Setting this parameter to 1 and commanding either a G28 move of all the axes or a pressing Second Home will cause the Z axis to move to the maximum position prior to moving to machine zero When this parameter is set to zero the Z axis will move directly to machine zero Previously the Z axis would move directly to machine zero regardless of this parameter bit This enhancement was made primarily for the Gantry Router mills 19 PAL LOAD AUTODOOR This bit tells the control tha
253. eplace MOCON PCB Electrical Service If spindle is still not turning replace spindle drive Electrical Service NOTE Before installing a replacement spindle the cause of the previous failure must be determined NOISE Check the tooling balanced tooling will run smoother possible reducing the noise Check for misalignment between the motor and the spindle If misalignment is noted loosen the motor mount ing bolts run the spindle at 1000 rpm and then tighten the mounting bolts Remove the coolant union and run the spindle if the spindle runs quiter the coolant union may need replacing OVERHEATING Run program O02021 with the air pressure to the spindle at 30 psi Program time is approximately 2 hours If possible run the program overnight by changing M30 to M99 so it can repeat Adjust spindle speed override depending on maximum spindle speed of machine Set at 100 for 8 000 RPM machines Set at 120 for 12 000 RPM machines N100 N200 N1000 N2000 S750M3 M97 P1000 L15 S7500M3 S10000M3 G04 P600 M97 P2000 L15 G04 P30 G04 P30 S2500M3 M30 S500 M3 S500M3 G04 P600 G04 P150 G04 P150 S5000M3 M99 M99 G04 P900 If at any time during this procedure the spindle temperature rises above 150 degrees start the procedure over from the beginning and follow the steps below If the temperature rises above 150 a second time contact your dealer NOTE Once run in program is complete res
254. er To IOPCB PSUP P27 P57 Ext Drawbar Mtr Resitor HOPT P3 P58 810A PC main DB fwd rev BF load Q bar P59 810 Main DB Up Dwn Shuttle In Out Mtrs P60 860A 5V 12V Logic Pwr IOPCB PSUP 27 P61 540 Outputs Cable 24 55 MOCON P14 P62 540A Outputs Cable Mcd Relay MCD Relay P1 P63 550 Inputs Cable MOCON P10 P64 520 Outputs Cable 8 15 MOCON P12 P65 510 Outputs Cable 0 7 MOCON P11 P66 M27 Air Blast P67 M28 Beeper P68 310 Pallet CW CCW P69 220 TC Air Door P70 530 Outputs Cable 16 23 MOCON P13 TB1 M21 24 Probe M Fin User Spare TB2 M25 User Spare 269 Cable Locations 96 0189 rev L June 2005 PLUG CABLE TO LOCATION PLUG P1 700B PROCESSOR 850 P2 KEYPAD P3 700A CYCLE START HOLD SWITCHES P4 730 SP LOAD METER P5 P6 AUX FPANEL J1 J2 REMOTE JOG HANDLE J3 750 MOCON P18 J5 MIKRON ONLY J7 EXTERNAL KEYBOARD J12 860C FT PANEL FAN See Keyboard Diagnostic section of this manual for Troubleshooting information SERIAL KEYBOARD INTERFACE PCB WITH HANDLE JOG P3 J14 P2 J2 J12 J4 J6 P1 J11 J9 J10 P6A P8 P7 P6 P4 J3 J7 KEYBOARD KEYPAD SPEAKER GND SUPPLY SPARE 1 SPARE 2 RS 232 OP SW TC METER PAL 1 AUX FRONT PANEL PAL 2 SPARE START HOLD J1 P5 RJH 850 PAL READY Cable Locations 270 96 0189 rev L June
255. ere are some parameters that are used as a divisor and therefore must never be set to zero If the problem cannot be corrected by parameters cycle power on the machine If the alarm reoccurs call your dealer and report the sequence of events that lead to the alarm 179 LOW PRESSURE TRANS OIL Transmission oil is low or low pressure condition in oil lines 180 PALLET FIXTURE NOT CLAMPED The Pallet Fixture clamped input indicates that the pallet or fixture is not clamped and it is unsafe to run the spindle jog an axis or start a part program by pressing CYCLE START This could also indicate that a previous pallet change was incomplete and the pallet changer needs to be recovered 182 X CABLE FAULT Cable from X axis encoder does not have valid differential signals 183 Y CABLE FAULT Cable from Y axis encoder does not have valid differential signals 184 Z CABLE FAULT Cable from Z axis encoder does not have valid differential signals 185 A CABLE FAULT Cable from A axis encoder does not have valid differential signals 186 SPINDLE NOT TURNING Status from spindle drive indicates it is not at speed when expected 187 B SERVO ERROR TOO LARGE Too much load or speed on B axis motor The difference between the motor position and the commanded position has exceeded Parameter 159 The motor may also be stalled disconnected or the driver failed The servos will be turned off and a RESET must be done to restart This alarm can be caused by problems with
256. es F 65 deg C This can be caused by an extended overload of the motor such as leaving the slide at the stops for several minutes 138 A AXIS MOTOR OVERHEAT Servo motor overheat The temperature sensor in the motor indicates over 150 degrees F 65 deg C This can be caused by an extended overload of the motor such as leaving the slide at the stops for several minutes 33 Alarms 96 0189 rev L June 2005 139 X MOTOR Z FAULT Encoder marker pulse count failure This alarm usually indicates that the encoder has been damaged and encoder position data is unreliable This can also be caused by loose encoder connectors 140 Y MOTOR Z FAULT Encoder marker pulse count failure This alarm usually indicates that the encoder has been damaged and encoder position data is unreliable This can also be caused by loose encoder connectors 141 Z MOTOR Z FAULT Encoder marker pulse count failure This alarm usually indicates that the encoder has been damaged and encoder position data is unreliable This can also be caused by loose encoder connectors 142 A MOTOR Z FAULT Encoder marker pulse count failure This alarm usually indicates that the encoder has been damaged and encoder position data is unreliable This can also be caused by loose encoder connectors 143 SPINDLE ORIENTATION LOST Spindle orientation lost during a tool change operation This can be caused by failure of encoder cables belts MOCON or vector drive 144 TIMEOUT CALL YOUR DEALER Time al
257. et Changer H frame to Pallet alignment procedure PALLET CHANGER H FRAME TO PALLET ALIGNMENT There are two stages to properly aligning the pallet changer H frame and the pallets The first is to align the pallets to the H frame The second is to align the pallet load station to the H frame Stage 1 1 Go to the parameter page and scroll to find parameter 76 Write down the current value Adjust parameter 76 to a large number e g 99999999999 this will delay the low air alarm 2 Enter Debug mode Go to the Alarms page key in DEBUG and press Enter and scroll to the Pos Raw Data page 3 Jog the Z axis until the pins on the H frame are aligned with the holes in the pallet Enter the value of Z axis Actual into parameter 64 4 Enter the Pallet Changer Restore page press Tool Changer Restore and select the pallet changer restore option 5 Home the Z axis and verify the pallet to H frame alignment 6 Unclamp the pallet and then turn down the main air pressure regulator to approximately 10 psi Mechanical Service 122 96 0189 rev L June 2005 7 Press the key to raise the pallet Turn up the air pressure at the air regulator slowly and verify that the H frame and pallet are aligned To lower the H frame and pallet raise the air pressure and press the button for pallet down 8 If the alignment is incorrect repeat the steps to set parameter 64 9 Once the alignment is complete restore the main air pressure re
258. et the air pressure back to 25psi prior to checking spindle temperature If the spindle fails this test for any reason check the following Check for correct amount of lubrication NOTE Over lubrication is a common source of overheating Check the oil flow carefully Troubleshooting 9 96 0189 rev L June 2005 Ensure that the correct oil is being used refer to Maintenance Schedule STALLING LOW TORQUE Generally complaints of stalling or low torque relate to incorrect tooling or machining practices A spindle that is tending to seize will yield a poor finish and run very hot and very loud Investigate machining problems before concluding that the problem exists with the spindle or spindle drive SPINDLE DRIVE Vector Drive To properly troubleshoot the Vector Drive use the following questions as a guide What alarms are generated When does the alarm occur Is the Vector Drive top fault light on Is there a fault light on any of the servo amplifiers Does the alarm reset Does the spindle motor turn at all Does the spindle turn freely by hand Have the C axis parameters been confirmed What is the input voltage to the vector drive unit What does the DC Bus voltage measure 320 VDC to 345 VDC Does the DC Bus voltage displayed on the diagnostic page match the measured DC Bus voltage All of the questions above must be answered The DC Bus voltage should be between
259. etes an alarm is generated the servos are turned off and all motion stops The control will operate as though the zero search was never performed The RESET can be used to turn servos on but you can jog that axis only slowly 5 18 Y AXIS BRAKE MOTOR The servo brake motor compensates for the weight of the spindle head The brake is released when the servo motors are activated however the disk brake engagement spline may produce a small noise when the head is in motion this is normal A parameters governs the ability of the brake motor therefore parameter 25 Y Axis Torque Preload set correctly Check the parameters sections for the correct value 5 19 PALLET CHANGER FOR THE EC SERIES EC 300 ROTARY TABLE HRT210C3 The rotary table is a HAAS 210 equipped with a special platter compatible with the pallet operation The table is mounted on the pallet changer casting and a drive shaft bearing assembly is inserted into its spindle on the brake side A nut housing is inserted into spindle of the table on the platter side and an air blast manifold is mounted onto the table platter LOAD STATION EC 300 The load station uses the 2 built in rotary table to index the part while in the the load station Hold the Pallet Index button and the pallet will rotate The pallet rotates in one direction only 214 Technical Reference 96 0189 rev L June 2005 EC 400 The load station is a 90 degree manual indexing station that holds a palle
260. exactly Motor Wave Generator Assembly Wave Generator Shoulder Washer 20 6112 MSHCS 43 1651 Harmonic Drive Flexspline Circlular Spline A A A A Phasing the Wave Generator to the Harmonic Drive view from above 4 Turn the Motor Wave Generator assembly over and set lightly on the Harmonic Drive If the two elliptical rings are in phase they will mesh If they do not mesh easily remove the Motor Wave Generator assembly and verify correct alignment of the elliptical rings and repeat this Step 151 96 0189 rev L June 2005 Mechanical Service 5 Bolt the Gearbox Adapter to the Harmonic Drive by inserting four SHCS into the countersunk holes in the Gearbox Adapter NOTE To test for a dedoidal out of phase condition perform the following operation Turn the Harmonic Drive Motor assembly over and set it on the Motor casing Harmonic Drive up Insert a 5mm hex wrench through the center hole in the Harmonic Drive into the MSCHS installed in Assembly Motor Wave Generator Step 7 Turn the hex wrench with a drill For one complete revolution of the input there should be two equal deflections or pulses felt through the drill 6 Turn the complete assembly over to expose the Harmonic Drive Keep this free of contaminents Lightly grease and install the remaining O Ring into the groove This O Ring seals the Harmonic Drive from coolant during machine operation 7 Install the Pinion Assembly from
261. f however SCALE FACT X is set to zero the value of ENC SCALE FACTOR will be used for the scale ratio instead Note that any value outside the range of 1 to 100 will be ignored and the scale ratio will remain unaffected Note also that currently these parameters are intended for use only on rotary axes A and B 245 Parameters 96 0189 rev L June 2005 589 Y ENC SCALE FACTOR See parameter 588 for description 590 Z ENC SCALE FACTOR See parameter 588 for description 591 A ENC SCALE FACTOR See parameter 588 for description 592 B ENC SCALE FACTOR See parameter 588 for description 593 Sp ENC SCALE FACTOR See parameter 588 for description 594 U ENC SCALE FACTOR See parameter 588 for description 595 V ENC SCALE FACTOR See parameter 588 for description 596 W ENC SCALE FACTOR See parameter 588 for description 600 PEAK SPIN PWR KW This parameter supports the spindle kilowatt KW load display which appears on the current commands page next to the spindle load percentage This parameter should be set to the peak power output in KW for the spindle motor 601 TOOL CHANGE DELAY On a mill where the operator needs to be warned that a running program is about to do a tool change no enclosure it will beep and delay for the duration specified by parameter 601 If parameter 601 is set to zero there will be no beep or delay If the operator changes tools by pressing buttons on any kind of tool changer there will be no beep or delay If
262. faces then reattach the Z axis way cover to the saddle cover 18 Replace the rear enclosure panel Mechanical Service 112 96 0189 rev L June 2005 3 10 EC 300 PALLET CHANGER PALLET CHANGER DISASSEMBLY Pallet Changer Disassembly can be done from the Load Station of the EC 300 without removing any enclosure parts 1 Enter M 17 in MDI mode and press Cycle Start to un clamp the pallet recommend 25 rapid Wait until the assembly has fully risen to its highest point and begins to rotate and press Emer gency Stop Rotate the pallet as required to remove the components 2 Remove the sheet metal guards on top of the clam shell cover 3 Remove the clam shell by unbolting the twenty 20 screws in the rotating door and along the bottom of the clam shell Caution The clam shell can be removed by simply lifting up and over the rotary table once the sheet metal guards have been removed DO NOT remove or adjust the pallet on the rotary table 4 Remove the two door caps on top of the door panel rotate the door 90 Sheet Metal Guides Door Cap Rotating Door Clam Shell 5 Remove rotating doors and the white plastic cable fairlead The doors come off in 2 halves Keep cables out of the way The Harmonic Drive Assembly can be removed at this point by removing the 6 six 3 8 24 socket head cap screws holding the Flange Plate and Servo Motor to the frame support and lifting the entire assem
263. flags used to turn servo related functions on and off This parameter is not used when the machine is equipped with a Haas vector drive The left and right cursor arrows are used to select the function being changed All values are 0 or 1 only The function names are 0 C LIN SCALE EN Used to enable linear scales for the C axis 1 C INVRT LN SCL Used to invert the C axis linear scale 2 DSBL SCALE Z Used to disable the linear scale Z test 3 C ZERO AXIS TC Used to return axis to the position specified by the TOOL CHANGER OFFSET parameter prior to a tool change On mills with a gimbaled spindle this bit must be set to 1 on the A and B axes parameter 269 and 270 and 0 on all other axes 4 C 2ND HOME BTN Used to move axis to coordinate specified in Work Offset G129 5 C NEG COMP DIR Used to negate the direction of thermal compensation 6 C DELAY AXIS 0 Used with an APL to ensure C axis is zeroed before A axis of APL 16 SCALE Z HIST For HAAS diagnostic use only 272 X SCREW COMP T CONST This parameter is the thermal compensation time constant and is the time constant governing the rate of cool down of the screw 273 Y SCREW COMP T CONST This parameter is the thermal compensation time constant and is the time constant governing the rate of cool down of the screw 274 Z SCREW COMP T CONST This parameter is the thermal compensation time constant and is the time constant governing the rate of cool down of the screw 275 A SCREW
264. function properly yet may not deliver the advertised power This is noticed more often when using phase converters A phase converter should only be used if all other methods cannot be used The maximum leg to leg or leg to ground voltage should not exceed 260 volts or 504 volts for high voltage ma chines with the Internal High Voltage Option 1 The current requirements shown in the table reflect the circuit breaker size internal to the machine This breaker has an extremely slow trip time It may be necessary to size the external service breaker up by 20 25 as indicated by power supply for proper operation 2 The high voltage requirements shown reflect the Internal 400V configuration which is standard on European machines Domestic and all other users must use the External 480V option AIR REQUIREMENTS The mill requires a minimum of 100 psi at the input to the pressure regulator on the back of the machine A volume of 4 scfm 9scfm for EC and HS mills is also necessary This should be supplied by at least a two horsepower compressor with a minimum 20 gallon tank that turns on when the pressure drops to 100 psi NOTE Add 2 scfm to the above minimum air requirements if the operator will be using the air nozzle during pneumatic operations Machine Type Main Air Regulator Input Airline Hose Size EC 300 85 psi 1 2 I D EC 400 85psi 1 2 I D EC 1600 85psi 1 2 I D HS 3 4 6 7 incl R models 85psi 1 2 I D VF
265. ge Power Supply P9 860 12 12 5 VDC In From Low Voltage Power Supply P10 90B 115VAC Door Fan P11 90B 115VAC Monitor P12 90C 115VAC Regen Fan P13 90C 115VAC SMTC PCB P4 P14 90C 115VAC spare P15 90C 115VAC spare P16 90C 115VAC spare P17 90C 115VAC Trans PCB P2 P18 90C 115VAC spare P19 90 3PH 115VAC IO PCB P56 P20 930 230V CLNT TSC IO PCB P44 P21 160 Chip Conv 230V 3PH IO PCB P39 P23 170 Auto Off Contactor Contactor K1 IO PCB P42 P22 740 On Off Front Panel P24 Prim Sec To T5 P25 71 72 73 Overvolt Protection From Contactor K1 P26 860 12VDC SKBIF P27 860 12 5 VDC IO PCB P60 P28 860 12 5 VDC Motif PCB P15 P29 860 12 5 VDC Processor PCB J3 P30 860 12 12 5 VDC spare P31 860 12 5 VDC Video PCB P1 P32 860 12 12 5 VDC Mocon 1 PCB P15 P33 860 12 12 5 VDC Mocon 2 PCB P15 P34 860 12 VDC SMTC PCB P2 P35 860 12 VDC MCD Relay PCB P2 TB1 94 95 96 115VAC From Transformer TB2 90A 115 VAC Out Barfeeder T C PCBA P8 TB3 77 78 79 3PH 230V In From Transformer 267 Cable Locations 96 0189 rev L June 2005 I O PCB I O PLUG CABLE TO LOCATION PLUG P1 140B Chip Conveyor P2 820B T C In smtc arm mark T P3 820 DB Up Down TC out SMTC shuttle out P4 900 TSC Pump Low TSC pressure P5 770 E Stop Switch A Front Panel P6 770A E Stop Switch B P7 770B E Stop Switch C P8 1050 Side Door Open P9 1050A Sid
266. ger not at home and either the Z or A or B axis or any combination is not Interlocked at zero If RESET E STOP or POWER OFF occurs during tool change Z axis motion and tool changer motion may not be safe Check the position of the tool changer and remove the tool if possible Re initialize with the AUTO ALL AXES button but be sure that the pocket facing the spindle afterwards does not contain a tool 151 LOW THRU SPINDLE COOLANT For machines with Through the Spindle Coolant only This alarm will shut off the coolant spigot feed and pump all at once It will turn on purge wait for the amount of time specified in parameter 237 for the coolant to purge and then turn off the purge Check for low coolant tank level any filter or intake strainer clogging or for any kinked or clogged coolant lines Verify proper pump and machine phasing If no problems are found with any of these and none of the coolant lines are clogged or kinked call your dealer 152 SELF TEST FAIL Control has detected an electronics fault All motors and solenoids are shut down This is most likely caused by a fault of the processor board stack Call your dealer 153 X AXIS Z CH MISSING Z Reference signal from encoder was not received as expected Can be caused by loose connections encoder contamination or parameter error 154 Y AXIS Z CH MISSING Z Reference signal from encoder was not received as expected Can be caused by loose connections encoder contamination or paramete
267. gh to install the shims It is only necessary to remove the 8 bolts on the receiver there is at least 2 of travel for lifting the receiver before the union contacts the bottom of the rotary Shims are replaced at a 2 1 ratio for the error indicated on the locating keys Example indicated error of 001 would require a 002 shim Install the shims as necessary and repeat the receiver verification procedure until the geometry is correct 127 Mechanical Service 96 0189 rev L June 2005 Indicating the pallet 1 Install the new pallet on the receiver and indicate across the 45 degree angles on the receiver locating keys until they are parallel with the X axis The keys must be parallel to the x axis within 0005 if the keys are not parallel proceed to step 9 2 To indicate the flatness of the pallet attach a magentic base to the spindle nose and using a 0001 or 0005 indicator Indicate down the center of the pallet and note the reading at the front and back edge about 1 from the edge of the pallet in Z axis Repeat this in the X axis and note the reading NOTE Check both pallets before making any adjustments The pallets should be within 0005 of each other 3 With magnetic base still on the spindle nose place the indicator on the face of the pallet at the center and 1 from the front edge toward the spindle Zero the indicator dial and set the Z axis position to zero 4 Jog Z axis off of the pallet far enough to allow rotati
268. ght Electrical Service 182 96 0189 rev L June 2005 3 Check the connections on the transformer at the bottom right corner of the rear cabinet The three black wires labeled 74 75 and 76 must be moved to the terminal block triple which corresponds to the average voltage measured in step 2 above There are four positions for the input power for the 260 volt transformer and five positions for the 480 volt transformer The labels showing the input voltage range for each terminal position are as shown in the following illustrations LOW VOLT 260 244V 243 227V 226 211V 210 195V LOW VOLT LOW VOLT 260 244V 243 227V 226 211V 210 195V HIGH VOLT HIGH VOLT 488 458V 457 429V 428 403V 402 377V 376 354V 4 Transformer T5 supplies 24VAC used to power the main contactor There are two versions of this transformer for use on 240 and 400V machines 32 0964B and 32 0965B respectively The 240V transformer has two input connectors located about two inches from the transformer which allow it to be connected to either 240V or 200V Users that have 220V 240V RMS input power should use the connector labeled 200V Users with the External High Voltage Option should use the 240V connector if they have 420V 510V 60Hz power or the 200V connector if they have 50Hz power Failure to use the correct input connector will result in either overheating of the main contactor or failure to reliably engage the main contactor
269. gin opening If the door does not move off the door closed switch within this amount of time alarm 238 DOOR FAULT will be generated This parameter should be set to 1000 1 0 seconds nominally 253 SPIGOT FWD POS DLY This parameter is used to specify the length of a delay units are ms when moving the coolant spigot forward This parameter should be set to zero on all machines 254 TC AIR DOOR CLEARANCE This parameter incorporates the X axis door clearance for the Mini horizontal The mill uses this position during a tool change to avoid hitting the tool changer door as part of the tool changer door enters the machining area during a tool change This parameter also supports the VB 1 Bridge Mill tool carousel air door The air door is a clamshell shaped door covering the tool carousel which raises up at one side by air power to allow the spindle to access the tools In order for it to open and close there must be sufficient clearance between it and the spindle This parameter must be set to the correct value in encoder units parameter 223 AIR TC DOOR DELAY must set to a non zero value parameter 267 ZERO AXIS TC must be set to 1 and parameter 278 TC DR SWITCH must be set to 1 When a tool change is commanded the following steps are performed 1 The Y axis is moved to the position specified by parameter 254 2 The air door is commanded to open 3 There is a delay specified by parameter 223 to allow the door to open fully 4 The Y axis is mov
270. go to the lube air panel at rear of mill and continuously press both white buttons in center of solenoid air valves while assistant pulls the pallet off the receiver After correcting the condition run an M50 to continue machining Horizontal Mills RP Pallet is not clamped The RP pallet change was not completed or the pallet was not clamped properly when a spindle command was given After correcting the condition run an M50 to continue machining 632 APC UNCLAMP ERROR The pallet did not unclamp in the amount of time allowed This can be caused by a bad air solenoid a blocked or kinked airline or a mechanical problem After correcting the condition run an M50 to continue machining 633 APC CLAMP ERROR The pallet did not clamp in the amount of time allowed by parameter 316 This alarm is most likely caused by the mill table not being in the correct position This can be adjusted using the setting for the X position 121 125 as described in the Installation section If the pallet is in the correct position but not clamped push the pallet against the hard stop and run M18 If the pallet is clamped but not correctly run an M17 to unclamp push the pallet to the correct position and run an M18 to clamp the pallet Less common causes could be that the slip clutch is slipping the motor is at fault or an airline is blocked or kinked After correcting the condition run an M50 to continue machining 634 APC MISLOCATED PALLET A pallet is not
271. gulator to the correct pressure 85psi and finish the pallet changer restore sequence 10 Exit Debug type DEBUG and press Enter form the alarms page This completes the first stage of the alignment procedure Stage 2 Alignment of the pallet load station pins to the H Frame At this stage the H frame has been aligned to the rotary axis Stage 1 has been completed 1 Loosen the four alignment pin bolts on the load station Rotate the pallet at the load station to access all the bolts 2 Rotate the pallet load station to home Enter pallet changer recovery 3 Unclamp the pallet and raise the H frame 4 Reduce the main air pressure regulator to approximately 10 psi 5 Enter pallet changer restore and Command the H frame down 6 Increase the air pressure at the main pressure regulator until the H frame starts to lower Verify the pallet is engaging the alignment pins 7 Once the pallet is seated on the alignment pins tighten them 8 Increase the main air pressure regulator to 85 psi and finish the pallet changer restore sequence 9 Close doors and command several pallet changes to verify smooth operation 10 Set parameter 76 to the original number Note pallet changer recovery reduces rapids to 25 The pallet at the load station must always be returned to home before automatic pallet changes can occur 123 Mechanical Service 96 0189 rev L June 2005 H FRAME SWITCH ADJUSTMENT H frame up sensor
272. h into the cam box Connect the proximity switch connector to the plug on the switch bracket Proximity Switch Connection Bracket 3 Power On machine Press E Stop Mechanical Service 92 96 0189 rev L June 2005 4 Screw the proximity sensor into the cam box an additional 1 8 turn after the L E D light comes on Loosen both nuts then re tighten the inner nut against the cam box housing Tighten the outer nut against the inner nut 5 Repeat this procedure for each proximity sensor switch 6 Refill the cam box with oil Penzgear 320 to the fill level line 7 Check for correct operation of the tool changer and alignment Adjust as necessary 8 Replace the carousel disc and top cover plate Apply blue loctite to the fasteners and tighten SETTING PARAMETER 64 Caution The EC 400 Z axis can crash into the pallet changer actuator if Parameter 64 is not set correctly For Z axis this is the displacement from home switch to tool change position and machine zero Distance from Home in Inches X Line Encoder Constant Z axis tool change position setting Example 625 x 138718 861699 To reset Parameter 64 Z axis tool change position if an ATC assembly has been replaced or realigned 1 Enter PARAMETERS page and record original Parameter 64 setting value 2 Make sure there are no tools in the spindle head or tool pocket positions Command the spindle head to its tool change position Enter DEBUG and record
273. he Stud holes indicated below Install to a height of 2 175 Studs Pivot Pin 2 Use a brass hammer or punch to insert the 2 Pivot Pins into the table as shown in the figure on the previous page 3 Clean the Brake Ring mounting surface with alcohol and a lint free rag Apply a coating of grease to the cleaned surface Do not grease the area immediately surrounding the hole for the Hydraulic Cylinder shaft 4 Place the Stop Block into the hole for the Hydraulic Cylinder shaft Insert the two SHCS and tighten 156 Mechanical Service 96 0189 rev L June 2005 5 With an assistant lift and lower the Brake Ring Assembly onto the Table Fit the Brake Ring over the Pivot Pins and Studs The Brake Ring should rest against the Table If there is interference make sure the Pivot Block is in the fully retracted position 6 Place a drop of Loctite onto each of the 10 SHCS and insert into the machined holes in the area between the Pivot Pins Tighten the SHCS in a circular pattern from the center outward as shown The torque value is 80 ft lbs Pivot Pin Flex Nut Torque Sequence Brake Ring SHCS 7 Grease the counterbores machined into the Stud holes along the legs of the Brake Ring Place a Thrust Washer and a Flex Nut onto each Stud and tighten completely Back off each Flex Nut slightly approximately 1 3 Check the actuation of the brake after completion of Hydraulic Cylinder installation procedure The Flex Nuts should
274. he Y Axis CAUTION Do not screw the column too far over since the hardstops are removed 8 Remove the axis motor in accordance with the specific motor removal section 9 Remove the coupling 10 Loosen the SHCS on the locknut at the motor end of the ball screw and remove the locknut 11 Loosen the SHCS and remove the bearing sleeve from the coupling housing Push on the opposite end of the ball screw to loosen CAUTION Do not pry the bearing sleeve away from the housing Damage to the sleeve bearing motor housing or ball screw will result Bearing Sleeve Mounting Location Mechanical Service 102 96 0189 rev L June 2005 Installation 1 Ensure all mating surfaces on the bearing sleeve motor housing nut housing and ball nut are free of dirt burrs grease or other contaminants CAUTION Mating surfaces must be clean or misalignment may occur seriously affecting the proper operation of the machine 2 Place the bearing sleeve in the motor mount It may be necessary to align the bearings in the sleeve to facilitate mounting on the ball screw 3 Install the SHCS on the bearing sleeve and torque to 15 ft lb Place a drop of blue Loctite on each of the SHCS before inserting 4 Manually screw the column over in order to access the bearing support This is not possible when repairing the Y Axis CAUTION Do not screw the column too far over since the hardstops are removed 5 Screw the clamp nut on th
275. he air pressure gauge during a tool change a 10psi drop is the maximum allowed Using the air gun during tool changes may cause faults if the air supply to the machine is marginal Allow 2 HP of air compressor per machine i e 5 machines require a 10hp air compres sor Use a minimum of 3 8 ID hose for the EC 300 or 1 2 ID for EC 400 Avoid quick disconnects in the air supply lines they are restrictive CAROUSEL ROTATION MOTOR A DC brush motor is used to rotate the carousel between tool changes The motor has an encoder and is driven by the single axis control mounted inside the control 5 2 TOOL CLAMP UNCLAMP Air pressure is used to release the spring loaded tool clamp When the tool is unclamped air is directed down the center of the spindle to clear the taper of water oil or chips Tool unclamp can be commanded from a program not recommended or from the keyboard The manual button only operates in MDI or JOG modes TOOL CLAMP UNCLAMP AIR SOLENOIDS A single solenoid controls the air pressure to release the tool clamp This corresponds to relay K15 When the relay is activated 115V AC is applied to the solenoid This applies air pressure to release the tool Relay K15 is on the I O PCB Circuit breaker CB4 will interrupt power to this solenoid 200 Technical Reference 96 0189 rev L June 2005 TOOL CLAMP UNCLAMP SENSE SWITCHES There are two switches located on the tool release piston assembly that are used to sense t
276. he amount of time allowed for the contactors to stabilize after a switch is commanded before current is applied to the motor 201 X SCREW COMP COEF This is the coefficient of heating of the ball screw and is used to shorten the screw length 205 A SCREW COMP COEF This parameter should be set to 0 229 Parameters 96 0189 rev L June 2005 206 SPIGOT POSITION Vertical mills only Maximum number of spigot positions 207 SPIGOT TIMEOUT MS Vertical mills only Maximum timeout allowed for spigot to traverse one spigot location 208 SPIN FAN OFF DELAY Delay for turning the spindle fan off after the spindle has been turned off 209 COMMON SWITCH 2 Parameter 209 is a collection of general purpose single bit flags used to turn some functions on and off The left and right cursor arrows are used to select the function being changed All values are 0 or 1 only The function names are 0 HS SERIES CNCSet to one for HS series mills set to zero for all other mills 1 RESET STOPS TL CHGR Tool changer can be stopped with RESET button 2 CHAIN TOOL CHANGER On all HS mills with the 60 or 120 pocket chain style tool changer it must be set to 1 On all other mills it must be set to zero 3 ENABLE CHIP CONVEYR Enables chip conveyor if machine is so equipped 4 50 RAPID KEYBOARD When 1 the control will support the 50 rapid traverse key For controls without a 50 rapid keypad set this bit to 0 5 FRONT DOOR When enabled the control will
277. he ball nut 352 RELAY BANK SELECT This parameter allows the user to change which bank of relays is to be used Parameter 209 bit 23 MCD RLY BRD assumes that relay bank one is to be used It may be set to a number from 0 to 3 inclu sive M codes M21 through M28 will be switched to the selected bank This parameter requires a revision S I O board If a previous board is installed without the additional banks of relays this parameter should be set to zero Bank Relay Location Description 0 I O PCB Internal machine functions 1 I O PCB User relay outputs some may be used for internal functions 2 1st M code PCB 8M option 8 additional user outputs 3 2nd M code PCB Typically used for built in options such as side mount tool 2nd M code PCB changer etc 430 W RATIO STEPS UNIT For the EC300 and MDC1 this parameter is set to 57344 This parameter controls the rotation of the pallet When a pallet change is performed the pallet will rotate 180 degrees It is essential that this parameter is checked after a software upgrade 586 MAX DOOR OPN SP RPM This parameter specifies the maximum allowable spindle RPM after the door has been opened manually or commanded open by an M80 588 X ENC SCALE FACTOR This axis parameter work in place of the axis parameters called SCALE X LO and SCALE X HI If SCALE FACT X is set to 1 the scale ratio is determined by SCALE X LO and SCALE X HI as follows HI LO 0 0 3 0 1 5 1 0 7 1 1 9 I
278. he clamp plate will lower to the clamped position via the clamp springs Comment This is a dangerous condition If the table is partially on or partially off of the clamp plate potential damage to the indexer can result If the table is heading towards the clamp plate and the clamp plate lowers due to loss of air a crash will result Troubleshooting 25 96 0189 rev L June 2005 1 5 AUTOMATIC TOOL CHANGER ATC Refer to the alarm description when problems arise with the ATC See Spindle section for additional trouble shooting information CRASHING Crashing of the ATC is usually a result of operator error The most common ATC crashes is the part or fixture on the mill table crashes into long tooling or into the ATC double arm during a tool change Inspect the pocket involved in the crash for damage and replace parts as necessary The machine will normally home the Z axis as part of the tool change sequence Check Parameter 209 bit TC Z NO HOME and ensure it is set to zero SIDE MOUNT TOOL CHANGER RECOVERY FLOW CHART END TOOL CHANGE RESTORE SIDEMOUNT pressing TCR button if alarms exist Y IS THERE A TOOL IN THE ARM OR THE SPINDLE Y N WILL THE ARM PREVENT ANY TOOL IN THE SPINDLE OR THE POCKET FROM BEING REMOVED Y N Y Y N USE THE FOLLOWING COMMANDS UNTIL YOU CAN REMOVE ALL THE TOOLS FROM THE SPINDLE AND THE ARM CAROUSEL CAN BE MOVED WITH RIGHT AND LEFT ARROWS ATC FWD OR REV
279. he delay time in ms from the moment the spigot motor is turned off to the moment the spigot is stopped in the reverse direction 619 Pre Gear Change Dly This parameter specifies the delay time in milliseconds after the spindle has been commanded to stop and before the solenoid for the gear change is commanded to start It should be set to 100 on all machines 246 Parameters 96 0189 rev L June 2005 620 X Axis Plus Travel Limit Note that only parameters 623 and 624 for the A and B axes are intended to be used and only on the Trunnion Mills VF5TR and VF6TR where it is necessary to place the home switch in the middle of the travel range in order to keep the table flat when at the home position and limit movement to 120 degrees The PLUS TRAVEL LIMIT parameter is used to store the number of encoder steps that a rotary can take in the plus direction from its current home position The control then takes into account these updated travel limits for jog and feed conditions For example if the steps unit on the A axis is 4000 and the PLUS TRAVEL LIMIT is set to 20000 then the control will allow the A rotary to go up to 5 degrees before stopping This assumes that the encoder scale factor is set to zero The same applies for the B axis This feature will enable the home switch to be moved to any desired location so that a rotary can make the proper orientation during zero return Note that parameter 591 and 592 AB ENC SCALE FACTOR will be applicabl
280. he factory for availability 4 Completely remove the transmission mounting bolts and pull the transmission towards the rear of the machine until it is clear of the column casting Installation 1 Put drive and encoder belts on transmission pulleys This must be done before installing the transmission assembly 2 Secure the lifting device to the transmission assembly Lift and position the transmission on the back of the spindle head 3 Install bolts and belts Adjust the belt tension by lifting or lowering the transmission Once proper belt tension is attained tighten all the bolts 4 Remove the lifting equipment 5 Install Encoder and TRP as described in their specific sections Mechanical Service 138 96 0189 rev L June 2005 6 Connect the cables to the motor and transmission and then replace the cover BELTS REPLACEMENT The motor and transmission assembly must be removed to replace the spindle drive and spindle encoder belt See the motor and transmission section for instructions SPINDLE ENCODER REPLACEMENT Removal 1 Remove the tool release piston to access the encoder See TRP Service section 2 Remove the four bolts that hold the encoder bracket to the spindle head Disconnect the cable Remove the four bolts that hold the encoder to the bracket Installation 1 Bolt the encoder to the bracket 2 Install the belt on the encoder pulley and then install the bracket to the spindle head Verify that the b
281. he four screws that hold the spindle load meter assembly to the control panel Take care to hold the assembly in place until all screws have been removed Remove the assembly 5 Installation is reverse of removal Ensure leads go the correct location KEYPAD REPLACEMENT 1 Turn the power off and disconnect power to the machine 2 Remove the four screws holding the rear cover panel to the back of the control panel Take care to hold the cover panel in place until all screws have been removed 3 Unplug the keypad s 24 pin ribbon cable from the Keyboard Interface board 4 Remove the screws from the front of the control panel Take care to hold the front cover panel in place until all screws have been removed Remove the pieces and set aside in a safe place 5 Using a flat blunt tool such as putty knife pry the keypad away from the control panel Pull the ribbon cable through the opening in the control to remove 6 To replace first put the bezel spacer in place and fasten temporarily with screws in the top cor ners Figure 4 5 5 Keypad installation Electrical Service 196 96 0189 rev L June 2005 7 Insert the ribbon cable through the opening in the control panel Expose the adhesive strip on the back of the keypad and press the keypad in place in the upper right corner of the keypad recess Press to the control panel to mount Plug the ribbon cable into the Keyboard Interface board taking care to not bend the pins on
282. he position of the tool clamping mechanism They are both normally closed but one open once clamped and the other when unclamped When both switches are closed it indicates that the draw bar is between positions A tool change operation will wait until the unclamped switch is sensed before the tool is removed from the spindle This prevents any possibility of breaking the tool changer or its support mounts The diagnostic display can be used to display the status of the relay outputs and the switch inputs The Precharge and TSC system applies low air pressure and releases the clamped switch 5 3 SPINDLE OPERATION Spindle speed functions are controlled primarily by the S address code The S address specifies RPM in integer values from 1 to maximum spindle speed Parameter 131 NOT TO BE CHANGED BY USER When using the Through the Spindle Coolant option the maximum spindle speed is 10 000 RPM for all spindles The spindle is hardened and ground to the precise tool holder dimensions providing an excellent fit to the holder Spindle Warm up All spindles which have been idle for more than 4 days must be thermally cycled prior to operation above 6 000 RPM This will prevent possible overheating of the spindle due to settling of lubrication A 20 minute warm up program has been supplied with the machine which will bring the spindle up to speed slowly and allow the spindle to thermally stabilize This program may also be used daily for spindle
283. he swivel elbow Loosen this joint only enough to let air escape 7 Apply air pressure to the pressure booster by pressing the yellow pin button on the air valve assembly Do not activate the pressure booster for more than a second at a time 8 When all air has escaped the hydraulic system tighten the hydraulic hose Readjust the high pressure regulator to 70 psi 9 If any air leaks have been noticed during this operation take appropriate measures to fix them before installing the assembly Mechanical Service 136 96 0189 rev L June 2005 INSTALLATION HYDRAULIC CYLINDER 1 Lift the hydraulic cylinder into its area beneath the table See the following figure for the approxi mate location The hose connections should face the left of the table away from the pressure booster to prevent kinks in the lines when routed 2 Thread 4 1 1 4 shcs through the mounting tabs of the hydraulic cylinder into the table Leave these loose for final alignment of the hydraulic cylinder see final alignment hydraulic cylin der 3 Route the hydraulic hose and air port tubing beneath the hydraulic cylinder and through the holes machined to the right Install cable plates using BHCS to retain the lines Fit the plastic tabs over the cable plates to prevent damage to cables during operation Locations of Brake Cylinder Pressure Booster Components installed from beneath FINAL ALIGNMENT HYDRAULIC CYLINDER The following steps are
284. hine is allowed to settle after detecting the indexer Down switch If the parameter is zero the feature is backward compatible 704 SMTC2 UNCLAMP POS This parameter supports the high speed tool changer It specifies the absolute position in degrees 1000 which the TT axis will stop at in order to unclamp the tool 705 SMTC2 CLAMP POS This parameter supports the high speed tool changer It specifies the absolute position in degrees 1000 which the TT axis will stop at in order to clamp the tool 708 Pallet Changer Axis Specifies the mocon channel of the MDC 1 and EC 300 pallet changer It enables both the servo axis pallet changer and the Super SMTC tool changer to operate on the same machine On an MDC 1 with a single mocon board this parameter must be set to 4 On an MDC 1 or EC 300 with two mocon boards this param eter must be set to 8 On all other machines this parameter must be set to 0 Note also that when this parameter is set to 4 the B axis parameters are used to control the pallet changer and the message USE Tt PARAMS will not be displayed When this parameter is set to 8 the W axis parameters are used to control the pallet changer 709 SMTC DR Output Rely Specifies the output relay that should be activated for the tool changer door Set to 39 for the EC300 Set to 1 for the EC400 Set to 26 for the HS series mills Set to zero for all other mills without a tool changer door 710 Tool Changer Type Specifies which type of tool ch
285. his parameter and the negative MAX TRAVEL 213 B TOOL CHANGE OFFSET This parameter sets the distance between the B axis grid offset Parameter 170 and the spindle home position The B axis will be limited in movement to the area between the positive value of this parameter and the negative MAX TRAVEL This parameter must be used on all mills with the 60 or 120 pocket chain style tool changer as opposed to parameter 215 CAROUSEL OFFSET which is used on other side mount tool changers Note that on a machine with a single mocon board the Tt axis parameters are automatically copied to the B axis parameters and only the Tt axis parameters can be altered 214 D Y CURRENT RATIO UNIT This defines the ratio between the two winding configurations This default winding is Y and the parameters are set for the Y winding This number is used to adjust the parameters for the delta winding when the windings are switched 215 CAROUSEL OFFSET Used on horizontal mills only Parameter used to align tool 1 of tool changing carousel precisely Units are encoder steps 216 CNVYR RELAY DELAY Delay time in 1 50 seconds required on conveyor relays before another action can be commanded Default is 50 217 CNVYR IGNORE OC TIM Amount of time in 1 50 seconds before overcurrent is checked after conveyor motor is turned on Default is 50 218 CONVYR RETRY REV TIM Amount of time that the conveyor is reversed in 1 50 seconds after overcurrent is sensed Default is
286. his assembly to the Mounting Plate using Loctite and supplied SHCS INSTALLATION 1 Position the Air Valve Assembly near its mounting location at the Air Lube Panel Route all air tubing to the Air Valve 2 Cut each air tubing line to fit and insert into the appropriate regulator outlet on the Air Valve Assem bly 3 Position the Air Valve Assembly properly then thread 4 SHCS into the mounting holes and tighten 159 96 0189 rev L June 2005 Mechanical Service 3 22 4TH AXIS BRAKE CYLINDER PRESSURE BOOSTER THEORY OF OPERATION The Pressure Booster gives the ability to develop and use high hydraulic pressure without incurring the cost of an on board HPU The Pressure Booster has a high pressure side a low pressure side and a fluid fill port on the front of the unit The Pressure Booster Assembly is located in the bottom of the Rotary Table There is a cutout underneath the Rotary Table to provide access for service and replacement of the Pressure Booster and component parts ASSEMBLY PRESSURE BOOSTER The Pressure Booster comes packaged with extra components not needed for its proper operation in this application Where applicable in the following steps use a small amount of thread sealer on all pipe threads 1 The Pressure Booster is shipped full of hydraulic oil Tilt the Pressure Booster on end before removing the plug from the container 2 Thread Adapter into the Pressure Booster and tighten 3 Thread the Nipp
287. ht Install Cable Plates using BHCS to retain the lines Fit the plastic tabs over the Cable Plates to prevent damage to cables during operation Locations of Brake Cylinder Pressure Booster Components installed from beneath FINAL ALIGNMENT HYDRAULIC CYLINDER The following Steps are performed from above the Table 1 Apply air pressure to the Hydraulic Cylinder This will cause the piston in the Hydraulic Cylinder to extend When the piston has extended thread an SHCS into the pilot hole in the piston shaft and tighten This will properly align the Hydraulic Cylinder to the Brake Assembly 2 Tighten the four SHCS that mount the Hydraulic Cylinder to the Table Relieve the hydraulic pressure Electrical Service 176 96 0189 rev L June 2005 4 ELECTRICAL SERVICE 40 Install lock out clasp and lock with paddlock to secure Circuit Breaker in the OFF position Make sure the circuit breaker is locked in the off position before attempting any electrical work to avoid pos sible shock CAUTION Working with the electrical services required for the Horizontal mill can be extremely hazardous The electrical power must be off and steps must be taken to ensure that it will not be turned on while you are working with it In most cases this means turning off a circuit breaker in a panel and then locking the panel door However if your connection is different or you are not sure how to do this check with the appropriate personnel in yo
288. ide of an IF THEN WHILE or M99 block 517 EXPRSN NOT ALLOWED WITH N OR O A macro expression cannot be used with N or O Do not declare O 1 etc 518 ILLEGAL MACRO EXPRSN REFERENCE A macro expression cannot be used with N or O Do not declare O 1 etc 519 TERM EXPECTED In the evaluation of a macro expression an operand was expected but not found 520 OPERATOR EXPECTED In the evaluation of a macro expression an operator was expected but not found 521 ILLEGAL FUNCTIONAL PARAMETER An illegal value was passed to a function such as SQRT or ASIN 522 ILLEGAL ASSIGNMENT VAR OR VALUE A variable was referenced for writing The variable referenced is read only 523 CONDITIONAL REQUIRED PRIOR TO THEN A THEN was encountered and a conditional statement was not processed in the same block 524 END FOUND WITH NO MATCHING DO An END was encountered without encountering a previous matching DO DO END numbers must agree 525 VAR REF ILLEGAL DURING MOVEMENT Variable cannot be read during axis movement 526 COMMAND FOUND ON DO END LINE A G code command was found on a WHILE DO or END macro block Move the G code to a separate block 527 NOT EXPECTED OR THEN REQUIRED Only one assignment is allowed per block or a THEN statement is missing 528 PARAMETER PRECEDES G65 On G65 lines all parameters must follow the G65 G code Place parameters after G65 529 ILLEGAL G65 PARAMETER The addresses G L N O and P cannot be used to pass paramete
289. ider Tool Pocket Assembly Carousel Slider Adjustment Set Screw Top View Pocket in Load Position Pocket in Stored Position Tool Pocket Orientation Set Screw Adjustment PROXIMITY SWITCH REMOVAL INSTALLATION Removal 1 Power Off machine Remove the carousel number disc and the top cover plate 2 Remove the 1 4 NPT plug near the cam box output shaft and drain the cam box oil 3 Disconnect the proximity switch connector from the bracket on the top of the assembly 4 Loosen the double nuts retaining the proximity switch Carefully remove the proximity switch from the cam box assembly Refer to following figure 91 96 0189 rev L June 2005 Mechanical Service Tool Clamp Sensor Origin Sensor Motor Stop Sensor Oil Fill Level Trigger Grooves Cam Box Pulley 4X Cam Box Mounting SHCS 3X Proximity Sensors Oil Fill Breather Proximity Sensor Switch Location Installation The proximity trigger disk inside the cam box determines the sensor operation The sensor must be approxi mately 030 away from a flat surface on the disk to function properly An L E D light will come on at the back of the sensor when it is triggered 1 Look through the sensor hole and rotate the cam box pulley by hand until the groove is not visible 2 Screw two nuts to the threaded section of the proximity switch Snug the two nuts together and apply thread sealant to the threads Carefully screw the switc
290. idual voltage even after power has been shut off and or disconnected Never work inside this cabinet until the small red CHARGE light on the servo amplifiers go out The servo amplifiers are on the left side of the main control cabinet and about halfway down This light is at the top of the circuit card at the center of the assembly Until this light goes out there are dangerous voltages in the assembly EVEN WHEN POWER IS SHUT OFF GROUND STRAPS MUST BE USED WHEN HANDLING BOARDS NOTE The arrangement of these boards may differ from the order of replacement that follows The steps for replacement will only differ in which board may need to be removed before getting to the necessary board MOCON BOARD NOTE Refer to Cable Locations for a diagram of this board 1 Turn machine power off 2 Turn the main switch upper right of electrical cabinet to the off position 3 Open the cabinet door and wait until the red CHARGE light s on the servo amplifiers go out before beginning any work inside the electrical cabinet 4 Disconnect all leads to the Motor Controller MOCON board Ensure all cables are properly labeled for reconnecting later 5 After all cables have been disconnected unscrew the standoffs taking care to hold the board in place until all standoffs have been removed NOTE If the VIDEO KEYBOARD or PROCESSOR boards need replacing please skip the next step 6 Replace the MOCON board attaching it to th
291. ied by the TOOL CHANGER OFFSET parameter prior to a tool change On mills with a gimbaled spindle this bit must be set to 1 on the A and B axes parameter 269 and 270 and 0 on all other axes On all mills with 60 or 120 pocket chain style tool changer this bit must be set to 1 It will cause to tool changer offset parameter to be used for tool changes 4 B 2ND HOME BTN Used to move axis to coordinate specified in Work Offset G129 5 B NEG COMP DIR Used to negate the direction of thermal compensation 6 B DELAY AXIS 0 Used with an APL to ensure B axis is zeroed before A axis of APL 7 B MAX TRAVEL INP This bit is set to 1 on five axes machines This bit indicates that there is a switch visible through MOCON that detects if the axis has rotated all the way round It is used to tell the control to skip the first zero switch when zeroing so it can unwrap the cables 9 B TEMP SENSOR This performs Ball Screw Thermal Compensation via a temperature sensor attached to the ball nut When this bit is set to 1 the feature is activated for that axis Note that this feature can only be used when temperature sensors are installed The following parameters must be set appropriately 236 Parameters 96 0189 rev L June 2005 201 132 133 XYZ SCREW COMP COEF 8000000 272 273 274 XYZ SCREW COMP T CONST 28000 351 TEMP PROBE OFFSET 450000 16 SCALE Z HIST For HAAS diagnostic use only 271 C SWITCHES Parameter 271 is a collection of single bit
292. ignals NOTE See the 8M option section for more details M FUNCTION RELAYS The I O PC board has five relays M21 25 that may be available to the user M21 is already wired out to P12 at the side of the control cabinet This is a four pin DIN connector and includes the M FIN signal NOTE Refer to the Diagnostic section in the manual for specific machine Inputs and Outputs NOTE Some or all of the M21 25 on the I O PCB may be used for factory installed options M FIN DISCRETE INPUT The M FIN discrete input is a low voltage circuit When the circuit is open there is 12V DC at this signal When this line is brought to ground there will be about 10 milliamps of current M FIN is discrete input 1009 and is wired from input 1009 on the I O PCB The return line for grounding the circuit should also come from that PCB For reliability these two wires should be routed in a shielded cable where the shield is grounded at one end only The diagnostic display will show this signal a 1 when the circuit is open and a 0 when this circuit is grounded 212 Technical Reference 96 0189 rev L June 2005 5 16 LUBRICATION SYSTEM The lubrication system is a resistance type system which forces oil through metering units at each of the lubricating points within the machine The system uses one metering unit at each of the lubricating points one for each linear guide pad one for each lead screw and one for spindle lubrication A single
293. iguration where the door is driven open by a timed operation If it is set to 1 this indicates the configuration where the door is spring loaded closed and is driven open by the timed operation against the door open switch In open position the door switch signal is 0 low The switch status is checked before and after commanding the door to open in order to be fail safe For all horizontal mills that have the switch installed this bit must be set to 1 For all other mills this bit must be set to 0 24 HS2 SMTC CAROUSEL 25 HS3 SMTC CAROUSEL 26 S MNT BIT 1 Bits 26 27 and 28 work together to specify the type of sidemount tool changer that is installed on a vertical mill The following table shows the bit combinations that must be used Bit 26 27 28 0 0 0 No side mount tool changer installed 1 0 0 Serpentine 1 0 1 0 Serpentine 2 1 1 0 Serpentine 3 0 0 1 Disk 1 1 0 1 Disk 2 0 1 1 Disk 3 1 1 1 Disk 4 27 S MNT BIT 2 Bits 26 27 and 28 work together to specify the type of sidemount tool changer that is installed on a vertical mill 28 S MNT BIT 3 Bits 26 27 and 28 work together to specify the type of sidemount tool changer that is installed on a vertical mill 29 DOOR SAFETY SW INV This bit supports the CE door interlock that locks when power is turned off For machines that have the regular door lock that locks when power is applied this bit must be set to 0 For machines that have the inverted door lock this bit must be set to
294. ills A and B axes CK TRAVL LIM must be set to 1 21 ROT TRVL LIM Rotary travel limits are used 22 D FILTER X8 Enables the 8 tap FIR filter Used to eliminate high frequency vibrations depending on the axis motor 218 Parameters 96 0189 rev L June 2005 23 D FILTER X4 Enables the 4 tap FIR filter Used to eliminate high frequency vibrations depending on the axis motor 24 TORQUE ONLY For HAAS diagnostic use only 25 3 EREV MREV The 2 EREV MREV and 3 EREV MREV bits have two definitions depending on whether one or two encoders are present For single encoder systems the bits are used to define the ratio between the electrical rotation of the spindle motor and the mechanical rotation of the motor For two encoder systems the definition is the electrical rotation of the motor to the mechanical rotation of the spindle motor encoder which includes any pulley ratio between the motor and the motor encoder 26 2 EREV MREV The 2 EREV MREV and 3 EREV MREV bits have two definitions depending on whether one or two encoders are present For single encoder systems the bits are used to define the ratio between the electrical rotation of the spindle motor and the mechanical rotation of the motor For two encoder systems the definition is the electrical rotation of the motor to the mechanical rotation of the spindle motor encoder which includes any pulley ratio between the motor and the motor encoder 27 NON MUX PHAS For HAAS diagnostic use only
295. in Fig 1 3 1 and manually push the mill column to the left and right while listening for a clunk The dial indicator should return to zero after releasing the column NOTE The servo motors must be on to check backlash by this method 5 If backlash is found refer to Backlash Possible Causes in this section CHECKING Y AXIS 1 Set up a dial indicator and base on the mill table as shown in Fig 1 3 2 Figure 1 3 2 Dial indicator in position to check Y axis 2 Set dial indicator and the Distance to go display in the HANDLE JOG mode to zero as follows Zero the dial indicator Press the MDI key on the control panel Press the HANDLE JOG key on the control panel The Distance to go display in the lower right hand corner of the screen should read X 0 Y 0 Z 0 3 Set the rate of travel to 001 on the control panel and jog the machine 010 in the positive Y direction Jog back to zero 0 on the display The dial indicator should read zero 0 0001 4 Repeat Step 3 in the negative direction Troubleshooting 15 96 0189 rev L June 2005 TOTAL DEVIATION BETWEEN THE DIAL INDICATOR AND THE CONTROL PANEL DISPLAY SHOULD NOT EXCEED 0002 An alternate method for checking backlash is to place the dial indicator as shown in Fig 1 3 2 and manually push up and down on the spindle head while listening for a clunk The dial indicator should return to zero after releasing the spindle head NOTE
296. indle Housing 6 30 6954 Lube Line Assembly Y Axis 7 32 1457 Encoder 8 60 1813 Encoder M23 Short 9 20 2965B Standoff Rod 10 20 0726 Transmission Subplate 11 20 0017 Air Cylinder Subplate 12 20 6097 Coolant Manifold 13 25 6096 Manifold Cover 14 58 3062 3 8 NPT Elbow 15 58 1725 3 8 NPT Tee 16 30 0013 TRP Assembly 17 59 0144 Fan Guard 18 25 5649 Fan Mounting Shroud 19 62 4010 20HP Spindle Motor 20 30 3260C Gear Oil Pump Assembly 21 25 5647 Spindle Motor Shroud 22 30 7255 Check Value Assembly 23 30 7280 TRP TSC Solenoid Assembly 24 20 2549 Trans Plate 25 25 6292 Spindle Sound Shield 26 20 1455 50T Pully 27 20 2962 Read Head Mount 28 50 9010 Linear Guide 29 20 2507 Spindle Head 30 57 0372 Head Cover 31 57 0372 Encoder Cover Gasket 32 25 5565 Encoder Cover 346 Assembly Drawings 96 0189 rev L June 2005 EC 1600 Tool Release Piston 1 2 3 4 5 6 7 8 9 3 4 10 7 6 8 11 12 13 15 16 17 18 11 27 9 6 25 24 23 21 20 26 19 28 17 29 TSC Standard 50T Sub Plate 14 22 1 20 0018 Air Cyl Shaft 2 57 0027 O Ring 2 121 4X 3 57 0082 O Ring 2 448 2X 4 20 0019 Air Cyl Piston 2X 5 20 0020 Lower Air Cyl Spacer 6 57 0095 O Ring 2 327 3X 7 48 1662 Dowel Pin 6X 8 20 0022 Air Cyl Housing 9 58 1695 90 Degree Elbow 3X 10 20 0021 Upper Air Cyl Spacer 11 25 0009 Switch Bracket 2X 12 32 2204 Clamp P
297. installed The following parameters must be set appropriately 234 Parameters 96 0189 rev L June 2005 201 132 133 XYZ SCREW COMP COEF 8000000 272 273 274 XYZ SCREW COMP T CONST 28000 351 TEMP PROBE OFFSET 450000 16 SCALE Z HIST For HAAS diagnostic use only 267 Y SWITCHES Parameter 267 is a collection of single bit flags used to turn servo related functions on and off The left and right cursor arrows are used to select the function being changed All values are 0 or 1 only The function names are 0 Y LIN SCALE EN Used to enable linear scales for the Y axis 1 Y INVRT LN SCL Used to invert the Y axis linear scale 2 DSBL SCALE Z Used to disable the linear scale Z test 3 Y ZERO AXIS TC Used to return axis to the position specified by the TOOL CHANGER OFFSET parameter prior to a tool change On mills with a gimbaled spindle this bit must be set to 1 on the A and B axes parameter 269 and 270 and 0 on all other axes 4 Y 2ND HOME BTN Used to move axis to coordinate specified in Work Offset G129 5 Y NEG COMP DIR Used to negate the direction of thermal compensation 6 Y DELAY AXIS 0 Used with an APL to ensure Y axis is zeroed before A axis of APL 7 Y MAX TRAVEL INP This bit is set to 1 on five axes machines This bit indicates that there is a switch visible through MOCON that detects if the axis has rotated all the way round It is used to tell the control to skip the first zero switch when zeroing so it can unwr
298. into the Bearing Holder g Lightly grease the O Ring on the end of the Extension Tube Assy 30 1242 Apply blue Loctite to the thread on the end Insert the Extension Tube down into the Drawbar Tighten by hand as far as possible It has left hand threads Mechanical Service 144 96 0189 rev L June 2005 h Block Spindle rotation with a bolt bar or socket inserted into one of the Pulley holes It will stop against the TRP Fork i Tighten the Extension Tube to 15 20 ft lb Remove the bolt from the Spindle Pulley j Install the Rotating Union Lightly grease the O ring DO NOT put Loctite on the threads i Thread the Coolant Union onto the end of the Extension Tube it has left hand threads DO NOT USE LOCTITE Tighten the threads snugly using two wrenches ii Attach the clear plastic Drain Hose to the barb connector on the side of the union Use a hose clamp if one is available The hose must travel downward below the union to drain off collected coolant The union will be damaged if coolant collects inside the union iii Thread the black coolant hose onto the connector on the check valve assembly Tighten with a wrench Do not over tighten k Measure the runout at the top of the rotating union with a dial indicator Record the measurement on the Service Report l Check the Tool Clamp and Unclamp switches They should not have moved m Test run the TSC system to check for leaks 4 Plug the 3 air hoses in the T
299. ion the precision level on the center of the pallet parallel to X Axis and note level Then position the level in line with the Z axis and note level If necessary loosen the center leveling screws and adjust rough level before proceeding Roll Position the precision level on center of the table parallel to X Axis Jog the Z axis full travel in each direction and note any deviation in the level Pitch Position the precision level on center of the table parallel to Z Axis Jog the Z axis full travel in each direction and note any deviation in the level Adjust for any deviation of pitch or roll as necessary 125 Mechanical Service 96 0189 rev L June 2005 Receiver Geometry Verification Note The receiver is never adjusted to correct pallet flatness It is adjusted for runout and concentric ity Both need to be confirmed before the pallet is installed Indicate the receiver concentricity by first rotating the A axis 45deg Then indicate the outside vertical edge or outermost edge of the locating key that is facing the spindle Set the Z axis position to zero and move the indicator off in Z axis to allow for A axis rotation Then rotate at 90deg intervals until all 4 locating pads have been indicated The specification is 0003 00762mm or less Indicate the receiver runout by indicating the top of the locating pads on the receiver On machines with 1 or 45 degree indexers move off the pad in Z axis rotate A axis 90 deg to next pa
300. ip rate calculated depends on two other variables speed and current Slip rate slip gain x speed max speed x current max current The slip gain value is the value that slip rate would assume at maximum speed and maximum current 16 384 1 Hz 181 C MIN SLIP The minimum value allowed from the slip rate From the equation Slip rate slip gain x speed max speed x current max current It can be seen that at a zero speed the slip rate would become zero Therefore a minimum value for slip rate is required 16 384 1Hz 182 C ACCELERATION Maximum acceleration of axis The value is the units of encoder steps second second at the motor 183 C MAX FREQ The frequency at which the motor will be run when maximum spindle RPM is commanded Units 0 01 Hz two implied decimal places 228 Parameters 96 0189 rev L June 2005 184 C MAX ERROR The maximum allowable error in Hz between commanded spindle speed and actual speed If set to zero it will default to 1 4 of Parameter 183 185 C FUSE LEVEL See Parameter 10 for description 186 C DECELERATION Maximum deceleration of axis in encoder steps per second per second 187 C HIGH GEAR STEPS REV This name is used when a Vector Drive is installed This function takes on two mean ings depending on how many spindle encoders are used on the machine If only one encoder is present it is the number of encoder steps per mechanical revolution of the spindle motor when the transmission is i
301. ired to complete one full rotation of the platter For example an HRT 210 with a 90 1 gear ratio a final drive ratio of 2 1 and an encoder count of 2000 lines would be 2000 x 4 x 90 x 2 360 4000 steps for a brushless HRT 210 with a 90 1 gear ratio a final drive ratio of 2 1 and an encoder count of 8192 the formula would be 8192 x 4 x 90 x 2 360 16384 steps If for example 16384 ended up being 13107 2 non integer the user must make sure the single bits SCALE FACT X and the COMBINATION OF SCALE X LO and SCALE X HI are turned on in parameter 43 When the scale factor x bit is 1 the scale ratio is interpreted as divide by X where X depends on scale x lo and scale x hi see parameter 1 for scale x lo and scale x hi values For example 8192 x 4 x 72 x 2 360 13107 2 You would then turn on the scale fact x bit and the scale x lo bit which would give you a factor of 5 thus 13107 2 x 5 65536 encoder steps 48 A MAX TRAVEL STEPS See Parameter 6 for description Normally this parameter would not apply to the A axis however this parameter is used on mills with a gimbaled spindle 5 axis mills On a VR series mill this parameter is used to limit the amount of angular movement of the spindle A and B axes The A and B axes are limited in move ment to a distance between negative MAX TRAVEL and positive TOOL CHANGE OFFSET On 5 axes mills A and B axes ROT TRVL LIM must be set to 1 MAX TRAVEL and TOOL CHANGE OFFSET must
302. is a problem with serial I O or interrupts Disconnect anything on the external RS 232 and test again SIO Serial I O initialization complete Normally On If this light does not come on there is a problem with the serial ports Disconnect anything on the external RS 232 and test again POR Power on reset complete Normally On If this light does not come on there is a serious problem with the processor PCB Check that the EPROM is plugged in Test the card with the buss connectors off HALT Processor halted in catastrophic fault Normally Off If this light comes on there is a serious problem with the processor PCB Check that the EPROM is plugged in Test the card with the buss connectors off 206 Technical Reference 96 0189 rev L June 2005 5V 5V logic power supply is present Normally On If this light does not come on check the low voltage power supply and check that all three phases of 230V input power are present There 1 two position DIP switch on the processor PCB labled S1 Switch S1 1 must be ON to auto start the CNC operational program If S1 1 is OFF the PGM light will remain off Switch S2 1 is used to enable FLASH If it is disabled it will not be possible to write to FLASH The processor connectors are J1 Address buss J2 Data buss J4 Serial port 1 for upload download DNC 850 J5 Serial port 2 for auxiliary 5th axis 850A J3 Power connector J6 Battery MEMORY RETENTION BATTERY The memo
303. is running and table is clamped Result Table remains clamped upon attempting to unclamp the clamp plate will not rise and the clamp status switch will show the table as clamped The machine will generate an alarm Comment This is a safe condition The table will remain clamped Machine will not function until solenoid is replaced 6 Failure The solenoid on the safety valve burns out or loses power when the table is clamped and the machine is operating Result The machine will continue to function normally It will clamp and unclamp without incident In the event the machine is E Stopped in the middle of a table index the clamp plate remains unclamped If power is lost or the machine is powered off during a table index the clamp plate will clamp Comment A failed safety circuit valve is not detectable This is an unsafe condition as it is found only when the machine has already crashed 7 Failure Table clamped and machine loses air pressure Result The low air pressure alarm will reach its time limit and alarm out the machine If air is lost while the machine is cutting the table will remain clamped via the clamp springs Comment The clamp springs are adequate to prevent the table from moving grossly off of the locating fingers 8 Failure Table unclamped and the machine loses air during a pallet change Result The low air pressure alarm will not alarm out the machine until it has reached its time limit At the time of air loss t
304. ission View the sight glass on the side of the transmission box as shown The oil level should be half way on the sight glass Fill as needed Oil Change 1 Remove the sheet metal from the spindle head 2 Remove the drain plug as shown Inspect the magnetic drainplug for signs of metal particles 3 Blow downward with an air hose in the vicinity of the fill hole to prevent dirt and metal particles from entering the gear case Remove the fill plug 4 Add Mobil DTE 25 gear oil until the oil level is half way up the sightglass 5 Run a spindle warm up and check for leaks EC SERIES PALLET CHANGER ROTARY TABLE Oil Replacement EC 300 Periodically check the oil level in the reservoir and keep it filled It is not necessary to replace the oil Remove 8 BHCS on Bottom Remove row of 6 BHCS on Top Remove 3 BHCS on Sides Clam Shell Rotary Table Oil Reservoir Maintenance 259 96 0189 rev L June 2005 EC 400 Full Fourth Axis Rotary Table Perform Every 2 years Air Vent pressure relief Oil Drain Oil Fill Sight Glass Oil Fill Connection Oil Reservoir Pre Fill Pallet Side Spindle Side Oil In Solenoid Plunger 1 Remove the fourteen 14 BHCS on the right Z axis way cover at the receiver end and slide it toward the column 2 Remove the left Z axis way cover Jog the Z axis all the way toward the column and rotate the H frame 45 counter clockwise Remove the thirteen 13 BHCS th
305. it tool to the spindle 9 If necessary loosen the five ATC SHCS and use a mallet to align the mounting bracket Adjust the ATC along the mounting slots and align the tool and spindle s center 10 Check the spindle tool change position If the spindle tool change position has changed reset Parameter 64 per the instructions in this chapter 11 Return to normal operation Insert tool holders through the spindle and perform several tool changes Observe the tool changer during operation and make any adjustments if necessary 12 Torque the ATC mounting SHCS to 80 ft lbs Replace all cam box sheet metal covers and fasten ers Apply blue loctite to the fasteners and tighten EC 300 TOOL CHANGER DOOR OPEN SWITCH ADJUSTMENT The tool changer door must be completely open before the sensor switch on the air cylinder changes its state 1 With the machine on E stop disconnect the main air supply 2 Clamped to the air cylinder with a hose clamp is the tool changer door open switch Move the sensor switch toward the rod end of the air cylinder until it reaches the end cap of the air cylinder 3 Open the tool changer door all the way Watch the diagnostic screen Slowly slide the sensor switch back along the air cylinder until the tool changer door bit changes from 0 to 1 83 96 0189 rev L June 2005 Mechanical Service TC Door Open View Rotated 90 CCW Spring Damper TC Door Closed Hose Clamp Tool Changer Door Open
306. its commanded position within the allowed time alarm 625 INVALID TC START CONDITION is generated 311 ARM BUMP TIME DEG This parameter supports the side mount tool changers During tool change recovery the arm may be moved a small amount by pressing the ATC FWD or ATC REV key Each press of the key will cause the arm motors to run for the amount of time in milliseconds specified by this parameter For mills without a side mount tool changer this parameter should be set to 0 For the high speed tool changer this parameter specifies the number of thousandths of degrees to bump the arm i e 1000 1 deg On horizontal mills with a side mount tool chager the arm may be rotated a small amount by pressing the END or PAGE DOWN keys The shuttle may be moved by pressing the Left Arrow or Right Arrow keys Each press of the key will cause the motor to run for the amount of time in milliseconds specified by this parameter This parameter is most commonly set to 30 312 CAROUSEL BUMP TIME This parameter supports the side mount tool changers During tool change recovery the carousel may be moved a small amount by pressing the Left Arrow or Right Arrow key Each press of the key will cause the carousel motors to run for the amount of time in milliseconds specified by this parameter For mills without a side mount tool changer this parameter should be set to 0 313 POCKET INCREMENT This is a parameter for the bridge mill Under normal circumstances i
307. ket to bottom left linear guide pad and leave bolts loose Grease the edges of the door that will be sliding against main panel amp door guide Slide door into door guides and attach to the lower door bracket Align door so it is square to panel prior to tightening the door bracket screws Loosen 4 linear guide pad bolts and push door flush against main panel face and re tighten Drive Chain 10 Place chain around idler assemblies and attach one end to bottom door bracket at the hole closest to the lower idler assembly using a master link Install jam nut onto threaded right handed side of the turnbuckle Attach the opposite end of the turnbuckle to the other hole in the bottom door bracket using a second master link Make sure chain is properly located on both idler assemblies Tighten the chain using the turnbuckle and lock with jam nut 11 Retract air cylinder and top door to the closed position Move the bottom door so the top edge is even with the first bend line in the top door Attach chain retainer to top connect bracket and lock it into the chain 12 Verify the operation of both doors Move the top connect bracket back and forth with the cylinder stroke The rod aligner should prevent any binding SETTING SPINDLE ORIENTATION 1 POWER UP machine Go to PARAMETERS Unlock PARAMETERS and change the value under PARAMETER 257 to 0 2 Place a tool into the spindle Enter TCR mode Align the spindle dogs to the double arm key
308. l Front Switch Box 9 59 0278 Knob and Screw 10 20 1341 Tool Hodler Block 11 20 0798 Bracket Tool Holder 12 25 5412 Nozzle Holder Backet 13 25 4946 Panel Front Right 14 58 1677 Fitg bkhd NPT 1 4 x 750 dia 15 58 3618 Fitg NPT 1 4F x NPT 1 4M 90 Brass 16 25 4950B Pan Front Upper 17 25 4971 Apron Left Front 18 25 4947A Panel Front Left 19 59 0123 Wire Clip 20 25 4949A Panel Side Left Top 21 25 5420 Stiffner brkt panel left 22 25 4952 Top Cover Front 23 25 4953 J Box Top Cover 24 25 5260 Z Frame Front Door Window 25 28 0152 Window Door Front 26 25 4997A Door Front 27 54 0030 Guide Wheel 28 25 5402 Door Hook 29 25 4043 Latch Spring 30 20 0259 4X Bottom Door Spacer 31 59 6210 Handle Door 32 25 1292 Mount Door Handle 33 25 5415 Door Guide Bracket 34 32 5074A Front Door Clse Switch 35 25 5416 Door Switch Dog 36 58 0670A Coolant Drain Tube 37 20 6016 Rail Spacer 38 20 1433 V Track Door 39 25 4970 Apron Right Front 40 25 4948 Panel Side Right Top 41 25 4043 Latch Spring EC 400 Front Assembly 337 Assembly Drawings 96 0189 rev L June 2005 1 2 3 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 27 29 EC 400 Column Assembly 1 20 2043 Column Machined 2 25 4996 BRKT Carrier Column 3 58 3045 Lube Fitg Adaptor 4 58 3045 Lube Fitg Adaptor 5 58 0634 Copper Tubing Column 6 22 7458 Cam Linear Guide
309. l Rotating Door 24 25 5239A Retainer Seal Rotating Door 25 57 0330 2X Seal Rotating Door Cover 26 25 5234B Rotating Door Cover 27 20 2284B 2X Cable Rotating Door 339 Assembly Drawings 96 0189 rev L June 2005 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 10 42 43 44 45 47 46 48 49 EC 400 Receiver Assembly 340 Assembly Drawings 96 0189 rev L June 2005 EC 400 Receiver Assembly 1 20 1123A Pallet plug 2 135 parker O ring 2 20 2048A Pallet machined 3 40 1639 SHCS 3 8 16x1 8 4 20 1995 Receiver clamp plate 5 30 6551 Air blast assembly 6 48 1667 Dowel pin 1 2x3 2 7 20 2041 Receiver body machined 57 0328 O ring 2 339 viton 2 25 5252 Receiver wear surface 2 57 0337 V ring seal 40 16575 SHCS 8 8 20 1994 Receiver piston 25 5250 Piston wear surface 9 57 0329 O ring 2 10 20 1996A Receiver shaft 57 0328 O ring 3 57 5148 O ring 11 20 1997 Receiver nut 12 20 1999A Receiver seal plate 40 1500 SHCS 16 13 20 2022A Rotary table platter 43 1600 SHCS 8 45 0114 Washer 8 40 1646 SHCS 8 45 0038 Washer 8 14 2 4285 Face Gear 2 15 57 0337 O ring 16 35 4284A Spindle gear assy 48 0035 Dowel pin 3 8 x 57 2121 O ring 2 161 17 57 0337 O ring 18 25 5011 Right tele Z axis way cover 19 57 0326 Right tele way cover gasket 20 25 630
310. l face where the door guide will be mounted Mount door guide to main panel with the guide spacer between them using 10 32 flat head screws 6 Grease the edges of the door that will be sliding against main panel amp door guide Slide top door into door guide and place flange onto linear guide pad top right Put the top door bracket over the door flange and position the door between the bracket and the upper linear guide truck Push door flush against main panel and tighten the four bolts that hold the bracket to the linear guide Check sliding motion of top door bracket and truck this should be smooth and uniform 85 96 0189 rev L June 2005 Mechanical Service 7 Retract air cylinder rod Place a 7 16 washer over rod aligner thread Move top door bracket down to air cylinder rod aligner The hole in bracket should line up with rod aligner without forcing it over rod end If not loosen air cylinder mounting bolts reposition and then retighten the bolts Place flat washer and split washer over rod end and tighten with a 7 16 20 nut By hand move the cylinder rod door bracket and door in and out looking for any binding If there is any misalignment loosen the air cylinder mounting bolts and let it self align then retighten the bolts 8 Grease main panel faces where door guides will be mounted Mount door guides to main panel with guide spacers sandwiched between them via 10 32 zinc flat head screws 9 Attach the lower door brac
311. l filters To change the filter element follow these steps 1 Remove the screws that hold the oil reservoir to the pump body carefully lower the reservoir and set aside 2 Use a strap wrench pipe wrench or adjustable pliers to unscrew the end cap see the figure Caution Use a screwdriver or similar tool to stop the filter from turning while the end cap is removed 3 Remove the oil filter element from the filter body once the end cap is removed 4 Clean the inside of the filter housing and the filter end cap as required 5 Install the new oil filter element p n 94 3059 O ring and the end cap Use the same tools that were used to remove the filter end cap to tighten it Do Not Over Tighten 6 Replace the oil reservoir ensure the gasket seats properly between the reservoir and the top flange O Ring Un screw end cap Screwdriver Filter Element Oil Filter P N 94 3059 Maintenance 257 96 0189 rev L June 2005 SIDE MOUNT TOOL CHANGER GEARBOX OIL Checking the oil level Oil Fill Level 1 13 12 11 10 9 8 7 6 5 4 3 2 23 22 21 20 19 18 17 16 15 14 24 Carousel Number Disc Disc Mounting BHCS 6 Oil Fill Plug Oil Fill Level Drain Plug Vertical Mills EC Series Mills Vertical Mills View the Oil level sight glass in the location shown The proper level is half way on the sight glass If more oil is needed fill the gear box
312. l help the final alignment Snug bolts while spindle is rotating then stop the spindle and torque the bolts 5 Install the air blast purge bracket and solenoid on the back of the motor Ensure the cylinder is centered over the motor shaft adjust as necessary Connect the air line to the solenoid 3 3 Tool Release Piston TRP Transfer Tube Coupler Hub Coupler Spider Shaft Adaptor Shaft O Ring Transfer Tube and Motor Shaft Motor and Air Blast Purge Bracket 65 Mechanical Service 96 0189 rev L June 2005 50 TAPER TRANSMISSION AND MOTOR REPLACEMENT Removal 1 Lower the Z axis travel to its full negative value full down Position the mill table so that it is centered on the X axis and as close to the doors as possible full Y This will allow the best working surface 2 Clean the mill table of any grease coolant or chips You will be standing on the mill table during this procedure and need firm footing 3 Power OFF the machine Remove all air and power service from the machine 4 Remove the head covers Refer to the Head Covers Removal Installation section 5 Remove the TRP assembly Refer to the 50 Taper Spindle TRP Removal section CAUTION The TRP assembly is very heavy When moving ensure you have a place to set the assembly when removed NOTE Make sure you collect all washers and spacers from beneath the TRP assembly Keep these separated in sets 6 Remove the TSC exten
313. large enough to exceed the continuous rating of the motor The servos will be turned off when this occurs This can be caused by running into the mechanical stops It can also be caused by anything that causes a very high load on the motors 112 NO INTERRUPT Electronics fault Call your dealer 113 SHUTTLE IN FAULT Tool changer is not completely to the right During a tool changer operation the tool in out shuttle failed to get to the in position Parameters 62 and 63 can adjust the time out times This alarm can be caused by anything that jams the motion of the slide or by the presence of a tool in the pocket facing the spindle A loss of power to the tool changer can also cause this Check relays K9 K12 and fuse F1 on IOPCB 114 SHUTTLE OUT FAULT Tool changer is not completely to the left During a tool changer operation the tool in out shuttle failed to get to the in position Parameters 62 and 63 can adjust the time out times This alarm can be caused by anything that jams the motion of the slide or by the presence of a tool in the pocket facing the spindle A loss of power to the tool changer can also cause this Check relays K9 K12 and fuse F1 on IOPCB 115 TURRET ROTATE FAULT Tool carousel motor not in position During a tool changer operation the tool turret failed to start moving or failed to stop at the right position Parameters 60 and 61 can adjust the time out times This alarm can be caused by anything that jams the rotation of the turret
314. larm for one axis can be caused by a bad grounding on the motor leads of another axis Axis Cable Fault During a self test the encoder cable signals were found to be invalid This alarm is usually caused by a bad cable or a bad connection on the motor encoder connectors Check the cable for any breaks and the encoder connectors at the motor controller board Machine noise can also cause this alarm although it is less common Troubleshooting 29 96 0189 rev L June 2005 Alarm 101 MOCON Comm Failure During a self test of communications between the MOCON and main processor the main proces sor does not respond and is suspected to be dead This alarm is generated and the servos are stopped Check all ribbon cable connections and all grounding Machine noise can also cause this alarm although it is less common Alarm 157 MOCON Watchdog Fault The self test of the MOCON has failed Replace the MOCON Rotary CRC Error Alarm 261 This alarm is normally the result of an incomplete software installation To correct this error Change Setting 30 to any selection but OFF note the original selection Then go to parameter 43 and change one of the bits from 1 to 0 or vice versa and press WRITE The bit must be changed from its original value to its alternate value Simply changing the Setting and Parameter bit from one value to another and then back again corrects the fault and will clear any further occurrences of the alar
315. late using the removed SHCS 6 Place and secure the TSC valve bracket to the right side of the motor lift plate using the removed SHCS if equipped 7 Properly orient the transmission motor assembly if necessary Insert the four SHCS that attach the transmission mount plate to the spindle head 8 Use a Belt Tensioning Tool to tighten drive belts Do not overtighten the drive belts 9 Slip on the Encoder belt Reattach the Encoder bracket 10 Replace the TRP assembly See 50 Taper Spindle TRP Installation 11 Replace the TSC union and extension shaft Refer to the Through The Spindle Coolant System section NOTE The TSC union and extension shaft are reverse thread 12 Lubricate any new or removed parts if necessary Remove the wood spacer if used Check to make sure all connections are secure 13 Reconnect air and power services If equipped with TSC check drawbar for runout See the Adjusting Extension Tube Runout section 67 Mechanical Service 96 0189 rev L June 2005 14 Replace sheetmetal 15 Set spindle orientation Refer to the Spindle Orientation section 16 Check Toolchanger function TOOL RELEASE PISTON REPLACEMENT Removal 1 Remove the rear enclosure panel 2 Jog the Y axis all the way to the top Insert a sturdy piece of wood on the bottom of the column casting Jog the Y axis down until the bottom of the spindle head rests on the wood This will prevent the s
316. le new part into the Adapter 4 Thread the T Fitting onto the Nipple and tighten so that it is oriented as shown in the following figure Nipple T Fitting 5 Thread the Nipple into the right side of the T Fitting Thread the Street Elbow into the left side of the T Fitting as shown below Tighten all parts 6 Thread 90 Degree Elbow onto the Nipple Thread Nipple into the Elbow Tighten to orient as shown in the following figure 160 Mechanical Service 96 0189 rev L June 2005 Street Elbow 2 7 Thread the Hose Barb into the remaining 90 Degree Elbow and attach to the Pressure Booster assembly Orient as shown in the following figure Hose Barb 8 Attach the Braided Hose to the Hose Barb using the supplied hose clamp Use caution when moving the Pressure Booster Assembly as the internal hydraulic fluid can spill from the Braided Hose 9 Remove the plug in the center hole of the Pressure Booster Thread a 4 SAE to NPT female Adapter new part into the center hole 10 Thread the Hydraulic Hose into the Adapter 11 Thread the Reducer into the Street Elbow Thread the Muffler and Reducer together then attach to the Street Elbow Tighten all parts This will act as a snorkel for the system 161 96 0189 rev L June 2005 Mechanical Service FINAL ASSEMBLY Orient the Plate as shown and attach to the bottom of the Pressure Booster Pressure Booster Assembly Low Side Port Tubing Elbow Plate Pres
317. leave both 490 cables 2 and 3 discon nected from the drive and power up the machine a Does the DC Bus voltage come up If not the Vector Drive is faulty b Measure the voltage between terminals 1 and 3 The voltage should be 300 VDC or more If not the Vector Drive is faulty If both a and b check out okay there is a problem with either the amplifiers or the REGEN load 10 Troubleshooting 96 0189 rev L June 2005 If the fault occurs upon acceleration or the spindle accelerates slowly or the spindle makes noise do the following 7 Disconnect the output cables to the spindle motor Turn on the machine and press lt RESET gt Do not command the spindle to turn With a volt meter measure the DC voltage between each output phase terminals 9 10 and 11 to the 320V RTN terminal 3 The meter should read 165 VDC in each case else one phase is faulty 8 Measure the resistance across the motor wires from phase to phase and from each phase to chassis The meter should read 1 ohms phase to phase and open phase to chassis If the fault occurs upon deceleration or acceleration just as the spindle reaches its speci fied speed or if an overvoltage alarm 119 occurred do the following 9 Disconnect the REGEN load resistors terminals 1 and 2 and measure the resistance from each wire lead to chassis ground and between the wire leads The meter should read open lead to ground and 8 6 ohms between the leads 10 Meas
318. lic oil fill the hydraulic port to remove any remaining air 3 Install a reducer into the hydraulic port and then install a swivel elbow into the reducer Thread the hydraulic hose from the pressure booster into the swivel elbow Orient the swivel elbow as shown and tighten Install an elbow into the air port and orient the elbow as shown Hydraulic Cylinder Swivel Elbow Hydraulic Hose Elbow Hydraulic Port Air Port Hydraulic Cylinder 135 Mechanical Service 96 0189 rev L June 2005 4 Cut the tubing to fit once installed in the table Insert one end of one piece of tubing into the elbow on the air side of the hydraulic cylinder 5 Thread one of the two remaining elbows into the low pressure port of the pressure booster located in the middle of the pressure booster Insert one end of one piece of tubing into the low pressure elbow Coil the tubing and mark with masking tape See figure 6 Place the pressure booster flat on the work surface Route the braided hose upward use caution to avoid fluid spillage 7 Thread the remaining elbow into the high pressure port located on the rear of the pressure booster cylinder Insert one end of one piece of tubing into the high pressure elbow Coil the tubing and mark with masking tape See figure 8 Use cable ties to secure the tubing lines to follow the hydraulic hose out PRESSURE BOOSTER ASSEMBLY BENCH TEST Prior to installation of the pressure booster assembly
319. llowed in milliseconds for the tool pocket to be raised or lowered If the pocket does not move to its commanded position within the time allowed by this parameter and by parameter 62 alarm 626 TOOL POCKET SLIDE ERROR is gener ated For mills without a side mount tool changer this parameter should be set to 0 307 POCK UN LOCK DELAY This parameter supports the side mount tool changers It specifies the time allowed in milliseconds to lock or unlock a tool pocket For mills without a side mount tool changer this parameter should be set to 0 308 ARM ROTATE TIME This parameter supports the side mount tool changers It specifies the time allowed in milliseconds for the arm to rotate to the next position The positions are Clamp Unclamp and Origin If the arm does not move to the commanded position within the allowed time alarm 622 TOOL ARM FAULT is generated For mills without a side mount tool changer this parameter should be set to 0 309 MOTOR COAST TIME This parameter supports the side mount tool changers It specifies the time allowed for the tool changer to start only If the arm has not moved after the allowed time alarm 627 ATC ARM POSITION TIMEOUT is generated Units are milliseconds 310 CAM LOCK DELAY This parameter supports the side mount tool changers It specifies the time allowed in milliseconds to lock the cam by pushing the shot pin in or to unlock the cam by pulling the shot pin out If the shot pin has not moved to
320. located for use prior to payment exceeded Call your dealer 145 X LIMIT SWITCH Axis hit limit switch or switch disconnected The stored stroke limits should stop the slides before they hit the limit switches Verify the value of parameter 125 Grid Offset and check the wiring to the limit switch and connector P5 at the side of the main cabinet Can also be caused by a loose encoder shaft at the back of the motor or coupling of motor to the screw 146 Y LIMIT SWITCH Axis hit limit switch or switch disconnected The stored stroke limits should stop the slides before they hit the limit switches Verify the value of parameter 126 Grid Offset and check the wiring to the limit switch and connector P5 at the side of the main cabinet Can also be caused by a loose encoder shaft at the back of the motor or coupling of motor to the screw 147 Z LIMIT SWITCH Axis hit limit switch or switch disconnected The stored stroke limits should stop the slides before they hit the limit switches Verify the value of parameter 127 Grid Offset and check the wiring to the limit switch and connector P5 at the side of the main cabinet Can also be caused by a loose encoder shaft at the back of the motor or coupling of motor to the screw 148 A LIMIT SWITCH Normally disabled for rotary axis 149 SPINDLE TURNING A signal from spindle drive indicating that the spindle drive is stopped is not present while a tool change operation is going on 150 Z AND TOOL INTERLOCKED Tool chan
321. low The booster is located on the front of the machine s table Access the booster fill fitting and add Mobile DTE 24 oil to bring the oil level to the high oil level line marked on the booster If the alarm reoccurs within 90 days contact your Haas Dealer for service 644 APC LOW AIR PRESSURE A low air pressure condition was detected during pallet changer operation Check that the air supply is 100 PSI minimum Check that the air supply line is the correct diameter Check that the mill pres sure regulator is set to 85 PSI If this alarm continues to occur check the entire pressurized air system for any abnormal air leakage 645 RP PALLET JAMMED CHECK FOR OBSTRUCTION The pallet changer has not rotated away from its original position CW CCW in a reasonable time or has not achieved its final position CW CCW in a reasonable time or has not been permitted to lower to the fully down position After correcting the condition run an M50 to continue machining 646 RP CW CCW SWITCH ILLEGAL CONDITION Both of the switches that sense the rotational position of the pallet changer are indicating the impossible condition that the pallet changer is rotated CW and CCW at the same time Only one switch should be tripped at a time Check the function of the rotational sense switches their connectors and their wiring After correcting the condition run an M50 to continue machining 647 RP UP DOWN SWITCH ILLEGAL CONDITION LIFT CYLINDER The switches that sen
322. lso be caused by loose scale connectors 669 W AXIS LINEAR SCALE Z FAULT Encoder marker pulse count failure This alarm usually indicates that the Z Fault encoder has been damaged and encoder position data is unreliable This can also be caused by loose scale connectors 670 TT or B OVER TRAVEL RANGE Commanded TT or B axis move would exceed the allowed machine range Machine coordinates are in the negative direction This condition indicates either an error in the user s program or improper offsets 671 TT or B LIMIT SWITCH Axis hit limit switch or switch disconnected The stored stroke limits should stop the slides before they hit the limit switches Verify the value of parameter 481 Grid Offset and check the wiring to the limit switch and connector P5 at the side of the main cabinet Can also be caused by a loose encoder shaft at the back of the motor or coupling of motor to the screw 53 Alarms 96 0189 rev L June 2005 673 TT or B SERVO ERROR TOO LARGE Too much load or speed on TT or B axis motor The difference between the motor position and the commanded position has exceeded Parameter 470 The motor may also be stalled discon nected or the driver failed The servos will be turned off and a RESET must be done to restart This alarm can be caused by problems with the driver motor or the slide being run into the mechanical stops 674 TT or B SERVO OVERLOAD Excessive load on TT or B axis motor This can occur if the load on the motor ove
323. lt Plug Load Station Index Disc Incoming air 85 psi from machine regulator Safety Solenoid H Frame Up Solenoid H Frame Down Solenoid 2 379 O Ring inside Rod End Shoulder Screw and Jam Nut amp 2X Washer Hidden 6X Dowel Pins H frame up Reed Switch and Hose Clamp From Preceding Page Mechanical Service 120 96 0189 rev L June 2005 PALLET CHANGER DISASSEMBLY AND REPLACEMENT Disassembly 1 Remove the rotating door and the servo motor sheet metal cover 2 Unplug the electrical wires to the servo motor Dismount the servo motor held to the umbrella mount plate with four 4 SHCS 3 Remove the SHCS that hold the gearbox and the cycloid tube to the torque tube Remove the gearbox with the cycloid tube 4 If the cycloid hub must be removed from the gear box cover the gear box hole to prevent contami nation 5 Unbolt the torque tube from the bearing cap and lift it off of the dowel pins 6 Unbolt the bearing cap and lift it off of the dowel pins exposing the wave spring four bearings and bearing spacer 7 Remove the two 2 hardstops from the H frame 9 Remove the eight 8 SHCS that hold the H frame to the hub Carefully lift off the H frame from the dowel pins 10 Lift the hub off of the APC shaft 11 If the bearings need to be replaced remove them from below the hub using a punch If the bearings are removed replace them Pack the new bearings with Moly grease 12 Remove
324. lt of sideways movement of a tool holder in the spindle Fretting can leave a wave pattern on the mating surfaces and will affect the fit and finish of both the tool holder and the spindle If light fretting is present check the application to ensure proper machining techniques are being used check the feeds and speeds for the tools and material being used Light fretting and rust may be cleaned from the tool holder with a fine scotchbrite hand pad and solvent If scotchbrite is used clean the tool holder and spindle taper thoroughly after use with an alcohol pad Apply a thin coat of light oil to the taper of the tool holder Grease the pull stud 12 Troubleshooting 96 0189 rev L June 2005 1 3 SERVO MOTORS BALL SCREWS NOT OPERATING All problems that are caused by servo motor failures should register an alarm Check the alarm history to determine thecause of the problem before any action is taken Servo motor is not functioning Check the power cable from electrical cabinet to ensure connection is tight Encoder is faulty or contaminated Alarms 139 142 153 156 Replace motor assembly on brushless machines Open circuit in motor Alarms103 106 Replace motor assembly Axis Motor Motor has overheated resulting in damage to the interior components Alarms 135 138 176 Replace motor assembly Axis Motor Wiring is broken shorted or missing shield Alarms 153 156 175 182 185 Check for
325. m Change the bit and Setting 30 back to their original values Press Reset to clear the alarms or cycle power to the machine SAVING THE MACHINE INFORMATION To review a machine s set up save the parameters settings offsets variables and G code programs and alarm history to a floppy disk To do this insert a blank diskette press LISTPROG POSIT enter the machine s serial number and press F2 The new file suffix will be HIS 30 Alarms 96 0189 rev L June 2005 2 ALARMS Any time an alarm is present the lower right hand corner of the screen will have a blinking ALARM Push the ALARM display key to view the current alarm All alarms are displayed with a reference number and a complete description If the RESET key is pressed one alarm will be removed from the list of alarms If there are more than 18 alarms only the last 18 are displayed and the RESET must be used to see the rest The presence of any alarm will prevent the operator from starting a program The ALARMS DISPLAY can be selected at any time by pressing the ALARM MESGS button When there are no alarms the display will show NO ALARM If there are any alarms they will be listed with the most recent alarm at the bottom of the list The CURSOR and PAGE UP and PAGE DOWN buttons can be used to move through a large number of alarms The CURSOR right and left buttons can be used to turn on and off the ALARM history display Note that tool changer alarms can be easily corre
326. m the receiver 5 Remove the BHCS and the coupling housing cover plate from the coupling housing 6 Loosen the SHCS on the motor coupling at the ball screw 7 Disconnect all wiring from the motor 8 Remove the SHCS and remove the motor from the coupling housing INSTALLATION 1 Inspect the motor coupling and replace it if required Visually inspect the flex plates to ensure they are parallel to the coupling halves Slide the new coupling onto the motor shaft until the coupling half is flush to the end of the shaft NOTE The slot in the locking collar must be positioned 45 degrees between the bolt hole pattern of the coupler If improperly aligned the coupler will not have enough clamping force on the ball screw or motor shaft Refer to diagram in Coupling Replacement section 2 Reconnect all wiring to the motor 3 Align the key on the motor shaft Slide the motor into the coupling housing inserting the end of the ball screw into the motor coupling 4 Reinstall and tighten down the SHCS that hold the motor to the housing 5 Tighten the SHCS on the motor coupling at the ball screw Place a drop of blue Loctite on the screw before inserting 6 Replace the cover plate 7 EC 400 Replace the Z axis way cover 8 Check for backlash in the Z axis ball screw Troubleshooting section or noisy operation 9 Set the grid offset after the new motor has been changed COUPLING REPLACEMENT REMOVA
327. ment may occur seriously affecting the proper operation of the machine 2 Hold the ball screw vertically with the motor end down and the nut near the support end top 3 Hold the ball screw at the front left side of the machine and lower into place rotating the ballscrew into position CAUTION Be careful not to bump or scratch ball screw 4 Gently push the bearing support end of the ball screw into the bearing in the bearing support housing 5 Replace the bearing pack 6 Rotate the ballscrew nut so it goes into the nut housing and start the SHCS that secure the ballscrew nut to the nut housing Do not tighten 7 Reattach the oil line to the ball screw nut 8 Replace the X axis motor in accordance with the appropriate section 9 Torque the SHCS from the nut to the nut housing to 15 ft lb 30 ft lbs for EC 1600 105 96 0189 rev L June 2005 Mechanical Service 10 The following sequence is important to ensure proper installation of the ball screw Tighten the locknut hand tight on the motor end Install and tighten locknut on bearing support Ensure the nut does not touch the bearing support Install the shaft lock onto the bearing support end of the ballscrew This will keep the ball screw from turning while torquing the lock Place a spanner wrench on the locknut at the motor end of the assembly EC 300 Torque the clamp nut against the bearing sleeve to 15 ft lbs EC 1600 Torque the
328. motor to stop If the arm has not stopped after the allowed time alarm 627 ATC ARM POSITION TIMEOUT is generated 64 Z TOOL CHANGE OFFSET On Vertical mills For Z axis displacement from home switch to tool change position and machine zero About 4 6 inches so for an 8192 line encoder this gives 4 6 x 138718 638103 Alternate use for machines with a type 4 servo axis pallet changer This parameter positions the pallet for a pallet change For example the Z axis travel on the EC400 is done by moving the pallet not the column and therefore will not affect a tool change Also parameter 64 is generally used during zero return and that usage is consistent in the EC400 65 NUMBER OF TOOLS Number of tool positions in tool changer This number must be set to the configuration machine The maximum number of tool positions is 32 except Horizontal mills with a side mount tool changer This parameter must be 60 for the HS 60 SMTC and 120 for the HS 120 SMTC 66 SPINDLE ORI DELAY Maximum delay allowed when orienting spindle Units are milliseconds After this time an alarm is generated 67 GEAR CHANGE DELAY Maximum delay allowed when changing gears Units are milliseconds After this time an alarm is generated 68 DRAW BAR MAX DELAY Maximum delay allowed when clamping and unclamping tool Units are milliseconds After this time an alarm is generated 69 A AIR BRAKE DELAY Delay provided for air to release from brake on A axis prior to moving Unit
329. mped position switch for correct operation the switch and wiring for damage and pallet alignment Check the pallet clamp mechanism for correct operation After determining the cause and correcting the problem press Tool Changer Restore to enter pallet changer recovery recover the pallet changer and then continue operation Parameter 317 specifies the pallet clamp timeout period 947 APC PALLET UNCLAMP TIMEOUT The pallet in the mill did not unclamp in the time allowed Check for foreign objects between the pallet and the clamp plate Verify there is an adequate supply of air pressure and air volume Check air solenoids for sticking and air release ports for clogging Check the pallet clamped position switch for correct operation the switch and wiring for damage and pallet alignment Check the pallet clamp plate for damage After determining the cause and correcting the problem press Tool Changer Restore to enter pallet changer recovery recover the pallet changer and continue operation Parameter 316 specifies the unclamp timeout period 948 APC SOFTWARE ERROR Fault in pallet changer software Note the actions that caused this alarm Also record the following information On the control panel press PARAM DGNOS key to get the DGNOS screen Then press PAGE UP to the PC INPUTS page Record the values of PC STATE ALARM ST and ALARM If this alarm recurs regularly call your dealer 949 APC AXIS VISIBLE The pallet changer axis must be invisible for th
330. n S code 391 FEATURE DISABLED An attempt was made to use a control feature not enabled by a parameter bit Set the parameter bit to 1 392 B AXIS DISABLED An attempt was made to program the B axis while it was disabled DISABLED bit in Parameter 151 set to 1 or invisible INVIS AXIS bit in Parameter 151 set to 1 or a program commanded the B axis while it was the outside rotary table ROTARY INDEX button feature MAP 4TH AXIS bit in Parameter 315 set to 1 393 INVALID MOTION IN G74 OR G84 Rigid Tapping can only be in the Z minus G74 or G84 direction Make sure that the distance from the initial position to the commanded Z depth is in the minus direction 394 B OVER TRAVEL RANGE B axis will exceed stored stroke limits This is a parameter in negative direction and is machine zero in the positive direction This will only occur during the operation of a user s program 395 NO G107 ROTARY AXIS SPECIFIED A rotary axis must be specified in order to perform cylindrical mapping 396 INVALID G107 ROTARY AXIS SPECIFIED The rotary axis specified is not a valid axis or has been disabled 397 AUX AXIS IN G93 BLOCK This alarm is generated if a G code block specifies any form of interpolated motion that involves BOTH one or more of the regular axes X Y Z A B etc AND one or more of the auxiliary axes C U V W 398 AUX AXIS SERVO OFF Aux axis servo shut off due to a fault 400 SKIP SIGNAL DURING RESTART A skip signal G code G31 G35 G3
331. n high gear On direct drive machines the encoder is mounted on the motor while on others it is on the spindle or transmission output N Encoder steps enc rev Enc pulley ratio X High Gear Ratio For machines with a spindle and spindle motor encoder it is the number of spindle motor encoder steps per mechanical revolution of the encoder Its purpose is to specify the resolution of the spindle motor encoder This parameter is used in conjunction with parameter 176 bits 25 and 26 which control the ratio between the electrical revolution of the motor to the mechanical revolution of the encoder If a vector drive is not installed this parameter is called STEPS REVOLUTION and is not used 188 C ORIENT GAIN The value is the proportional gain used in the position control loop when performing a spindle orientation 189 C BASE FREQ This is the rated frequency of the motor 190 C HI SP CURR LIM At speeds higher than the base frequency the maximum current that is applied to the motor must be reduced This is done linearly from base frequency to max frequency This value is the max current at the max frequency 191 C MAX CURRENT Sets maximum current allowed from the vector drive to the spindle motor 4095 max 192 C MAG CURRENT This is the magnetization component of the current in the motor also called the flux or field current 193 C SPIN ORIENT MARGIN When a spindle orientation is done if the actual position of the spindle is within this
332. n the front side of the spindle in a cross pattern until all bolts are completely tight 4 Reset spindle orientation and check the tool changer adjustment 5 Refer to the Spindle Overheating section of Troubleshooting and use the spindle run in pro gram Verify that the spindle temperatures are acceptable SPINDLE SWEEP ADJUSTMENT NOTE The machine must be properly leveled for the spindle sweep adjustment to be accurate 1 Place an indicator on the table and insert a 6 precision test bar into the spindle 2 Jog the Z axis while indicating the bottom and then the side of the test bar The readings must be within 0 0005 10 in both the Y Z and X Z planes as stated in the inspection report supplied with the machine 3 Shim the spindle if necessary to correct the spindle sweep to specifications Recheck spindle sweep Mechanical Service 70 96 0189 rev L June 2005 3 4 DRAWBAR REPLACEMENT DRAWBAR REPLACEMENT IN LINE DRIVE The drawbar is only replaceable on the 8000 RPM spindle The 12000 RPM spindle has a non serviceable draw bar Note 12000 spindles only Should a spindle fail both the spindle and drawbar are to be replaced as a unit Removal Remove the spindle as described in the Spindle Removal section Remove the keys from the drawbar and remove the drawbar from the spindle Installation Clean and grease the shaft and shaft adaptor Install the drawbar unit Install the two keys flat sid
333. ne movement is attempted Misalignment of the facegear at the home position will cause malfunction Make sure that software 12 08 or later is loaded and the table is initialized on the settings page This assures that all parameters are set for this option To perform all of the procedures in this section the Z axis waycovers must be removed See the Z axis way cover removal section of this chapter A AXIS INDEXER LIFT SWITCH SETUP Lift Switch Setup 1 Disconnect the main air supply then plug the air line to the brake solenoid 2 Release the air pressure at the table by activating the clamp release solenoid plunger Mechanical Service 128 96 0189 rev L June 2005 3 Connect the test air regulator Haas P N T 2150 to the shop air supply Connect the outlet to the rotary table at the platter lift air in connection Air In Be sure that the regulator adjustment knob is fully open Air In Solenoid Plunger Platter Up Platter Down Sensor Switch Sensor Switch Lift Switch Bracket Lift Switch Bracket 4 Turn the regulator adjustment knob to 20 40 PSI and toggle the air pressure to the clamp fittings 5 Set an indicator on the machine with the stylus on the platter or pallet 6 Go to the diagnostics page DGNOS 7 Slightly loosen the two mounting screws on the lift switch mounted on the lift switch bracket 8 Raise and lower the pallet with the regulator adjustment knob Note that the platter up state i
334. ng X Axis Motor Coupling Housing Cover Bumper Support Bearing Housing Coupling Housing 6X SHCS 6X SHCS 4X FLHCS Bearing Locknut Bearing Locknut Bumper Ballscrew Nut Housing 4X BHCS EC 400 Removal 1 Turn the machine ON Zero return all axes and put the machine in HANDLE JOG mode 2 Remove the rear enclosure panel 3 Jog the Y axis to the bottom of its travel Jog the X axis towards the tool changer 4 POWER OFF the machine Mechanical Service 104 96 0189 rev L June 2005 5 Remove the hardstop and locknut from the bearing support 6 Remove the SHCS that secure the nut housing to the ball screw nut 7 Remove the oil line from the ball screw nut 8 Rotate the nut on the ball screw in order to move the nut near the bearing support end of the ballscrew CAUTION Do not move the column too far over since the hardstops are removed 9 Remove the X axis motor and bearing sleeve in accordance with appropriate sections 10 Pull the ball screw towards the control box side and out of the bearing in the bearing support 11 Lift the ball screw up forward and to the side of the machine until the motor end of the ball screw is free Carefully remove the ball screw Installation 1 Ensure all mating on the bearing sleeve coupling housing nut housing and ball nut are free of dirt burrs grease or other contaminants CAUTION Mating surfaces must be clean or misalign
335. ng NPT 3 8F x NPT 3 8M 90 Brass 21 58 3644 Nipple 3 8 NPT x 2 1 2 Brass 22 25 5291A Chip Basket 23 58 1693 Fitting LBO 1 2 NPT 3 8M STR 24 58 1693 Fitting LBO 1 2 NPT 3 8M STR 333 Assembly Drawings 96 0189 rev L June 2005 EC 400 Front Trough Assembly Chip Conveyor System 1 30 6477B Chip Conveyor 2 25 5309 Extension Cover Chip Conveyor 3 25 5025A Coolant Trough Extension 4 57 0334A Gasket Coolant Trough 5 25 4944 x2 Brace Auger Trough 6 25 5292 Motor Access Cover 57 0333 Gasket Extension Box 7 25 5288A Coolant Trough 8 58 0336 Pipe Plug 3 8 Brass 9 58 1679 Fitting Bulkhead NPT 3 8 x 1 10 25 5308A Chip Shield Conveyor 1 2 3 4 5 6 7 8 9 10 334 Assembly Drawings 96 0189 rev L June 2005 1 58 3680 x2 Fitting LBO 3 8 x NPT 1 4 M STR 2 58 3618 Fiting NPT 1 4F x NPT 1 4M 90 Brass 3 58 1677 Fitting BKHD NPT 1 4 x 750 Dia 4 25 5009 Brkt Base Cover 5 25 5006 Shield Bottom X A0xis 6 25 5003 Base Cover 7 25 5004 Cover Trough Right 8 20 6413A Manifold Washdown 9 25 5005 Cover Trough Left 10 25 5010 Shield Base Cover Left EC 400 Bulkhead 335 Assembly Drawings 96 0189 rev L June 2005 EC 400 Front Assembly 336 Assembly Drawings 96 0189 rev L June 2005 1 25 4948 Panel Side Top Right 2 25 4999A Header Enclosure 3 25 4951A Stiffener Bracket 4 25 4413 Rack Tool Tray 5 25 4948 Panel Side Top Right 6 25 4946A Panel Front Right 7 25 1258 Cover Switch Box 8 25 1257A Pane
336. ng surfaces e g spindle head casting spindle nose or the table Don t rapid to position when checking accuracy The indicator may get bumped and give an inaccurate reading For best results feed to position at 5 10 inches per minute Check a suspected error with another indicator or method for verification Ensure that the indicator is parallel to the axis being checked to avoid tangential reading errors Center drill holes before using jobber length drills if accuracy is questioned 6 Troubleshooting 96 0189 rev L June 2005 Once machining practices have been eliminated as the source of the problem determine specifically what the machine is doing wrong Machine will not interpolate a round hole Check that the machine is level see Installation section of the Reference manual Check for backlash Servo Motors Ballscrews section Bored holes do not go straight through the workpiece Check that the machine is level see Installation section of the Reference manual Check for squareness in the Z axis Machine bores holes out of round Check that the machine is level see Installation section of the Reference manual Check the sweep of the machine see Spindle Sweep Adjustment section Bored holes are out of round or out of position Check for thermal growth of the ballscrew see Thermal Growth section The spindle is not parallel to the Z axis Check the sweep
337. nger recovery 270 C SERVO ERROR TOO LARGE Too much load or speed on C axis motor The difference between the motor position and the commanded position has exceeded Parameter 506 The motor may also be stalled disconnected or the driver failed The servos will be turned off and a RESET must be done to restart This alarm can be caused by problems with the driver motor 271 C SERVO OVERLOAD Excessive load on C axis motor This can occur if the load on the motor over a period of several seconds or even minutes is large enough to exceed the continuous rating of the motor The servos will be turned off when this occurs This alarm can be caused by anything that causes a very high load on the motors 272 C AXIS MOTOR OVERHEAT Servo motor overheat The temperature sensor in the motor indicates over 150 degrees F This can be caused by an extended overload of the motor such as leaving the slide at the stops for several minutes 273 C MOTOR Z FAULT Encoder marker pulse count failure This alarm usually indicates that the encoder has been damaged and encoder position data is unreliable This can also be caused by loose encoder connectors 274 C LIMIT SWITCH Axis hit limit switch or switch disconnected The stored stroke limits should stop the slides before they hit the limit switches Verify the value of parameter Grid Offset and check the wiring to the limit switch and connector P5 at the side of the main cabinet Can also be caused by a loose encoder shaf
338. not reached the counter clockwise position within twelve seconds 1004 CW CCW Switch Illegal Condition One or both of the switches that sense the rotational position of the pallet changer has failed its self test 1007 Up Down Switch Illegal Condition One or both of the switches that sense the lifted lowered position of the pallet changer has failed its self test 1008 Main Drawbar Locked In Up Position The main drawbar will not disengage from the pallet nut 1009 Main Drawbar Locked In Down Position The main drawbar will not move upward to the pallet nut 1010 Main Drawbar Switch Illegal Condition One or both of the switches that sense the up down position of the main drawbar has failed its self test 1011 Main Drawbar Unclamp Timeout The main drawbar has disengaged from the pallet nut but did not reach the main drawbar down switch 1012 Main Drawbar Clamp Timeout The main drawbar has begun to travel upward but did not reach the fully raised position within 15 seconds 59 Mechanical Service 96 0189 rev L June 2005 3 MECHANICAL SERVICE RECOMMENDED TORQUE VALUES FOR MACHINE FASTENERS The following chart should be used as a reference guide for torquing machine fasteners where specified DIAMETER TORQUE 8 32 30 in lb 1 4 20 15 ft lb 5 16 18 30 ft lb 3 8 16 50 ft lb M10 100 50 ft lb M12 65 100 ft lb 1 2 13 80 ft lb 3 4 10 275 ft lb 1 8 450 ft lb 3 1 WAY COVERS X AXIS WAY CO
339. not turn the servos off but will stop the zero return operation 52 Alarms 96 0189 rev L June 2005 653 V ZERO RET MARGIN TOO SMALL This alarm will occur if the home limit switches move or are misadjusted This alarm indicates that the zero return position may not be consistent from one zero return to the next The encoder Z channel signal must occur between 1 8 and 7 8 revolution of where the home switch releases This will not turn the servos off but will stop the zero return operation 654 W ZERO RET MARGIN TOO SMALL This alarm will occur if the home limit switches move or are misadjusted This alarm indicates that the zero return position may not be consistent from one zero return to the next The encoder Z channel signal must occur between 1 8 and 7 8 revolution of where the home switch releases This will not turn the servos off but will stop the zero return operation 655 U CABLE FAULT Cable from U axis encoder does not have valid differential signals 656 V CABLE FAULT Cable from V axis encoder does not have valid differential signals 657 W CABLE FAULT Cable from W axis encoder does not have valid differential signals 658 U PHASING ERROR Error occurred in phasing initialization of brushless motor This can be caused by a bad encoder or a cabling error 659 V PHASING ERROR Error occurred in phasing initialization of brushless motor This can be caused by a bad encoder or a cabling error 660 W PHASING ERROR Error occurred in pha
340. ns The external transformer has a 45 KVA rating Installation The transformer should be located as close to the machine as possible The input and output wiring of the transformer should conform to the local electrical codes and should be performed by a licensed electrician The following is for guidance only and should not be construed to alter the requirements of local regulations The input wire should not be smaller than the 6AWG for the 45KVA transformer Cable runs longer than 100 will require at least one size larger wire The output wire size should be 4 AWG The transformer is 480V to 240V isolation transformers with delta wound primary and secondary windings The primary windings offer 7 tap positions 2 above and 4 below the nominal input voltage of 480V For domestic installations and all others using 60Hz power the primary side should be wired as follows Electrical Service 184 96 0189 rev L June 2005 Input Voltage Range Tap 493 510 1 504 481 492 2 492 469 480 3 480 457 468 4 468 445 456 5 456 433 444 6 444 420 432 7 432 This should produce a voltage on the secondary side of 234 243 V RMS L L Verify this and readjust the taps as required At the machine connect the cables at the input of the internal 230V transformer to the 227 243V taps Apply power to the machine and verify that the DC voltage between pins 2 and 3 of the Vector Drive 2nd and 3rd pins from the left is 329 345VDC If not
341. nstead display the message DISK DONE indicating that communications have been established with the internal PC104 board and the user can now use the control 7 EXACT STOP MODE CHG Selects exact stop in moves when mode changes 8 SAFETY CIRCUIT This enables safety hardware if machine is so equipped 9 SPINDLE DRV LIN ACCEL Selects linear deceleration for rigid tapping 0 is quadratic 10 UNUSED 11 COOLANT SPIGOT Enables coolant spigot control and display 12 OVER TEMP IS N C Selects Regen over temp sensor as N C 13 SKIP OVERSHOOT Causes Skip G31 to act like Fanuc and overshoot sense point 14 NONINV SPINDLE STOP Non inverted spindle stopped status 15 SPIND LOAD MONITOR Spindle load monitor option is enabled 16 SPIND TEMP MONITOR Spindle temperature monitor option is enabled 17 ENABLE ROT amp SCALNG Enables rotation and scaling 18 ENABLE DNC Enables DNC selection from MDI 19 ENABLE BKGRND EDIT Enables BACKGROUND EDIT mode 20 ENABLE GROUND FAULT Enables ground fault detector 21 M19 SPINDLE ORIET This bit makes the P and R codes a protected feature which can only be enabled with an unlock code The unlock code will be printed on the parameter listing If this bit is set to 0 an M19 will orient the spindle to 0 degrees regardless of the value of any P or R code in the same block If this is set to 1 a P code in the block will cause the spindle to be oriented to the specified angle such as P180 Alternately
342. nt to purge when the TSC system is shut off This parameter may be increased by the user to a higher value to help purge coolant from small orifice tooling The minimum default value is 2500 milliseconds 238 MAX TSC SPINDLE RPM When TSC is enabled and in use this parameter limits the maximum spindle speed Default value is 10000 RPM On 50 taper machines the maximum spindle speed is 5000 RPM 239 SPNDL ENC STEPS REV This parameter sets the number of encoder steps per revolution of the spindle encoder 240 1ST AUX MAX TRAVEL This parameter sets the maximum travel of the first auxiliary C axis in the positive direction 241 2ND AUX MAX TRAVEL This parameter sets the maximum travel of the second auxiliary U axis in the positive direction 242 3RD AUX MAX TRAVEL This parameter sets the maximum travel of the third auxiliary V axis in the positive direction 232 Parameters 96 0189 rev L June 2005 243 4TH AUX MAX TRAVEL This parameter sets the maximum travel of the fourth auxiliary W axis in the positive direction 244 1ST AUX MIN TRAVEL This parameter sets the maximum travel of the first auxiliary C axis in the negative direction 245 2ND AUX MIN TRAVEL This parameter sets the maximum travel of the second auxiliary U axis in the negative direction 246 3RD AUX MIN TRAVEL This parameter sets the maximum travel of the third auxiliary V axis in the negative direction 247 4TH AUX MIN TRAVEL This parameter sets the maximum
343. o be thermal growth 7 A similar program can be written to test for thermal growth in the Y and Z axes if necessary SOLUTIONS Since there are many variables that affect thermal growth such as the ambient temperature of the shop and program feed rates it is difficult to give one solution for all problems Thermal growth problems can generally be eliminated by running a warm up program for approximately 20 minutes before machining parts The most effective warm up is to run the current program at an offset Z position above the part or table with the spindle cutting air This will allow the ballscrews to warm up to the correct temperature and stabilize Once the machine is at temperature the ballscrews won t expand any further unless they re allowed to cool down A warm up program should be run after each time the machine is left idle 8 Troubleshooting 96 0189 rev L June 2005 1 2 SPINDLE NOT TURNING Spindle not turning If there are any alarms refer to Alarms section Check that the spindle turns freely when machine is off Command spindle to turn at 1800 RPM and check spindle drive display If display blinks bb check spindle orientation switch Spindle Orientation If spindle drive does not light the RUN LED check forward reverse commands from IOPCB Electrical Service Check the wiring of analog speed command from MOTIF PCB to spindle drive cable 720 If spindle is still not turning r
344. o the encoder shaft plate to the full depth of the bore in the encoder shaft plate without binding 5 Verify that the encoder shaft plate can be inserted into the platter bore without binding The contacting surfaces must be flat and burr free 167 96 0189 rev L June 2005 Mechanical Service 3 700 Shaft Length 4 175 Encoder Shaft Encoder Mounting Plate O D is precision ground for measuring concentricity Encoder Cover Plate Encoder Shaft Plate Encoder Coupler Tube Flex Coupling Encoder Mounting Cup Encoder Measure from this surface Set Screws Encoder Mounting Plate Assembly 1 Install the encoder mounting cup with one 0 005 Haas p n 45 0057 shim washers under each screw location 2 Install the encoder onto the bottom of the encoder mounting plate Install the encoder mounting plate assembly onto the top of the encoder mounting cup Use three screws at 120 spacing to mount plate The remaining three threaded holes are for the encoder coupling tube 3 Attach a magnetic base and indicator to the inner race of the cross roller bearing and indicate off the top face of the encoder mounting plate Add or subtract shims to adjust the face run out of the top face of the encoder mounting plate flatness NTE 0 0005 Shims are available in the following thickness 0 001 45 0054 0 002 45 0055 0 003 45 0056 and 0 005 45 0057 4 Adjust the indicator to indicate off the outer diamete
345. oblems such as servo over loads To check simply pull on the wires after the screws are tightened 2 After the line voltage is connected to the machine make sure that main circuit breaker at top right of rear cabinet is OFF rotate the shaft that connects to the breaker counterclockwise until it snaps OFF Turn ON the power at the source Using an accurate digital voltmeter and appropriate safety procedures measure the voltage between all three pair phases at the main circuit breaker and write down the readings The voltage must be between 195 and 260 volts 360 and 480 volts for high voltage option NOTE Wide voltage fluctuations are common in many industrial areas you need to know the minimum and maximum voltage which will be supplied to the machine while it is in operation U S National Electrical Code specifies that machines should operate with a variation of 5 to 5 around an average supply voltage If problems with the line voltage occur or low line voltage is suspected an external transformer may be required If you suspect voltage problems the voltage should be checked every hour or two during a typical day to make sure that it does not fluctuate more than 5 or 5 from an average CAUTION Make sure that the main breaker is set to OFF and the power is off at your supply panel BEFORE you change the transformer connections Make sure that all three black wires are moved to the correct terminal block and that they are ti
346. od 16 Replace the rear enclosure panel Z AXIS BALL SCREW Removal Plane4 Plane5 Plane4 Plane5 Plane5 Plane6 Plane5 Plane4 Plane5 Z Axis Ballscrew Access Hole EC 300 Z axis Ball Screw Removal 109 96 0189 rev L June 2005 Mechanical Service Z Axis Way Cover Receiver Z Axis Ball Screw Coupling Coupling Housing Cover Bumper Bearing Locknut Support Bearing Housing 6X SHCS 4X SHCS Bearing Locknut Bumper 4X BHCS 5X SHCS Oil Line Fitting Ball Screw Nut Housing EC 400 Z Axis Ball Screw removal 1 Turn the machine ON ZERO RETURN all axes and put the machine in HANDLE JOG mode 2 Jog the Y axis to the bottom of its travel 3 EC 300 Remove the right front spindle head cover from the inside of the machine 4 Remove the rear enclosure panel 5 Remove the axis motor in accordance with Z Axis Motor Removal 6 EC 400 EC 1600 Remove the left and right Z axis way covers in accordance with Z axis Way cover removal 7 Remove the support bearing housing and hard stop bracket from the ball screw support bearing end of the ball screw at the front of the machine for EC 1600 components are found at the rear of the machine 8 Loosen the SHCS on the locknut at the bearing support end and remove the locknut For safety replace the hardstop 9 Loosen the SHCS on the locknut at the motor end and remove the clampnut 10 Disconnect
347. of the extractors due to a tool stuck in the taper then the unclamp switch is not adjusted correctly or the switch could be bad NOTE In a proper working system the spindle will pop slightly during a tool change This popping is normal provided it does not create flex in the double arm or the need to remove the tool with a mallet Troubleshooting 11 96 0189 rev L June 2005 Check the condition of the tooling verifying the taper on the tooling is ground and not turned Look for damage to the taper caused by chips in the taper or rough handling If the tooling is suspected try to duplicate the symptoms with known to be good tooling Check the condition of the spindle taper Look for damage caused by chips or damaged tooling Also look for damage such as deep gouges in the spindle taper caused by tool crashing Duplicate the cutting conditions under which the deflection occurs but do not execute an automatic tool change Try to release the tool using the tool release button If sticking is observed the deflection is not caused by improper ATC adjustment but is a problem in the spindle head on the machine Ensure the spindle is not running too hot 140 F 60 C or above Check air supply Max air pressure drop of 10 psi 69 kilopascals during a tool change is allowed Are the correct pull studs being used Tool Holder Spindle Fretting Is fretting present on the tool holder or spindle Fretting is the resu
348. of the machine see Spindle Sweep Adjust ment Machine mis positions holes Check for thermal growth of the ballscrew see Thermal Growth section Check that the machine is level see Installation section of the Reference manual Check for backlash see Servo Motors Ballscrews section Check the squareness of the X axis to the Y axis Machine leaves large steps when using a shell mill Check that the machine is level see Installation section of the Reference manual Check the sweep of the machine see Spindle Sweep Adjustment section Cutter diameter too large for depth of cut FINISH Machining yields a poor finish Check for gearbox vibration Check for backlash Accuracy Backlash Check the condition of the tooling and the spindle Check for spindle failure Check the condition of the axis motors Check that the machine is level See the Installation section of the Reference manual THERMAL GROWTH A possible source of accuracy and positioning errors is thermal growth of the ballscrew As the machine warms up the ballscrews expand in all three linear axes causing accuracy and positioning errors or inaccurate boring depths This is especially critical in jobs that require high accuracy machining multiple parts in one setup or machining one part with multiple setups NOTE The ballscrew will always expand away from the motor end VERIFY THERMAL GROWTH There
349. oil pump is used to lubricate the system The pump is powered only when the spindle and or an axis moves Once powered the pump cycles approximately 3 2 cc of oil every 30 minutes throughout the oil lines to the lube points The control monitors this system through an internal level switch in the reservoir and and external pressure switch on the lube panel LOW LUBRICATION AND LOW PRESSURE SENSE SWITCHES There is a low lube sense switch in the oil tank When the oil is low an alarm will be generated This alarm will not occur until the end of a program is reached There is also a lube pressure switch that senses the lube pressure Parameter 117 controls the lube pressure check If Parameter 117 is not zero the lube pressure is checked for cycling high within that period Parameter 117 has units of 1 50 seconds so 30 minutes gives a value of 108000 Parameter 57 bit Oiler on off indicates the lube pump is only powered when the spindle fan is powered The lube pressure is only checked when the pump is on 5 17 SWITCHES DOOR OPEN SENSE SWITCH The DOOR OPEN sense switch is a magnetic reed switch type and consists of two switches one on each half of the enclosure front doors These switches are normally closed and wired in series When the doors open one or both of these switches will open and the machine will stop with a Door Hold function When the door is closed again operation will continue normally Each side door also has a limit
350. ompensation applied due to motion and heating of screw when the machine is turned back on the compensation will be adjusted by the clock indicated elapsed time SPINDLE HEAD THERMAL COMPENSATION This feature integrates spindle speed over time and builds a model of thermal growth As the model shows the spindle head warming up the control adjusts the Z axes to compensate for thermal growth 250 96 0189 rev L June 2005 7 MAINTENANCE GENERAL REQUIREMENTS Operating Temperature Range 41 F to 104 F 5 to 40 C Storage Temperature Range 4 F to 158 F 20 to 70 C Ambient Humidity 20 95 relative humidity non condensing Altitude 0 7000 ft ELECTRICITY REQUIREMENTS All Machines Require AC input power is three phase Delta or Wye power except that the power source must be grounded e g leg or center leg for delta neutral for Wye Frequency range of 47 66 Hz Line voltage that does not fluctuate more than 10 Harmonic distortion not to exceed 10 of the total RMS voltage 20 15 HP System Standard VF and 10K EC300 EC400 195 260V Voltage Requirements 354 488V High Voltage Requirements Power Supply 1 50 AMP 25 AMP Haas Circuit Breaker 40 AMP 20 AMP If service run from elec panel is less than 100 use 8 GA WIRE 12 GA WIRE If service run from elec panel is more than 100 use 6 GA WIRE 10 GA WIRE 40 30 HP System 50 Taper 40 Taper HT 10K VF Super Speed EC 300 EC 400 12K 195 260V Voltage Requi
351. on Installation 1 Replace the damaged pocket with a new one Apply grease to the shaft Install the pocket slide and pocket into the carousel Apply a drop of Red Loctite to the pocket retaining screw and install Torque to 14 ft lbs 2 Clear all alarms Return to Tool Changer Recovery Mode and press lt gt This will extend the air cylinder shaft Install the pocket slide shoulder bolt taking care not to pinch the microswitch roller Ensure that the microswitch roller rests on the shoulder bolt head 3 Install the pocket stop using Blue Loctite and torquing the four SHCS to 40 ft lbs Activate the pocket up and down several times Restore the machine to automatic mode and perform a tool change by pressing lt MDI gt and then lt ATC FWD gt Check for any binding or interference of installed parts TOOL POCKET SLIDER ADJUSTMENT The slider set screw is used to adjust the tool pockets end of stroke with the circular path on the carousel housing 1 Rotate carousel by turning the carousel cam pulley by hand Mechanical Service 90 96 0189 rev L June 2005 2 Visually check for misalignment tool pockets should move smoothly 3 If necessary loosen the setscrew nut Adjust the setscrew in or out until the tool pocket is aligned with the circular path on the carousel housing Advance the tool pocket and observe for proper alignment 4 Tighten setscrew lock nut Air Cylinder Carousel Housing Tool Pocket Sl
352. on Y axis motor The difference between the motor position and the commanded position has exceeded Parameter 23 The motor may also be stalled disconnected or the driver failed The servos will be turned off and a RESET must be done to restart This alarm can be caused by problems with the driver motor or the slide being run into the mechanical stops 105 Z SERVO ERROR TOO LARGE Too much load or speed on Z axis motor The difference between the motor position and the commanded position has exceeded Parameter 37 The motor may also be stalled disconnected or the driver failed The servos will be turned off and a RESET must be done to restart This alarm can be caused by problems with the driver motor or the slide being run into the mechanical stops 106 A SERVO ERROR TOO LARGE Too much load or speed on A axis motor The difference between the motor position and the commanded position has exceeded Parameter 51 The motor may also be stalled disconnected or the driver failed The servos will be turned off and a RESET must be done to restart This alarm can be caused by problems with the driver motor or the slide being run into the mechanical stops 107 EMERGENCY OFF EMERGENCY STOP button was pressed Servos are also turned off After the E STOP is released the RESET button must be pressed at least twice to correct this once to clear the E STOP alarm and once to clear the Servo Off alarm This alarm will also be generated if there is a low pressu
353. on of the A axis 5 Jog A axis 90deg and return Z axis to zero position 6 Repeat step 5 until you have indicated and noted the pallet runout at 0 90 180 270 degrees 7 If the flatness is correct skip to step 9 8 Pallet flatness is adjusted by shimming under the rotary between the rotary casting and on top of the Z axis linear guide pads Note Any time adjustments are made in this area the ballnut and ballnut housing need to be realigned which is also true for the next step 9 The pallet square in relation to X axis is adjusted on the full 4th axis by indicating the front edge of the pallet until parallel and adjusting par 212 see the following section On the 1 and 45 degree indexers the entire rotary casting will need to be rotated until the pallet is parallel To do this it will be necessary to loosen the Z axis ballnut housing then the 16 bolts on the Z axis linear guide pads and physically shift the position of the casting The specification when indicating the front of the pallet is 0005 0127mm or less Once this is achieved it will be necessary to torque the 16 linear guide bolts realign the ballnut housing and ballnut and verify alignment 3 12 EC 400 ROTARY REPLACEMENT Warning The indexer will crash if the following procedures are not followed Read all material before proceeding When the Indexer is replaced in the EC 400 it must have the lift switch adjusted and parameter 212 set to zero before any other machi
354. or cleaning filter elements run TSC system with no tool in spindle for at least one minute to prime system Coolant will be used more quickly when the TSC system is in use Make sure to keep the coolant level up and to check the level more frequently check after every eight hour shift Premature wear of the pump can result from running with a low coolant level in the tank Intake Filter Assembly Dirt Indicator TSC Coolant Pump Assembly TSC Filter Assembly Wing Nuts 4 Intake Filter Housing Gasket 100 Mesh Intake Filter Disconnect Hose for Cleaning IMPORTANT CLEAN THE GATE FILTER REGULARLY GATE FILTER TSC Coolant Pump Assembly Cleaning the Intake Filter Gate Filter Warnings Use of coolants with extremely low lubricity can damage the TSC coolant tip and pump Shortened pump life reduction of pressure and increased maintenance are normal and to be expected in abrasive environments and are not covered by warranty A special filter in addition to the standard filter should be used contact Haas for recommendations Machining of ceramics and the like voids all warranty claims for wear and is done entirely at customer s risk Increased maintenance schedules are absolutely required with abrasive swarf The coolant must be changed more often and the tank thoroughly cleaned of sediment on the bottom An auxiliary coolant filter is recommended When machining castings sand from the casting process and
355. or the DISTANCE TO GO is 118 This equals of a revolution of the encoder Setting the Offset 1 Set the grid offset to zero Parameter 125 126 127 128 or 170 depending on the axis being set Setting 7 PARAMETER LOCK must be OFF to reset grid offset 2 Press ZERO RET and ZERO SINGL AXIS the axis you are setting X Y Z A or B 3 Calculate the grid offset using the following formula and write the result in Parameter 125 126 127 128 or 170 depending on the axis being set DISTANCE TO GO 118 x Ratio Grid Offset The Ratio steps unit for the X Y Z A and B axes are the values in Parameters 5 19 33 47 and 155 respectively 4 ZERO RET the axis again to use this offset NOTE If Z axis grid offset is reset Parameter 64 should be checked and adjusted accordingly Setting the Offset using the Grid Feature The control will calculate grid offset parameters 125 126 127 and so on using the GRID command It is recommended that the GRID command be used on each axis separately as follows 1 Turn the machine off and back on This will un zero all the axes 2 Select the ALARMS screen and enter DEBUG mode 3 Perform a ZERO SINGLE AXIS on each of the desired axes individually Ignore any ZERO RET MARGIN TOO SMALL alarms Note if a SERVO ERROR TOO LARGE alarm was generated this indicates that a GRID OFFSET parameter is out of range make sure it is 138718 to 138718 4 Select
356. or with the keyway in the Motor s shaft 6 Insert the Yaskawa Motor Key into the combined keyway Use a press to fit the key into the keyway Do not use the HAAS Motor Key CAUTION Do not use a hammer or other forceful method of inserting the key You will damage the fragile bearings and components of the Wave Generator 7 Place the Shoulder Washer over the Motor shaft Apply Loctite insert the MSHCS and tighten 150 Mechanical Service 96 0189 rev L June 2005 ASSEMBLY HARMONIC DRIVE 1 Cover your work area with a clean shop rag and place the Harmonic Drive with the smaller diameter end down on the work surface You should see the grease cavity of the Harmonic Drive 2 Remove the large O Ring from the included package and lightly grease Place in the groove in the face of the Harmonic Drive NOTE For proper operation of an HDC Gear Set it is essential that the ring of the Wave Generator be concentric with the ring of the Harmonic Drive The rings of the Wave Generator and Harmonic Drive are ellipses they are not circular Incorrect assembly will result in an off center or dedoidal condition resulting in poor performance and reduced service life 3 Place the Motor Wave Generator assembly next to the Harmonic Drive Turn the Harmonic Drive elliptical ring until the ring is closest to the front of the Harmonic Drive Orient the Wave Generator elliptical ring until it matches the positioning of the Harmonic Drive
357. oth ends of the ball screw If the symptom disappears replace the bearing sleeve Be certain to check for damage to the ball screw shaft where the bearing sleeve is mounted If the noise persists the ball screw is damaged and must be replaced When replacing the ball screw in an older machine always replace the bearing sleeve with the an angular contact design bearing sleeve Troubleshooting 13 96 0189 rev L June 2005 Check the ball screw for misalignment If incorrect perform alignment procedure in Ball Screw section Misalignment in the ball screw itself will tend to cause the ball screw to tighten up and make excessive noise at both ends of the travel The ballnut may get hot Misalignment radially at the yoke where the ball screw ball nut mounts is indicated by heating up of the ball nut on the ball screw and noise and tightness throughout the travel of the ball screw Misalignment at the yoke where the ball nut mounts is indicated by noise and tightness at both ends of the travel of the ball screw The ball nut may get hot NOTE Customer complaints of Ball Screw noise may not indicate a bad ball screw Ball screws from different manufacturers produce varying levels of noise Often machines are built with two or more different brands of ball screws in the same machine If complaints are generated about one axis screw in comparison to another it is possible that the screws are simply sourced from different manufacturers A
358. oth pallets as it is raised 19 The APC shaft does not rise The hub slides up the shaft on the 4 ball bearings The flat tang of the apc shaft slides inside a slot in the cycloid hub 20 The H frame Up switch checks H frame up status As the H frame rises the lock pin comes out of the hole in the bumper mount so the H frame can rotate 21 Once the H frame up switch indicates up the air blast solenoid is turned on and sends air blowing thru the air blast assembly at the top of the receiver Troubleshooting 21 96 0189 rev L June 2005 22 The servomotor rotates the H frame and pallets 180 deg by driving through the gearbox torque tube amp hub while the apc shaft cycloid hub and part of the gearbox remain stationary The servomotor rotates with the assembly 23 The H frame down switch gets a momentary false signal as it rotates past the tang on the APC shaft approximately mid stroke which the software ignores 24 The safety solenoid which is off prevents the H frame from suddenly lowering in the event of a power failure by blocking the vent port of the h frame up solenoid 25 When it has rotated 180 degrees the servomotor stops and holds position The encoder on the servomotor determines the rotational position 26 The H frame up solenoid is turned off 27 The H frame down solenoid and safety solenoids are turned on pressurizing the other side of the air cylinder while venting the side previously pressurized
359. ove axis to coordinate specified in Work Offset G129 5 A NEG COMP DIR Used to negate the direction of thermal compensation 6 A DELAY AXIS 0 Used with an APL to ensure A axis is zeroed before B axis of APL 7 A MAX TRAVEL INP This bit is set to 1 on five axes machines This bit indicates that there is a switch visible through MOCON that detects if the axis has rotated all the way round It is used to tell the control to skip the first zero switch when zeroing so it can unwrap the cables 9 A TEMP SENSOR This performs Ball Screw Thermal Compensation via a temperature sensor attached to the ball nut When this bit is set to 1 the feature is activated for that axis Note that this feature can only be used when temperature sensors are installed The following parameters must be set appropriately 201 132 133 XYZ SCREW COMP COEF 8000000 272 273 274 XYZ SCREW COMP T CONST 28000 351 TEMP PROBE OFFSET 450000 16 SCALE Z HIST For HAAS diagnostic use only 270 B SWITCHES Parameter 270 is a collection of single bit flags used to turn servo related functions on and off The left and right cursor arrows are used to select the function being changed All values are 0 or 1 only The function names are 0 B LIN SCALE EN Used to enable linear scales for the B axis 1 B INVRT LN SCL Used to invert the B axis linear scale 2 DSBL SCALE Z Used to disable the linear scale Z test 3 B ZERO AXIS TC Used to return axis to the position specif
360. oved from the CLAMP position to the UNCLAMP position and it coasted past the MOTOR STOP point or could not get to the UNCLAMP point same physical point as CLAMP The arm was being moved back to the ORIGIN position and it coasted past the MOTOR STOP point or could not get to the ORIGIN point 629 APC PIN CLEAR HOME SWITCH FAULT A pin clear switch was contacted when all pallets were at their home positions The most likely cause is debris on a switch Check for accumulation of debris on the pin clear switches and the pallet home switches Check switches and their electrical wiring for damage After correcting the condition run an M50 with P code for the pallet to be loaded to continue machining 50 Alarms 96 0189 rev L June 2005 630 APC DOOR SW FAULT SWITCH NOT EQUAL TO SOLENOID The APC Door Switch indicates the door is open but the solenoid shows the door has been commanded to close Either the door failed to close and is stuck or the switch itself is broken or stuck Also the door switch wiring may have a fault Check switch then cable After correcting the condition run an M50 to continue machining 631 PALLET NOT CLAMPED Vertical Mills APC Pallet not clamped or home Do not attempt to move X or Y axes of the mill until the APC is in a safe condition One pallet is at home but the other pallet is neither clamped nor at home Locate the unclamped pallet and return to home if possible If drive pin is engaged or pallet is partially clamped
361. perature and over voltage protection There is a 10 amp 20A for a medium amplifier supply fuse for failure protection This fuse is relatively slow therefore it can handle the 30 amp peak Actual continues current limit to the motor is controlled by software The user should never attempt to replace these fuses Commands to the amplifier are 5 volts current in two legs of the motor and a digital enable signal A signal from the amplifier indicates drive fault or sustained high current in stalled motor The connectors on the amplifiers are H V 320 volts DC H V 320 volts return A motor lead phase A B motor lead phase B C motor lead phase C J1 Three pin Molex connector used for 12 and GND J2 Eight pin Molex connector used for input signals 5 6 INPUT OUTPUT ASSEMBLY The IOPCB contains a circuit for electronically turning the drawbar motors power on and off This prevents any arcing of the drawbar motor relays and increases their life tremendously This includes an adjustable current limit to the tool changer Potentiometer R45 adjusts the current limit to the drawbar motors motors R45 should be set to limit current to between 9 and 11 amps The IOPCB also contains a circuit for sensing a ground fault condition of the servo power supply If more than 1 75 amps is detected flowing through the grounding connection of the 160V DC buss a ground fault alarm is generated and the control will turn off servos and stop Rel
362. performed from above the Table 1 Apply air pressure to the hydraulic cylinder This will cause the piston in the hydraulic cylinder to extend When the piston has extended thread an shcs into the pilot hole in the piston shaft and tighten This will properly align the hydraulic cylinder to the brake assembly 2 Tighten the four shcs that mount the hydraulic cylinder to the table Relieve the hydraulic pressure 137 Mechanical Service 96 0189 rev L June 2005 3 17 HS 3 4 6 7 MOTOR AND TRANSMISSION Removal Note The motor and transmission are removed as a unit Caution The motor transmission assembly is very heavy lifting equipment will be needed to safely remove and instal this assembly 1 Remove the wire cover on the bottom of the motor and transmission Mark and disconnect wires 2 Remove the Tool Release Piston and Spindle Encoder as described in their specific sections 3 From the back of the machine position a lifting device and fixture to support transmission Loosen the transmission mounting bolts The transmission can be lowered to remove the spindle belt from the back of the spindle The encoder belt should be loose as the encoder was previously removed The transmission can also be removed by lowering it onto blocks of wood 4 x4 inside the column casting From this point the transmission is pulled toward the rear of the machine to separate from the spindle head Haas Factory lifting tool shown Contact t
363. pindle head from falling in the event of an accident Power off the machine 3 Disconnect the main air supply at the lube air panel 4 Remove the spindle motor as described in the Spindle Motor Removal section 5 Remove the two 2 SHCS attaching the lower Y axis way cover to the spindle head casting and collapse it downward It is easiest to reach the TRP from the front side of the machine 6 Disconnect the TRP air lines and switch cables TRP Assembly 4X SHCS 4X SHCS 3 8 Air Hose Fitting Clamp Switch Unclamp Switch 1 4 Air Hose Fitting 4X Lockwasher 4X Lockwasher Cable Carrier Assembly 4X BHCS 4X Lockwasher Spindle Motor and Shroud Assembly Mechanical Service 68 96 0189 rev L June 2005 TRP Assembly 3 8 Air Hose Fitting Clamp Switch 4X SHCS 4X Lockwasher Spindle Motor and Shroud Assembly Unclamp Switch 1 4 Air Hose F 1 4 Air Hose Fitting 3 8 Air Hose Fitting View Rotated for Clarity Unclamp Switch Clamp Switch EC Series TRP assembly 7 Remove the four 4 SHCS holding the tool release piston assembly to the head casting 8 Remove the entire tool release piston assembly Installation 1 Loosely reinstall the tool release piston with the four 4 SHCS 2 Reconnect clamp unclamp switch cables and TRP air lines 3 Install the motor as described in the Spindle Motor Replacement section 4 Finish tightening the fo
364. power to the machine 2 Remove the screws holding the cover panel on the back of the control panel Take care to hold the cover panel in place until all screws have been removed 3 Disconnect the data cable from the receiver board on the LCD assembly J3 4 Disconnect the power cable and ground wire from the power supply board on the LCD assembly TB1 5 Disconnect the cables to the keyboard from the receiver assembly P1 and power supply TB2 on the LCD assembly 6 Remove the four 4 hex nuts and washers beginning with the bottom then remove the LCD assembly and set aside in a safe place CAUTION Take extreme care to not drop or damage the LCD assembly when removing from the control panel 7 Use gloves to avoid getting fingerprints on the new LCD Replace by sliding the new assembly onto the four bolts two each on top and bottom Place the washers and hex nuts on the bolts to hold in place Refer to Fig 4 5 1 Once all washers have been attached and nuts have been hand tightened tighten down completely Figure 4 5 1 Interior of control panel rear 193 Electrical Service 96 0189 rev L June 2005 8 Plug the keyboard cables into the new receiver board P1 and the power supply TB2 9 Plug the power cable into the power supply board TB1 and attach the green wire to ground 10 Plug the data cable into the receiver board J3 11 Replace the back cover panel and attach with the four screws previou
365. pper right of electrical cabinet to the off position 3 Using a large flat tip screwdriver loosen the three screws on the cabinet door and then open the door enough to safely work on the electrical panel 4 Disconnect all leads to the Power Distribution board and move aside for removal Ensure all cables are properly labeled for reconnecting later The illustration on the following page shows all cable numbers and the locations on the POWER board 5 After all cables have been disconnected remove the seven screws holding the POWER board to the cabinet and remove the board Take care to hold the POWER board in place until all screws have been removed NOTE If you need to replace the LOW VOLTAGE POWER SUPPLY board please skip the next step 6 Replace the POWER board attaching it with the seven screws previously removed Do not forget to use the lower left screw for a ground connection 7 Reconnect all cables to the POWER board at their proper location LOW VOLTAGE POWER SUPPLY NOTE Refer to Cable Locations for a diagram of this board 8 Remove the Power Distribution POWER board as described in steps 1 5 9 Disconnect all leads to the Low Voltage Power Supply LVPS board Ensure all cables are properly labeled for reconnecting later The following illustration shows all cable numbers and the locations on the LVPS board 10 After all cables have been disconnected unscrew the two standoffs at the bottom of the
366. pump and pressure gauge Tighten the fittings snugly with wrenches DO NOT OVERTIGHTEN 2 Run TSC system for one minute to purge air 3 Insert a TSC type tool holder with a TSC drill or restrictor in the spindle CAUTION Changing tools after running TSC can cause coolant to spray out Wear safety glasses 4 Set Parameter 236 to 100 5 Turn on TSC Test low coolant pressure switch by slowly shutting off the ball valve in the coolant line pump should shut off at 40 psi 10 psi If the switch is outside this range replace the switch NOTE Test the electrical continuity of the switch cable and the control function by monitoring the LO CLNT bit on the Diagnostics page Shorting the leads should cause the bit to switch from 1 to 0 Check this before replacing the pressure switch 6 Reset Parameter 236 to the default value 1000 Mechanical Service 132 96 0189 rev L June 2005 3 14 GRID OFFSET CALCULATION Please read this section in its entirety before attempting to set the grid offset Guidelines The encoder Z channel signal must occur between 1 8 and 7 8 revolution from where the home switch is released If DISTANCE TO GO is less than 1 8 0295 or greater than 7 8 2065 of a revolution it will alarm to Zero Return Margin Too Small In ZERO RETURN mode the DISTANCE TO GO is the amount the encoder rotated from when the switch was released until it found the Z channel signal The ideal amount f
367. quire the servo power to be cut when the door is opened 26 STATUS RELAYS This parameter bit supports the Machine Data Collection enhancement The default value for all machines is zero 27 UNUSED 28 ADVANCED TOOL MGMT This feature allows the user to specify groups of tools When the life of a tool based on feed time total time usage number of holes tool load or vibration has expired the control will automatically use another tool from the same group When all the tools from a group are used up the control will alarm 29 RND5 TRM TRL 30 RND5 HANDWHEEL 31 INTUITIVE PROG SYS When set to 1 the Intuitive Programming System is activated 316 APC PAL CLAMP TIME This is the time required to clamp the APC pallet to the receiver It should be set to 4000 on all pallet changing machines except the the EC 300 and MDC which should be set to 1000 Units are milliseconds 317 APC UNCLAMP TIME This is the time required to unclamp the APC pallet from the receiver It should be set to 4000 on all pallet changing machines except the the EC 300 and MDC which should be set to 1000 Units are milliseconds 318 APC PAL CHAIN TIME This is the time required to cycle the chain It should be set to 8000 Units are millisec onds 319 APC DOOR CLOSE TIME This is the time required to close the door It should be set to 6000 Units are millisec onds 320 RP DRAWBAR DOWN This is the time required for the drawbar to move down Units are millisecon
368. r Bearing Locknut Coupling Motor Housing Cover Bumper 6X SHCS Bearing Locknut Support Bearing Housing Y Axis lead Ballscrew 2X SHCS BACK OF SPINDLE CASTING Bearing 6X SHCS 2X SHCS 4X BHCS 6X SHCS Oil Line Fitting Ballscrew Nut EC 300 Y axis Ball Screw Assembly EC 400 Y axis Ball Screw Assembly 4 EC 300 Remove the column hood from the machine 5 EC 300 Remove the right side spindle head cover from the inside of the machine 6 Remove or collapse the the Y axis way covers loosen the SHCS and remove the clamp nut on the ball screw bearing plate end Hydraulic Counterbalance Y Axis Motor Y Axis Ball Screw Bearing Housing Motor Mount 4X SHCS 4X Lockwasher View Rotated looking up EC 1600 7 Loosen the SHCS and remove the clamp nut on the motor end of the ball screw 8 Disconnect the oil line from the ball nut 9 Remove the bearing sleeve SHCS and remove it from the bottom of the column 10 Remove the SHCS on the ball nut flange Remove the ball nut from the ball nut housing by manu ally screwing the nut up the ball screw 107 96 0189 rev L June 2005 Mechanical Service 11 Remove the upper bearing pack 12 Remove the ball screw out the top Y Axis Motor Spindle Assembly Hydraulic Counterbalance Bumper Bearing Locknut Coupling Bumper Bearing Locknut Y Axis lead Ballscrew 2X SHCS 2X SHCS Ballscrew Nut
369. r If the micro processor is colder the control will assume that the spindle is too cold or inadequately lubricated to be run safely at high speed and the following message will be displayed WARNING YOUR MACHINE IS COLD RUN A WARM UP PROGRAM BEFORE RUNNING THE SPINDLE AT HIGH SPEED OR DAMAGE MAY RESULT PRESS CANCEL TO CONTINUE The user must press CANCEL before continuing It is recommended that a spindle warm up program be run immediately This message will only appear once each time the machine has been turned on The initial value for this parameter is 70 degrees F To disable this feature change it to zero 259 COLD SPINDLE DAYS The first time Cycle Start is pressed after the machine has been turned on the control will compare the number of days that have passed since the machine was turned off against the value of this parameter If the machine has been off longer the control will assume that the spindle is too cold or inadequately lubricated to be run safely at high speed and the following message will be displayed WARNING YOUR MACHINE IS COLD RUN A WARM UP PROGRAM BEFORE RUNNING THE SPINDLE AT HIGH SPEED OR DAMAGE MAY RESULT PRESS CANCEL TO CONTINUE The user must press CANCEL before continuing It is recommended that a spindle warm up program be run immediately This message will only appear once each time the machine has been turned on The initial value for this parameter is 3 days To disable this feature ch
370. r a period of several seconds or even minutes is large enough to exceed the continuous rating of the motor The servos will be turned off when this occurs This can be caused by running into the mechanical stops or by a very high load on the motors If this alarm occurs on a machine with a VF SS type tool changer the most likely cause is a tool over 3 pounds not identified as heavy in the tool table 675 TT or B AXIS MOTOR OVERHEAT Servo motor overheat The temperature sensor in the motor indicates over 150 degrees F This can be caused by an extended overload of the motor such as leaving the slide at the stops for several minutes 676 TT or B MOTOR Z FAULT Encoder marker pulse count failure This alarm usually indicates that the encoder has been damaged and encoder position data is unreliable This can also be caused by loose encoder connectors 677 TT or B AXIS Z CH MISSING Z Reference signal from encoder was not received as expected Can be caused by loose connections encoder contamination or parameter error 678 TT or B AXIS DRIVE FAULT Current in TT or B servo motor beyond limit Possibly caused by a stalled or over loaded motor The servos are turned off This can be caused by running the axis into a mechanical stop A short in the motor or a short of one motor lead to ground can also cause it 679 TT or B ZERO RET MARGIN TOO SMALL This alarm will occur if the home limit switches move or are misadjusted This alarm indicates that the
371. r error 155 Z AXIS Z CH MISSING Z Reference signal from encoder was not received as expected Can be caused by loose connections encoder contamination or parameter error 156 A AXIS Z CH MISSING Z Reference signal from encoder was not received as expected Can be caused by loose connections encoder contamination or parameter error 34 Alarms 96 0189 rev L June 2005 157 MOCON WATCHDOG FAULT The self test of the MOCON has failed Call your dealer 158 VIDEO KEYBOARD PCB FAILURE During power on tests the control has detected a problem in either the keyboard or the video memory Call your dealer 159 KEYBOARD FAILURE Keyboard shorted or button pressed at power on A power on test of the membrane keypad has found a shorted button It can also be caused by a short in the cable from the main cabinet or by holding a switch down during power on 160 LOW VOLTAGE The line voltage to control is too low This alarm occurs when the AC line voltage drops more than 10 below nominal 161 X AXIS DRIVE FAULT Current in X servo motor beyond limit Possibly caused by a stalled or overloaded motor The servos are turned off This can be caused by running the axis into a mechanical stop A short in the motor or a short of one motor lead to ground can also cause it 162 Y AXIS DRIVE FAULT Current in Y servo motor beyond limit Possibly caused by a stalled or overloaded motor The servos are turned off This can be caused by running the axis into a mechani
372. r kinked airline or a mechanical problem After correcting the condition run an M50 to continue machining 640 APC MISSING PALLET REC Pallet change sequence was halted because receiver switch was not activated Pallet is either unclamped or not on the receiver Ensure the pallet is correctly located on receiver against hard stop then run M18 to clamp the pallet After correcting the condition run an M50 to continue machining 641 APC UNKNOWN CHAIN LOCATION Neither chain location switch is tripped so the control cannot locate the chain position This can occur if a pallet change is interrupted for any reason such as an alarm or an E STOP To correct this problem the pallets and chain must be moved back into a recognized position such as both pallets home or one pallet home and one on the receiver The chain position adjustment tool must be used to rotate the chain into position The pallets must be pushed into place by hand After correcting the condition run an M50 to continue machining 51 Alarms 96 0189 rev L June 2005 642 642 APC PIN CLEAR SWITCH FAULT One of the pallet changer pin clear switches was contacted unexpectedly The most likely cause is debris on a switch Also check the pin clear switches for damage and their electrical wiring for damage After correcting the condition run an M50 to continue machining 643 LOW BRAKE OIL A AXIS The oil level in the air oil booster supplying hydraulic pressure to the A axis brake is
373. r of the encoder mounting plate Sweep the outer diameter of the encoder mounting plate concentric to the cross roller bearing concentricity NTE 0 0005 5 Before proceeding test fit the encoder shaft into the encoder shaft plate to ensure that it fits in completely without binding and that the set screws have been completely backed out or removed Install flex coupling Install encoder shaft to the dimension shown in the assembly Install encoder coupling tube Failure to install encoder shaft to correct height will result in damage to flex coupling 168 Mechanical Service 96 0189 rev L June 2005 0 10 20 30 40 50 60 70 80 90 1 03 0 03 Encoder Shaft Coupler 52 4471 Encoder Mounting Plate 20 6114B Encoder 32 1459 6 Install the rotary table platter and indicate its bore concentric with the cross roller bearing concentricity NTE 0 0005 NOTE Be careful not to deflect the encoder shaft damage to the flex coupling may result 7 When installing the encoder shaft plate ensure that the flats on the encoder shaft are lined up with the set screw holes in the shaft plate Set screws must be removed before performing this opera tion 8 After seating the encoder shaft plate tighten the screws securing the encoder shaft plate to the platter Then install and tighten the set screws Install o ring onto the top of the encoder shaft plate 9 Install the encoder shaft plate Grease o ring
374. r on Table In Line Drive Tool Release Piston Assembly 6 Press the tool release button and hold it in Adjust the switch in or out until the switch just trips DB OPN 1 Cycle the tool release several times and confirm the switch is tripping Mechanical Service 74 96 0189 rev L June 2005 7 Check the adjustment Jog the Z axis down until the tool is 050 above the block and confirm that DB OPN 0 when the tool release button is pressed The switch must trip DB OPN 1 at 0 06 above the block and not trip DB OPN 0 at 0 05 above the block 8 Re adjust and repeat steps 1 6 if necessary 9 Set the pressure regulator back to 85PSI 10 Set parameter 76 back to the original setting Clamp Switch 1 If the machine is equipped with TSC remove the seal housing before continuing This step does not apply to In line drives with TSC 2 Remove the tool holder from the spindle 3 Delete everything in MDI mode and write 1120 1 4 Start with the upper switch all the way in Place a 0 02 shim between the tool release piston adjustment bolt and the drawbar 5 Push the PARAM DGNOS button twice to enter the diagnostics mode 6 Press CYCLE START 7 If DB CLS 0 tool Unclamp you are done do not check with 0 04 shim If not adjust the upper switch out until the switch is just un tripped DB CLS 0 8 Press RESET Replace the 0 02 shim with a 0 04 shim Press CYCLE START See that DB CLS 1 Rea
375. r parameter 128 2 Toggle air pressure to the lift piston using Haas tool P N T 2150 so that the platter is at the top of its travel 3 Zero the A axis only by pressing the ZERO RET key then the A key then the ZERO SINGL AXIS key 4 Go to parameter 128 and record the value 5 Jog the A axis to line up the front edge of the pallet with the X axis as close as the coupling position will allow E stop the machine 6 Slowly discharge the air pressure to the A axis and lower the platter into position 7 Rotate the worm shaft pulley to the extents of its travel and record the value The value at the middle of this range is the value for parameter 212 Enter that value 8 Remove tool T 2150 and replace the hoses 9 To fine adjust the front edge of the pallet it may be necessary to loosen the sixteen 16 SHCS that fasten the rotary body to the trucks and the ten 10 SHCS for the Z axis ball screw mount 10 Tap the rotary body into position within 0005 10 00 11 Tighten then torque the sixteen 16 SHCS that fasten the receiver body to the trucks Tighten the 5 Ballnut bolts allowing the housing to re align then torque the 10 housing bolts After the housing bolts have been torqued loosen the 5 Ballnut bolts and run the Ballnut away from and back to the motor If not binding occurs re tighten the Ballnut bolts SETTING PARAMETERS 212 AND 128 FULL 4TH A AXIS OFFSET Note 1 and 45 degree indexer Remove the Z axi
376. r steps A single entry in the table applies over a distance equal to two raised to this parameter power encoder steps 59 MAXIMUM FEED Maximum feed rate in inches per minute 60 TURRET START DELAY Maximum delay allowed in start of tool turret Units are milliseconds After this time an alarm is generated On Horizontal mills with a side mount tool changer this parameter is used to specify the time in milliseconds allowed for motor driven motions of the shuttle and arm If the motion has not completed within the time allowed by this parameter alarm 696 ATC MOTOR TIME OUT is generated This parameter should be set to 2000 61 TURRET STOP DELAY Maximum delay allowed in motion of tool turret Units are milliseconds After this time an alarm is generated On Horizontal mills with a side mount tool changer this parameter is used to specify the time in milliseconds allowed for air pressure driven arm in arm out moves If the motion has not completed within the time allowed by this parameter alarm 695 ATC AIR CYLINDER TIME OUT is generated This parameter should be set to 10000 62 SHUTTLE START DELAY This parameter is used to specify the time in milliseconds needed to allow the tool pocket to settle stop bouncing after being lowered in preparation for a tool change 63 SHUTTLE STOP DELAY This parameter is also used for vertical mills with a Side Mount Tool Changer It is used to specify the time allowed in milliseconds for the tool arm
377. raulic oil may occur Wear eye protection and have sufficient rags on hand to clean up any purged oil 7 Set the High Pressure regulator to approximately 5 10 PSI Remember that the Pressure Booster will still provide 12 1 pressure boost 8 Break the mating of the Hydraulic Hose and the Swivel Elbow Loosen this joint only enough to let air escape 9 Apply air pressure to the Pressure Booster by pressing the yellow pin button on the Air Valve Assembly Do not activate the Pressure Booster for more than a second at a time 10 When all air has escaped the hydraulic system tighten the Hydraulic Hose Readjust the High Pressure regulator to 70 PSI 11 If any air leaks have been noticed during this operation take appropriate measures to fix them before installing the assembly 175 96 0189 rev L June 2005 Mechanical Service INSTALLATION HYDRAULIC CYLINDER 1 Lift the Hydraulic Cylinder into its area beneath the Table See the Figure below for the approxi mate location The hose connections should face the left of the table away from the Pressure Booster to prevent kinks in the lines when routed 2 Thread 4 1 1 4 SHCS through the mounting tabs of the Hydraulic Cylinder into the Table Leave these loose for final alignment of the Hydraulic Cylinder see Final Alignment Hydraulic Cylinder 3 Route the Hydraulic Hose and air port Tubing beneath the Hydraulic Cylinder and through the mouse holes machined to the rig
378. re condition in the hydraulic counterbalance system In this case the alarm will not reset until the condition has been corrected 108 X SERVO OVERLOAD Excessive load on X axis motor This can occur if the load on the motor over a period of several seconds or even minutes is large enough to exceed the continuous rating of the motor The servos will be turned off when this occurs This can be caused by running into the mechanical stops It can also be caused by anything that causes a very high load on the motors 31 Alarms 96 0189 rev L June 2005 109 Y SERVO OVERLOAD Excessive load on Y axis motor This can occur if the load on the motor over a period of several seconds or even minutes is large enough to exceed the continuous rating of the motor The servos will be turned off when this occurs This can be caused by running into the mechanical stops It can also be caused by anything that causes a very high load on the motors 110 Z SERVO OVERLOAD Excessive load on Z axis motor This can occur if the load on the motor over a period of several seconds or even minutes is large enough to exceed the continuous rating of the motor The servos will be turned off when this occurs This can be caused by running into the mechanical stops It can also be caused by anything that causes a very high load on the motors 111 A SERVO OVERLOAD Excessive load on A axis motor This can occur if the load on the motor over a period of several seconds or even minutes is
379. re inserting Torque to 15 ft lb 12 Reinstall and tighten the hard stop on the ball screw support bearing 13 Reconnect the oil line to the ball nut 111 96 0189 rev L June 2005 Mechanical Service 14 Tighten the ball screw against the locknut as follows The sequence is important to ensure proper installation of the ball screw Tighten the locknut hand tight on the motor end Install and tighten locknut on bearing support Ensure the nut does not touch the support bearing Install the shaft lock onto the bearing support end of the ballscrew This will keep the ball screw from turning while torquing the locknut Place a spanner wrench on the locknut at the motor end of the assembly Torque the locknut against the bearing sleeve to 10 ft lb EC 1600 torque to 50 ft lbs With a T handle wrench hand tighten the locknut screw and mark with yellow paint Remove the shaft lock EC 300 Loosen the locknut screw and locknut at the bearing support end and tighten to 4 in lb against the bearing Retighten the clamp screw EC 400 EC 1600 Loosen the locknut screw and locknut at the bearing support end and tighten to 10 ft lbs against the bearing Retighten the clamp screw 15 Reinstall the axis motor in accordance with Z Axis Motor Installation 16 Check for backlash in the Z axis ball screw Troubleshooting section or noisy operation and the grid offset 17 EC 400 Clean and seal Permatex sur
380. re to the Table with 4 1 2 SHCS using the outermost holes in the Plate 4 Cut the Braided Hose to length and attach to the Hose Barb with a clamp INSTALLATION BEARING 1 Place the Bearing Retainer Ring onto the rotary table flat side down Orient the holes in the Ring so that they line up with the threaded holes in the rotary table 2 Stone the Table mating surface Clean with a lint free rag 3 With an assistant lift and place the Bearing onto the Table on top of the Spacer 4 Align the bolt holes in the Table with the countersunk holes in the outer Bearing race Make sure the Spacer will pull up into the inner Bearing diameter There should be no interference fit prob lems 5 Insert the SHCS by hand through the Bearing and into the Table 163 96 0189 rev L June 2005 Mechanical Service 6 Tighten the SHCS in a star pattern until the screws are snug Evenly tighten the screws to seat the Bearing then back off each SHCS 1 16 turn NOTE If you are installing the Bearing by yourself it will be useful to have a mirror positioned to see the indicator when it is on the far side of you 7 Remove four of the SHCS that lie along the X and Y axis 8 Attach a Magnetic Indicator Stand MIS to the inner Bearing race Adjust the indicator to point to the side of the outer Bearing surface as shown in the following figure Outer Bearing Inner Bearing Indicator Magnetic Stand 9 Turn the inner race
381. refer to Figure 3 12 13 Press the ATC FORWARD button until the double arm engages the tool manually rotate the spindle dogs if necessary Mechanical Service 86 96 0189 rev L June 2005 3 Enter DEBUG mode Record the encoder value under spindle orientation position Refer to Figure 3 12 13 4 Return to Parameter 257 Enter the spindle orientation value from DEBUG and lock parameters 5 In TCR mode press the ATC REVERSE button until the double arm is in the home position Return to normal operation mode 6 Manually insert tools into spindle and perform several tool changes Observe for any misalignment 7 Adjust the PARAMETER 257 setting value if necessary Align Spindle Dogs to Double Arm Key and Toolholder Slot Toolholder Slot Double Arm Key Spindle Orientation Setting DOUBLE ARM REMOVAL AND INSTALLATION Removal 1 In TCR mode lower the double arm POWER OFF machine 2 Underneath the double arm loosen the six SHCS from the lock ring Insert four new jack screws into the lock ring Coat the jack screw threads and tips with moly grease 3 Slowly tighten the jack screws in order to push the double arm away from the lock ring If neces sary tap the center of the double arm from underneath with a soft mallet until the double arm breaks free 4 Once the double arm is loose pull the double arm assembly off the shaft 87 96 0189 rev L June 2005 Mechanical Service 4X Double Arm Jack SH
382. rements 354 488V High Voltage Requirements2 Power Supply1 100 AMP 50 AMP Haas Circuit Breaker 80 AMP 40 AMP If service run from elec panel is less than 100 use 4 GA WIRE 8 GA WIRE If service run from elec panel is more than 100 use 2 GA WIRE 6 GA WIRE 40 30 HP System VS 1 3 HS 3 7 incl R models 195 260V Voltage Requirements Power Supply 125 AMP Haas Circuit Breaker 100 AMP If service run from ele panel is less than 100 use 2 GA WIRE If service run from ele panel is more than 100 use 0 GA WIRE WARNING A separate earth ground wire of the same conductor size as the input power is required to be connected to the chassis of the machine This ground wire is required for operator safety and for proper operation This ground must be supplied from the main plant ground at the service entrance and should be routed in the same conduit as the input power to the machine A local cold water pipe or ground rod adjacent to the machine cannot be used for this purpose Maintenance 251 96 0189 rev L June 2005 Input power to the machine must be grounded For wye power the neutral must be grounded For delta power a central leg ground or one leg ground should be used The machine will not function properly on ungrounded power This is not a factor with the External 480V Option The rated horsepower of the machine may not be achieved if the imbalance of the incoming voltage is beyond an acceptable limit The machine may
383. return to the 480V isolation transformer and readjust the taps as required Do not use the taps on the internal 230V transformer to adjust the voltage 50Hz Installations The external transformers are 60Hz rated and cannot be used at 50Hz without derating the input voltage For these applications the internal 230V transformer should be tapped on the lowest setting 195 210V RMS The external transformer should be tapped according to the table shown below If these tap setting do not produce a DC bus voltage between pins 2 and 3 on the Vector Drive between 320 and 345VDC readjust the taps on the external transformer as required DO NOT move the taps on the internal transformer from the lowest position Input Voltage Range Tap 423 440 1 504 412 422 2 492 401 411 3 480 391 400 4 468 381 390 5 456 371 380 6 444 355 370 7 432 185 Electrical Service 96 0189 rev L June 2005 4 3 FUSE REPLACEMENT Please read this section in its entirety before attempting to replace any fuses OVERVOLTAGE FUSES WARNING WARNING WARNING WARNING WARNING The electrical panel will have residual voltage even after power has been shut off and or disconnected Never work inside this cabinet until the small red CHARGE light on the servo drive assembly goes out The servo drive assembly is on the left side of the main control cabinet and about halfway down This light is at the top of the circuit card at the center of the assembly
384. rev L June 2005 Back COMMON ABBREVIATIONS AC Alternating Current AMP Ampere APC Automatic Pallet Changer APL Automatic Parts Loader ASCII American Standard Code for Information Interchange ATC Automatic Tool Changer ATC FWD Automatic Tool Changer Forward ATC REV Automatic Tool Changer Reverse AWG American Wire Gauge BHCS Button Head Cap Screw BT British Tooling Common usage CAD Computer Assisted Design CAM Computer Assisted Manufacturing Assisted Machining CAT 5 Category 5 Cable CB Circuit Breaker CC Cubic Centimeter CCW Counter Clock Wise CFM Cubic Feet per Minute CNC Computerized Numeric Control CNCR SPINDLE Concurrent Spindle with axis motion CRC Cyclic Redundancy Check digit CRT Cathode Ray Tube CT Caterpillar Tooling CTS Clear To Send CW Clock Wise DB Draw Bar DC Direct Current DGNOS Diagnostic DHCP Dynamic Host Configuration Protocol DIR Directory DNC Direct Numerical Control DOS Disk Operating System DTE Data Terminal Equipment ENA CNVR Enable Conveyor EOB End Of Block EOF End Of File EPROM Erasable Programmable Read Only Memory E STOP Emergency Stop FHCS Flat Head Cap Screw FT Foot FU Fuse FWD Forward GA Gauge HHB Hex Head Bolts HP Horse Power HS Horizontal Series of Machining Centers ID Inside Diameter IGBT Isolated Gate Bipolar Transistor IN Inch IOPCB Input Output Printed Circuit Board LAN Local Area Network LB Pound LED Light Emitting Diode 2 T
385. ries in the table of 256 is defined by Parameter 58 The entered values are limited to 127 encoder steps so the limit in inches is dependent on Parameters 5 19 and 33 Note that the first entry corresponds to machine position zero and subsequent entries are for increasingly negative positions in the machine coordinate system The user should not ever need to adjust the ball screw compensation tables ELECTRONIC THERMAL COMPENSATION When ballscrews rotate they generate heat Heat causes the ballscrews to expand In constant duty cycles the resultant ball screw growth can lead to cutting errors on the next morning start up The Haas ETC algorithm can accurately model this heating and cooling effect and electronically expand and contract the screw to give near glass scale accuracy and consistency This compensation is based on a model of the lead screw which calculates heating based on the distance traveled and the torque applied to the motor This compensation does not correct for thermal growth due to changes in ambient temperature or due to part expansion Electronic thermal compensation works by estimating the heating of the screw based on the total amount of travel over its length and including the amount of torque applied to the screw This heat is then turned into a thermal coefficient of expansion and the position of the axis is multiplied by the coefficient to get a correction amount If the machine is turned off when there is some c
386. ring heavy TSC usage Check way lube lubrication tank level Clean chips from way covers and bottom pan Clean chips from tool changer Wipe spindle taper with a clean cloth rag and apply light oil Weekly Check Through the Spindle Coolant TSC filters Clean or replace element if needed Check for proper operation of auto drain on filter regulator On machines with the TSC option clean the chip basket on the coolant tank Remove the tank cover and remove any sediment inside the tank Disconnect the coolant pump from the cabinet and power off the machine before working on the coolant tank Do this MONTHLY for machines without the TSC option Check air gauge regulator for 85 psi Check the spindle air pressure regulator for 17 psi For 15K spindle machines check spindle air pressure regulator for 20 psi For machines with the TSC option place a dab of grease on the V flange of tools Do this MONTHLY for machines without the TSC option Clean exterior surfaces with mild cleaner DO NOT use solvents Check the hydraulic counterbalance pressure according to the machine s specifica tions Monthly Check oil level in gear box For 40 taper spindles Remove inspection cover beneath spindle head Add oil slowly from top until oil begins dripping from overflow tube at bottom of sump tank For 50 taper spindles Check oil level in sight glass Add from side of gearbox if necessary Inspect way covers
387. rm Steps 9 through 11 until the Bearing reads within 0002 of true Torque the SHCS to 20 ft lbs in a star pattern there should be very little effort needed to reach this value if you have tight ened bolts during the previous Steps Torque the SHCS in sets of four rotating the Bearing between each screw Each SHCS of the set should be 90 degrees from each other 90 90 13 Recheck Bearing runout Ensure the Bearing remains within at least 0002 of true If the Bearing has slipped out of true repeat Steps 9 through 11 14 Torque the SHCS in 5 ft lbs increments Recheck Bearing runout after each torque sequence The final torque value is 45 ft lbs 15 Recheck Bearing runout Make sure the Bearing has not shifted after the final torque sequence ROTARY TABLE PLATTER REMOVAL AND INSTALLATION Removal 1 Remove the Encoder cover plate 2 Remove the encoder shaft plate Important There are two set screw in the encoder shaft plate 3 Remove the plastic bolt cover plugs and the bolts that secure the table to the bearing 4 Fasten lifting plates to the platter Do not use T nuts and eyebolt slippage can occur and the platter could fall Use chains to lift the rotary table Do not use synthetic lifting straps as these have a tendency to stretch which will cause the platter to be lifted off unevenly An unevenly lifted platter may cause damage to the components beneath it 165 96 0189 rev L June 2005 Mechanical Service
388. roubleshooting 96 0189 rev L June 2005 LO CLNT Low Coolant LOW AIR PR Low Air Pressure LVPS Low Voltage Power Supply MB Megabyte 1 million MCD RLY BRD M Code Relay Board MDI Manual Data Input MEM Memory M FIN M code Finished MM MilliMeter MOCON Motor Control MOTIF Motor Interface MSG Message MSHCP Metric Socket Head Cap Screw NC Numerical Control NC Normally Closed NO Normally Open OD Outside Diameter OPER Operator P Pocket PARAM Parameter PCB Printed Circuit Board PGM Program POR Power On Reset POSIT Positions PROG Program PSI Pounds per Square Inch PST Pallet Schedule Table PWM Pulse Width Modulation RAM Random Access Memory RET Return REV CNVR Reverse Conveyor RJH Remote Jog Handle RPDBDN Rotary Pallet Draw Bar Down RPDBUP Rotary Pallet Draw Bar Up RPM Revolutions Per Minute RTS Request To Send RXD Receive Data S Spindle Speed SDIST Servo Distribution PCB SFM Surface Feet per Minute SHCS Socket Head Cap Screw SIO Serial Input Output SKBIF Serial Key Board Inter Face PCB SMTC Side Mount Tool Changer SP Spindle T Tool Number TC Tool Changer TIR Total Indicated Runout TNC Tool Nose Compensation TRP Tool Release Piston TS Tail Stock TSC Thru the Spindle Coolant TXD Transmit Data VDI Verein Deutscher Ingenieure VMC Vertical Machining Center WAN Wide Area Network Troubleshooting 3 96 0189 rev L June 2005 1 TROUBLESHOOTING This section is intended for
389. rox Switch 13 32 2203 Unclamp Prox Switch 14 40 0006 SHCS 13x5 8X 15 59 0049 Compression Spring 16 20 1657 Spring Retainer 17 52 0003 Shaft Clamp 18 58 3631 Reducer 19 58 3050 90 Elbow 20 20 0015 Spindle Fork Lift 21 20 0013 Spindle Fork Spacer 4X 22 20 0014 22 0014 Spacer 4X 23 45 0014 Washer 010 24 45 0015 Washer 018 25 20 0017 Sub Plate EC 1600 26 20 2988 Sub Plate 27 20 7655 Bearing Holder 28 20 7654 Extension Tube 29 52 6200 Rotating Union 347 Assembly Drawings 96 0189 rev L June 2005 EC 1600 Table Assembly 5 Indexer 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 1 25 5541 Left Shroud 2 25 5542 Top Shroud 3 25 5544 Pump Cover Access 4 57 0373 Pump Cover Gasket 5 32 6929 Hydraulic Solenoid 6 25 5546 Hydraulic Valve Bracket 7 20 2528 Zero Ref Sensor Mount 8 20 6103 Ring Gear 9 20 2523 Hydraulic Clamp Cylinder Housing 10 51 0162 160mm Thrust Bearing 11 20 2524 Hydraulic Clamp Piston 12 20 2529 Face Gear 13 20 0973 Table Cover Center 14 20 2980 Indexing Platter 15 20 2530 Piston Adapeter 16 51 0168 Thrust Washer 160200 2 17 20 2522 Hydraulic Clamp Cylinder Cap 18 69 1700 Prox Sensor 19 25 5538 Retainer Platter Seal 20 25 9817 X Axis Chip Guard 21 20 2508 Table 22 30 7410 Saddle Oil Line 23 30 7510 Haskel Pump 24 2
390. rs 530 TOO MANY I J or K S IN G65 Only 10 occurrences of I J or K can occur in a G65 subroutine call Reduce the I J or K count 531 MACRO NESTING TOO DEEP Only four levels of macro nesting can occur Reduce the number of nested G65 calls 532 UNKNOWN CODE IN POCKET PATTERN Macro syntax is not allowed in a pocket pattern subroutine 533 MACRO VARIABLE UNDEFINED A conditional expression evaluated to an UNDEFINED value i e 0 Return True or False 534 DO OR END ALREADY IN USE Multiple use of a DO that has not been closed by an END in the same subroutine Use another DO number 535 ILLEGAL DPRNT STATEMENT A DPRNT statement has been formatted improperly or DPRNT does not begin block 536 COMMAND FOUND ON DPRNT LINE A G code was included on a DPRNT block Make two separate blocks 537 RS 232 ABORT ON DPRNT While a DPRNT statement was executing the RS 232 communications failed 538 MATCHING END NOT FOUND A WHILE DO statement does not contain a matching END statement Add the proper END statement 48 Alarms 96 0189 rev L June 2005 539 ILLEGAL GOTO Expression after GOTO not valid 540 MACRO SYNTAX NOT ALLOWED A section of code was interpreted by the control where macro statement syntax is not permitted 541 MACRO ALARM This alarm was generated by a macro command in a program 542 OPERATION NOT AVAILABLE This operation is not compatible with FNC mode 600 U OVER TRAVEL RANGE Commanded U axis move would exceed the allo
391. rupted program Save all programs to disk delete all then reload 39 Alarms 96 0189 rev L June 2005 258 INVALID DPRNT FORMAT Macro DPRNT statement not structured properly 259 LANGUAGE VERSION Problem with language files Please reload foreign language files 260 LANGUAGE CRC Indicates FLASH memory has been corrupted or damaged 261 ROTARY CRC ERROR Rotary table saved parameters used by Settings 30 78 have a CRC error 262 PARAMETER CRC MISSING RS 232 or disk read of parameter had no CRC when loading from disk or RS 232 263 LEAD SCREW CRC MISSING Lead screw compensation tables have no CRC when loading from disk or RS 232 264 ROTARY CRC MISSING Rotary table parameters have no CRC when loading from disk or RS 232 265 MACRO VARIABLE FILE CRC ERROR Macro variable file has a CRC error Possible corrupted file 266 TOOL CHANGER FAULT Run Tool Changer recovery 267 TOOL DOOR OUT OF POSITION This alarm will be generated on a horizontal mill during a tool change when parameter 278 TL DR SWITCH is set to 1 and the tool carousel air door switch indicates that the door is open after it was commanded closed or closed after it was commanded open This alarm will most likely be caused by a stuck or broken switch 268 DOOR OPEN M95 START Generated whenever an M95 Sleep Mode is encountered and the door is open The door must be closed in order to start sleep mode 269 TOOL ARM FAULT The tool changer arm is not in position Run tool cha
392. ry axis at a time 359 INVALID I J OR K IN G12 OR G13 Check your geometry 360 TOOL CHANGER DISABLED Check Parameter 57 361 GEAR CHANGER DISABLED Check Parameter 57 362 TOOL USAGE ALARM Tool life limit was reached To continue hi light the Usage count in the Current Com mands Tool Life display and press ORIGIN Then press RESET 363 COOLANT LOCKED OFF Override is off and program tried to turn on coolant 364 NO CIRC INTERP AUX AXIS Only rapid or feed is allowed with aux axes 365 P DEFINITION ERROR P value not defined or P value out of range An M59 or M69 must have a P value between the range of 1100 and 1155 If using G154 command then P value must be between 1 and 99 366 MISSING I K OR L IN G70 G71 OR G72 Check for missing values 367 CUTTER COMP INTERFERENCE G01 cannot be done with tool size 368 GROOVE TOO SMALL Tool too big to enter cut 369 TOOL TOO BIG Use a smaller tool for cut 370 POCKET DEFINITION ERROR Check geometry for G150 371 INVALID I J K OR Q Check G150 372 TOOL CHANGE IN CANNED CYCLE Tool change not allowed while canned cycle is active 373 INVALID CODE IN DNC A code found in a DNC program could not be interpreted because of DNC restrictions 374 MISSING XYZA IN G31 OR G36 G31 skip function requires an X Y Z or A move 375 MISSING Z OR H IN G37 G37 automatic tool length measurement function requires H code Z value and tool offset enabled X Y and A values not allowed 376 NO CUTT
393. ry retention battery is initially soldered into the processor PCB This is a 3 3V Lithium battery that maintains the contents of CMOS RAM during power off periods Prior to this battery being unusable an alarm will be generated indicating low battery If the battery is replaced within 30 days no data will be lost The battery is not needed when the machine is powered on Connector J6 on the processor PCB can be used to connect an external battery VIDEO KEYBOARD WITH FLOPPY The VIDEO and KB PCB generates the video data signals for the monitor and the scanning signals for the keyboard In addition the keyboard beeper is generated on this board There is a single jumper on this board used to select inverse video The video PCB connectors are P1 Power connector J3 Keyboard 700 J4 Address bus J5 Data J10 Floppy V J11 SPARE J12 Floppy J13 Video 760 J14 RS422 B J15 RS422 A MOTOR CONTROLLER MOCON The mill is equipped with a microprocessor based motor controller board MOCON It runs in parallel with the main processor receiving servo commands and closing the servo loop around the servo motors In addition to controlling the servos and detecting servo faults the motor controller board MOCON is also in charge of processing discrete inputs driving the I O board relays commanding the spindle and processing the jog handle input Another significant feature is that it controls 6 axes so there is no need for an additional boar
394. s Install o rings onto the encoder cover plate Install the encoder cover plate into the platter bore CHECKING A AXIS BACKLASH 1 Command the A axis brake to disengage To do this enter MDI and command an M11 Do not disconnect the air to the machine 2 Disable the A axis encoder by setting the parameter 43 bit 3 to 1 Note This will disable the rotary table position encoder and enable the drive motor encoder The drive motor gear will now hold position allowing backlash to be measured between the ring and pinion gear 3 Verify the brake is disengaged by ensuring the platter can be rotated a slight amount 4 Set up an indicator on the non rotary part of the table and set the indicator needle against a T slot See figure 169 96 0189 rev L June 2005 Mechanical Service 5 Manually rotate the platter back and forth At times additional force is required to overcome the friction Use platter lifting plates or a fixture on the platter with a cheater bar between them if necessary to move the platter 6 Take readings from the indicator every 10 for 360 Note the indicator must be repositioned each time Backlash should be between 0005 and 0007 If it is not within this range perform the following adjustment procedure A axis Backlash adjustment 1 Command the A axis brake to disengage To do this enter MDI and command an M11 Do not disconnect the air to the machine 2 Disable the A axis encoder by setting
395. s a layer of oil for the Ball Screw components to operate on eliminating metal to metal contact Should a problem with the lubrication system develop that failure will accelerate all wear issues 1 Dry metal to metal contact following lube breakdown will create intense heat at the contact points The Nut balls will weld to the nut races due to the heat and pressure of the preload When move ment of the Ball Screw continues the welds will be broken ripping off particles of both the balls and the races This loss of diameter will reduce the preload reducing machine accuracy Ball Screws with this type of wear but no screw surface marring can be repaired by the factory 2 A second cause of wear of the Ball Screws is material fatigue Material fatigue typically occurs at the end of the Ball Screw service life Signs of material fatigue include black contaminated coolant pitting of the screw surface loss of preload and metal flakes on the Ball Screw Ball Screws suffering from material fatigue are not repairable Contamination Contamination of the lubrication and or coolant systems of the machine will produce problems with the Ball Screws Check the condition of the lube on the Ball Screw threads 1 If the lube is wet and clean this indicates a properly functioning lube system 2 If the lube is thick and dark but free of metal chips the lube itself is old and must be changed out The entire system should be cleaned of the old l
396. s alarm will occur if the home limit switches move or are misadjusted This alarm indicates that the zero return position may not be consistent from one zero return to the next The encoder Z channel signal must occur between 1 8 and 7 8 revolution of where the home switch releases This will not turn the servos off but will stop the zero return operation 168 A ZERO RET MARGIN TOO SMALL This alarm will occur if the home limit switches move or are misadjusted This alarm indicates that the zero return position may not be consistent from one zero return to the next The encoder Z channel signal must occur between 1 8 and 7 8 revolution of where the home switch releases This will not turn the servos off but will stop the zero return operation 169 SPINDLE DIRECTION FAULT Problem with rigid tapping hardware The spindle started turning in the wrong direction 171 APC PALLET CLAMP TIMEOUT The pallet in the mill did not clamp in the time allowed Check for foreign objects under the pallet and between the pallet and the clamp plate Verify there is an adequate supply of air pressure and air volume Check air solenoids for sticking and air release ports for clogging Check the pallet position switch for correct operation the switch and wiring for damage and pallet alignment Check the pallet clamp mechanism for correct operation After determining the cause and correcting the problem run M50 P1 in MDI to recover the pallet changer and then continue operation
397. s are milliseconds 223 Parameters 96 0189 rev L June 2005 70 MIN SPIN DELAY TIME Minimum delay time in program after commanding new spindle speed and before pro ceeding Units are milliseconds 71 DRAW BAR OFFSET Offset provided in motion of Z axis to accommodate the tool pushing out of the spindle when unclamping tool Units are encoder steps 72 DRAW BAR Z VEL UNCL Speed of motion in Z axis to accommodate tool pushing out of the spindle when unclamping tool Units are encoder steps per second 73 SP HIGH G MIN SPEED Command speed used to rotate spindle motor when orienting spindle in high gear Units are maximum spindle RPM divided by 4096 This parameter is not used in machines equipped with a Haas vector drive 74 SP LOW G MIN SPEED Command speed used to rotate spindle motor when orienting spindle in low gear Units are maximum spindle RPM divided by 4096 This parameter is not used in machines equipped with a Haas vector drive 75 GEAR CHANGE SPEED Command speed used to rotate spindle motor when changing gears Units are maximum spindle RPM divided by 4096 76 LOW AIR DELAY Delay allowed after sensing low air pressure before alarm is generated Alarm skipped if air pressure returns before delay Units are 1 50 seconds 77 SP LOCK SETTLE TIME Required time in milliseconds that the spindle lock must be in place and stable before spindle orientation is considered complete 78 GEAR CH REV TIME Time in milliseconds before motor dire
398. s at 0 when up and 1 when down Adjust the position of the switch so that the platter lift state becomes 0 at 052 above the down position 9 Tighten the switch mounting screws when this height is achieved BLEEDING THE EC 1600 BRAKE It will take about 1 hour to properly bleed the EC 1600 brake assembly 1 Power off the machine and remove the indexing platter from the table using a proper lift and eye bolts The brake assembly and fly wheel will be exposed underneath 2 Disconnect all oil air lines and remove the fly wheel and clamp ring from the table Set the clamp ring on a firm work surface and reconnect the air oil lines 4 Slightly loosen the bleed valve on the clamp ring and slightly elevate the brake assembly so that air bubbles can escape more efficiently 5 Set air pressure to 1000 PSI OR LESS If air pressure is set to more than 1000 psi the clamp will become permanently damaged 6 Pressurize the clamp ring forcing air and air bubbles out of the oil through the bleed valve Re pressurize every five minuets for about 10 12 cycles or until the oil is completely clear of any air bubbles Re tighten the bleed valve 129 Mechanical Service 96 0189 rev L June 2005 Oil Bleed Valve Ring Gear Hydraulic Brake Assy Brake Booster Oil Line Air Lines SETTING PARAMETERS 212 AND 128 INDEXER A AXIS OFFSET 1 In Debug mode go to parameter 212 and enter 0 then press the Write key Repeat fo
399. s way cover from the 4th axis 1 In debug mode go to parameter 212 and enter 0 then press the Write key Repeat for parameter 128 2 Zero the A axis only by pressing the ZERO RET key then the A key then the ZERO SINGL AXIS key 3 Go to debug mode and type GRID followed by a space A 4 Go to parameter 128 and verify that the value has been entered 5 Jog the A axis to line up the front edge of the pallet with the X axis to a value of 0005 10 00 6 If removed replace the Z axis waycover Mechanical Service 130 96 0189 rev L June 2005 3 13 THROUGH THE SPINDLE COOLANT SYSTEM ADJUSTMENTS TOOLS REQUIRED Tool holder with small through coolant drill or small orifice tool T 1461 TSCHP Gauge Kit P N 93 9011 includes Ball valve 0 600 PSI coolant gauge PRIMING THE TSC SYSTEM NOTE When machine is ready to operate with coolant in the coolant tank prime the Through the Spindle Coolant TSC system according to the following proce dure 1 With no tool in the spindle switch to MDI mode 2 Press the AUX CLNT button to turn on TSC Wait for coolant to flow from the spindle 3 Run TSC system for at least one minute 4 Press the AUX CLNT button again to turn off TSC NOTE If the Low Tool Coolant alarm is received press RESET and turn TSC on again If the Low Tool Coolant alarm still does not clear check the pump pressure and coolant pressure switch settings as de
400. scribed below If the pump pressure is less than 60 psi with no tool in the spindle replace the pump head CHECKING PUMP PRESSURE NOTE If the coolant pressure with no tool in the spindle is 60 psi or less replace the pump assembly 30 3281A 1 Insert the 0 600 psi coolant pressure gauge into the coolant line between the machine enclosure and the TSC pump hose Use wrenches to tighten the fittings snug DO NOT OVERTIGHTEN 2 With no tool in the spindle prime the TSC system as previously described 3 Insert a standard no through hole in pull stud tool holder into the spindle 4 Turn on TSC 5 Check for leaks while TSC is still running Shut off TSC 6 Remove pressure gauge and reconnect the pump to the machine If the pump relief valve has been changed adjust the relief valve in the following manner 1 Remove the sealing cap from the pump relief valve Loosen the lock nut 2 Start with the pressure below 300 psi Adjust the pressure relief valve until the pressure on the gauge rises to 300 psi Tighten the lock nut and replace the sealing cap Setting range is 280 300psi 3 Mark across the pump and sealing cap with a paint marker This will indicate tampering 131 Mechanical Service 96 0189 rev L June 2005 TESTING THE COOLANT PRESSURE SWITCH 1 Insert the ball valve and pressure gauge into the coolant line between the machine enclosure and the TSC pump hose The ball valve must be between the
401. se the lifted and lowered position of the pallet changer are indicating the impossible condition that the pallet changer is both lifted and lowered at the same time Check the function of the lift and lower sense switches check the adjustment of the top switch check both switch electrical connections and their wiring After correcting the condition run an M50 to con tinue machining 648 RP MAIN DRAWBAR LOCKED IN PALLET CLAMPED POSITION The drawbar has not tripped the unclamp sense switch in a reasonable amount of time Check to see that the motor is plugged in at the connector panel in the rear of the machine and at the motor through the access panel check the function of the main drawbar motor does it turn or try to turn check the condition of the drive belt check power supply to the motor check the relays that supply power to the motor check the condition of the current limiting resistors After correcting the condition run an M50 to continue machining 649 RP MAIN DRAWBAR LOCKED IN PALLET UNCLAMPED POSITION The drawbar has not come off the unclamp sense switch in a reasonable amount of time Check to see that the motor is plugged in at the connector panel in the rear of the machine and at the motor through the access panel check the function of the main drawbar motor does it turn or try to turn check the condition of the drive belt check power supply to the motor check the relays that supply power to the motor check the condition of th
402. sed Harmonic Drive is prepacked with appropriate grease It is a self greasing unit requiring no maintenance ASSEMBLY BACKLASH TUBE AND PLATE 1 Place the Tube Backlash Adjuster onto the Cam Backlash Adjuster plate Turn the Tube so that the holes line up with the holes in the Plate This is an interference fit item Insert the 12 SCHS into the Tube and thread into the Plate Tighten the SCHS in a star pattern to ensure proper positioning of the Tube 2 Attach one Push Block to each side of the Plate using existing drilled holes and 6 supplied SCHS NOTE The Backlash Plate assembly is not attached to the Motor at this point to ease assembly into the table during installation 149 96 0189 rev L June 2005 Mechanical Service ASSEMBLY MOTOR WAVE GENERATOR 1 Sweat the Pinion Gear positioned so the groove is away from the flange over the shaft of the Sigma Adapter and set aside 2 Examine the spindle of your Yaskawa Sigma Motor If your Motor has the Motor Shaft Spacer already sweated onto the shaft skip to Step 4 3 Sweat the Motor Shaft Spacer over the shaft of the Motor Ensure the chamfer on the inner diam eter spacer faces the motor 4 Turn the Motor so that the shaft faces upward Place the Gearbox Adapter over the Motor shaft Insert the four SHCS through the tabs of the Motor case into the Gearbox Adapter and tighten 5 Place the Wave Generator over the Motor shaft Align the keyway in the Wave Generat
403. sing initialization of brushless motor This can be caused by a bad encoder or a cabling error 661 U TRANSITION FAULT Illegal transition of count pulses in U axis This alarm usually indicates that the encoder has been damaged and encoder position data is unreliable This can also be caused by loose connectors at the MOCON or MOTIF printed circuit board 662 V TRANSITION FAULT Illegal transition of count pulses in V axis This alarm usually indicates that the encoder has been damaged and encoder position data is unreliable This can also be caused by loose connectors at the MOCON or MOTIF printed circuit board 663 W TRANSITION FAULT Illegal transition of count pulses in W axis This alarm usually indicates that the encoder has been damaged and encoder position data is unreliable This can also be caused by loose connectors at the MOCON or MOTIF printed circuit board 664 U AXIS DISABLED Parameter has disabled this axis 665 V AXIS DISABLED Parameter has disabled this axis 666 W AXIS DISABLED Parameter has disabled this axis 667 U AXIS LINEAR SCALE Z FAULT Encoder marker pulse count failure This alarm usually indicates that the Z Fault encoder has been damaged and encoder position data is unreliable This can also be caused by loose scale connectors 668 V AXIS LINEAR SCALE Z FAULT Encoder marker pulse count failure This alarm usually indicates that the Z Fault encoder has been damaged and encoder position data is unreliable This can a
404. sion tube if the machine is equipped with Through the Spindle Coolant option Refer to the Through The Spindle Coolant System section NOTE The TSC union and extension shaft are reverse thread 7 If your machine is equipped with TSC remove the 3 16 SHCS that attach the TSC valve bracket to the right side of the motor Let the TSC valve bracket hang off the right side of the spindle head ensuring that the hoses do not get kinked 8 Remove the SHCS that attach the TRP solenoid assembly to the top of the motor lift plate Cable tie the assembly to the rear sheetmetal or column to prevent damage while removing the transmis sion motor assembly 9 Remove the quick disconnect electrical plug panel from the rear of the motor This is attached by four 3 16 SHCS Gently push the plug panel behind the motor and cable tie it to the rear sheetmetal or column 10 Remove the plug for the gear change solenoid 11 Remove the Encoder to Transmission Shaft belt This can most easily be accomplished by removing the four SHCS that attach the Encoder bracket to the spindle head located inside the spindle head cavity between the drive belts Access the panel on front of the head casting above the spindle 12 Remove the four large SHCS that attach the transmission mount plate to the spindle head and pull the transmission motor assembly towards the front of the machine slightly This proceedure will remove the tension on the drive belts
405. sly removed JOG HANDLE REPLACEMENT The JOG handle is actually a 100 line per revolution encoder We use 100 steps per revolution to move one of the servo axes If no axis is selected for jogging turning of the crank has no effect When the axis being moved reaches its travel limits the handle inputs will be ignored in the direction that would exceed the travel limits NOTE Parameter 57 can be used to reverse the direction of operation of the handle 1 Turn the machine power off 2 Remove the screws holding the cover panel on the back of the control panel Take care to hold the cover panel in place until all screws have been removed 3 Unplug the cable leading to the jog handle encoder IMPORTANT The blank pin side of the connec tor must face as shown in Fig 4 5 2 when reconnecting otherwise damage may occur to the machine Blank pin goes to this side of connector Figure 4 5 2 Jog handle encoder 4 Using the 5 64 allen wrench loosen the two screws holding the knob to the control panel and remove Electrical Service 194 96 0189 rev L June 2005 5V BLK 5V RED GND WHT A RED B GRN GND WHT RED A WHT YEL B WHT BRN A YEL B BRN Figure 4 5 3 Jog Handle removal Figure 4 5 4 Jog Handle wiring diagram 5 Remove the three screws holding the jog handle encoder to the control panel and remove 6 Replacement is reverse of removal Keep in mind the important notice in Step 3
406. so that lifting eyes can be installed or use straps to grip the top of the receiver Remove the receiver assembly through the operator door 9 Remove any shims that may be present on the rotary platter and put them aside for use later if necessary Installation 1 Lift the receiver assembly into the machine 2 Position the assembly orienting the clamp plate over the base and lower into place 3 Loosely install the 8 bolts in the receiver 4 Install the rotary union at the bottom of the receiver shaft 5 Reconnect the 3 hoses to the rotary union 6 Install and align the switch plate assembly Slide the assembly toward the rotating union center of the rotary as far as possible and tighten the mounting screw Make sure that the prox switches do not contact the union but are close enough to produce a sufficient reading 7 Connect the air supply to the machine and reset parameter 76 to 1500 8 Indicate the receiver using the verification procedure utilized before removing the receiver Adjust the receiver concentricity with the 8 bolts that attach the receiver to the rotary platter just snug If the concentricity changes the receiver runout will also change Because of this the concentricity should be correct before indicating or adjusting the receiver runout 9 If the receiver runout is not correct but the concentricity is it will be necessary to shim under the receiver It will only be necessary to lift the receiver just enou
407. spacer location diagram 1 Use the lifting straps to position the TRP The TRP is heavy use an overhead lifting device 2 Install the 4 bolts with the shim stock and spacers under the TRP Part No Description 30 0013A NEW 30 0013 OLD STYLE Fork 45 0014 0 010 Shim Washer 1 ea None 45 0015 0 018 Shim Washer 7 ea 5 ea 143 Mechanical Service 96 0189 rev L June 2005 TRP 45 0019 0 093 Nylon Washer 1 ea 1 ea Spacers 45 0017 0 010 Shim Washer 2 ea 2 ea 45 0018 0 015 Shim Washer 3 ea 2 ea NOTE TRP Spacers the nylon washer goes on top of the shims 3 If the machine is equipped with TSC re install the Extension Tube and Rotating Union in the following manner Otherwise skip this step NOTE If the Spindle Drawbar or Extension Tube has been replaced the Extension Tube Runout must be adjusted a Place a Tool Holder in the Spindle b Insert a 5 8 Allen wrench into the lower end of the piston shaft Loosen the 1 4 20 screw in the clamp collar on top of the piston shaft Insert a large flat blade screwdriver into the slot in the clamp collar and twist the collar off c Screw the Bearing Holder 20 7655 onto the piston shaft and tighten using a large wrench or pliers d Wipe clean the hole in the end of the Drawbar e Replace the Tool Release Piston f Apply a light layer of Molybdenum Grease to the inside of the Bearing Holder Insert the Wave Spring 59 0176
408. starts before clamping the pallet before the A axis or Z axis can be jogged or before starting a program with CYCLE START If the pallet began to lower during rotation check the lift mechanism for proper operation If this alarm occurred at start of pallet change or when clamping the pallet check for foreign objects or misalignment that prevent the frame from lowering all the way Verify there is an adequate supply of air pressure and air volume After correcting the cause press Tool Changer Restore to enter pallet changer recovery recover the pallet changer and then continue operation 953 APC MISLOCATED PALLET CLAMP The pallet changer clamp plate is not in the expected position The clamp plate must be unclamped while the pallet changer is rotating or before the pallet is lifted Verify there is an adequate supply of air pressure and air volume Check operation of the clamp mechanism air solenoids Check the pallet clamped position switch for correct operation the switch and wiring for damage and pallet alignment Check the pallet clamp plate for damage After correcting the cause press Tool Changer Restore to enter pallet changer recovery recover the pallet changer and then continue operation 954 APC INCOMPLETE PALLET CHANGE The last pallet change did not complete successfully or the mill has been initialized Press Tool Changer Restore to enter pallet changer recovery recover the pallet changer and then continue operation 955 APC INVAL
409. sure Booster Final Assembly bottom view PRESSURE BOOSTER ASSEMBLY Prior to installation of the Pressure Booster Assembly a test of this system should be performed This will identify leaks and allow for the system to be bled while it is still easily accessible Set the Air Valve Assembly on top of the Table or other high work surface Set the Pressure Booster Assembly onto the floor Bleed the Pressure Booster The booster should be filled to the top fill line before starting Use a manual vacuum pump to draw the air bubble out of the hose stopping before the pump fluid reservoir is full Release the pressure valve on the pump depress small needle like feature on the bottom empty the reservoir and repeat procedure It can take 5 to 8 vacuum cycles to remove all the air from the hose Take caution to refill the booster before the fluid level falls below the lower fill line or air will be introduced into the system It is critical to remove all air from booster hose failure to do so will introduce air into clamp ring 162 Mechanical Service 96 0189 rev L June 2005 1 Identify the low pressure Tubing line coming from the low pressure side of the Pressure Booster Connect this Tubing line to the Low Pressure Regulator of the Air Valve Assembly 2 Identify the high pressure Tubing line coming from the high pressure side of the Pressure Booster Connect this Tubing line to the High Pressure Regulator of the Air Valv
410. switch applies power to the contactor coil and the contactor thereafter maintains power to its coil The POWER OFF switch interrupts power to the contactor coil and will always turn power off POWER ON is a normally open switch and POWER OFF is normally closed The maximum voltage on the POWER ON and POWER OFF switches is 24V AC and this voltage is present any time the main circuit breaker is on SPINDLE LOAD METER The load meter measures the load on the spindle motor as a percentage of the rated continuous power of the motor There is a slight delay between a load and the actual reflection of the meter The eighth A to D input also provides a measure of the spindle load for cutter wear detection The second page of diagnostic data will display of spindle load The meter should agree with this display within 5 The spindle drive display 7 should also agree with the load meter within 5 Note that there are different types of spindle drive that are used in the control They are all equivalent in performance but are adjusted differently EMERGENCY STOP SWITCH The EMERGENCY STOP switch is normally closed If the switch opens or is broken power to the servos will be removed instantly This will also shut off the tool changer spindle drive and coolant pump Note that Parameter 57 contains a status switch that if set will cause the control to be powered down when EMERGENCY STOP is pressed You should not normally stop a tool change with EMERGENC
411. t Loosen the X axis cable carrier and position away from the back of the spindle casting 6 Remove the four 4 bolts that mount the spindle motor assembly to the column and remove the spindle motor assembly Mechanical Service 64 96 0189 rev L June 2005 Installation 1 Sweep the spindle before the motor installation is started 2 Check the condition of the coupler hub on top of the spindle and the condition of the coupler spider Lift the motor up and position it just above the TRP using a forklift or hoist Check the condition of the coupler hub on the motor and align it with the coupler on the spindle Inspect the transfer tube for damage and the O rings for deterioration Replace if necessary Note Insure that the transfer tube has been installed prior to motor installation 3 Bring the motor towards the TRP The couplers should engage with very little interference It may be necessary to rotate the spindle slightly to line up the coupler hubs or rock the motor housing back and forth to square the assemblies Do this using your hand on the spindle dogs at the nose of the spindle 4 Once the coupler hubs are mated install the bolts in that hold the motor to the spacer blocks leave them loose Join all the motor cables to the harness of the machine Command a spindle speed of 1000 rpm the motor mounting bolts are to be left loose Let the spindle run for about 5 minutes this allows the spindle assembly to seat and wil
412. t at the back of the motor or coupling of motor to the screw 275 C AXIS Z CH MISSING Z Reference signal from encoder was not received as expected Can be caused by loose connections encoder contamination or parameter error 276 C AXIS DRIVE FAULT Current in C servo motor beyond limit Possibly caused by a stalled or overloaded motor The servos are turned off It can also be caused by a short in the motor or a short of one of the motor leads to ground 277 C ZERO RET MARGIN TOO SMALL This alarm will occur if the home limit switches move or are misadjusted This alarm indicates that the zero return position may not be consistent from one zero return to the next The encoder Z channel signal must occur between 1 8 and 7 8 revolution of where the home switch releases This will not turn the servos off but will stop the zero return operation 278 C CABLE FAULT Cable from C axis encoder does not have valid differential signals 40 Alarms 96 0189 rev L June 2005 279 X AXIS LINEAR SCALE Z FAULT Encoder marker pulse count failure This alarm usually indicates that the Z Fault encoder has been damaged and encoder position data is unreliable This can also be caused by loose scale connectors 280 Y AXIS LINEAR SCALE Z FAULT Encoder marker pulse count failure This alarm usually indicates that the Z Fault encoder has been damaged and encoder position data is unreliable This can also be caused by loose scale connectors 281 Z AXIS LINEAR SCALE Z FA
413. t begin moving in the time allowed Check the door switch the door for mechanical binding and that the door motor and clutch are functioning correctly 239 UNKNOWN MOCON1 ALARM Mocon has reported an alarm to the current software The current version of software was unable to identify the alarm 240 EMPTY PROG OR NO EOB DNC program not found or no end of program found 241 INVALID CODE RS 232 load bad Data was stored as comment Check the program being received 242 NUMBER FORMAT ERROR OR TOO LONG Check input file for an improperly formatted number Number may have too many digits or multiple decimal points The erroneous data will be placed on the MESSAGES page as a com ment with trailing question mark 243 BAD NUMBER Data entered is not a number 244 MISSING Comment must end with a This alarm can also occur if a comment is greater than 80 characters long 245 UNKNOWN CODE Check input line or data from RS 232 This alarm can occur while editing data into a program or loading from RS 232 See MESSAGE PAGE for input line 246 STRING TOO LONG Input line is too long The data entry line must be shortened 247 CURSOR DATA BASE ERROR Cycle power on the machine If the alarm reoccurs call your dealer and report the sequence of events that lead to the alarm 248 NUMBER RANGE ERROR Number entry is out of range 249 PROG DATA BEGINS ODD Possible corrupted program Save all programs to disk delete all then reload 250 PRO
414. t securely into place while maintain ing the ability to index freely A manual indexing handle withdraws an indexing pin from the load station which makes it possible to rotate the turntable and the load by hand Four positions are available at 90 degree increments and at each increment the indexing pin will lock into position Pallet must be in the home position before a pallet change can be commanded POWER SUPPLY CABLES The load station drawbar gearmotor and the main drawbar gearmotor each have a power supply cable The load station motor is equipped with an extension cable to aid in motor replacement The connector is about 12 inches from the gearmotor Both power supplies are routed to their respective mounting locations from the central point of the solenoid mounting bracket at the rear of the machine where the disconnects are located AIR SUPPLY LINES The lifting cylinder has one large air supply line for lifting the pallets and their loads No return line is required because the cylinder is vented to the atmosphere and the weight of the assembly and load will cause the cylinder to lower The rotation cylinder is double acting and has two smaller air supply lines for clockwise and counterclockwise rotation The air blast system has one large air supply line which is connected to the lube tube adapter Each of the four air supply lines are routed to the solenoid mounting bracket at the rear of the Horizontal where the air sol
415. t should be set to 1 If it is set to 2 for example the control will only recognize every other pocket That is it will treat the tools and pockets as follows Tool 1 is in pocket 1 Tool 2 is in pocket 3 Tool 3 is in pocket 5 Tool 4 is in pocket 7 etc If this parameter is set to 3 the control will only recognize every third pocket and so on It is the operator s responsi bility to ensure that the total number of pockets in the tool changer is evenly divisible by this parameter value If not the control will pick the wrong pocket after the carousel has exceeded a full revolution 314 FEED DELTA V This parameter supports the motion control feature It is the maximum change in velocity in encoder steps per millisecond 241 Parameters 96 0189 rev L June 2005 315 COMMON SWITCH 4 0 ALIS M GRPHC When this bit is set to 0 all user defined M codes such as M50 normally used to do a pallet change on a horizontal mill will be ignored when a program is run in graphics mode If it is necessary to have graphics recognize such M codes this bit should be set to 1 1 GANTRY 2 NO X MOVE NEXT TOOL This parameter only affects horizontal mills and is intended for use primarily on the HS 3 If this bit is set to zero it will have no effect If it is set to one the X axis will not move following a NEXT TOOL button press The reason for this is because after pressing NEXT TOOL on an HS 1 or HS 2 the spindle which is mounted on the X axis is moved
416. t the pallet changer has an automatic door as opposed to the operator Auto Door feature This is so that an MDC can have either an Auto Door or an automatic pallet changer door 20 MAP 4TH AXIS This bit enables the Rotary Index button at the load station and prevents movement of the rotary outside of the work area i e rotary mounted on the outside pallet position 21 INV PAL DOOR SWITCH This parameter bit must be set to 1 on the MDC1 and zero on all other machines This bit indicates the polarity of the pallet changer door closed switch 22 PAL RECIEVER SWITCH This parameter supports the APC pallet receiver position switch When the switch is present the bit must be set to 1 otherwise it must be set to zero 23 RAPID gt HS FEED This bit enables straight line rapid moves Normally during a rapid move of two or more axes the axis with the shorter distance will finish first When this parameter is set to 1 the control will treat rapid moves as high speed feeds that is all axes will complete their motion at the same time 243 Parameters 96 0189 rev L June 2005 25 POWER DICONN RELAY When it is set to zero the machine behaves as before When it is set to 1 and parameter 57 SAFETY CIRC is set to 1 and the door is opened I GAIN on all axes will be cleared When the door is closed and power to the servos is restored the I GAIN values will be restored This is intended to be used in conjunction with special hardware by customers who re
417. table towards the front of the machine EC 1600 Slide the bearing support end of the ball screw under the column taking care not to damage the screw threads Position the ball screw to the right side of the nut housing and slide toward the front of the machine 3 Place the motor end of the ball screw through the nut housing and pull it toward the rear of the machine until the ball nut is seated in the nut housing 4 Place the bearing sleeve in the motor mount It may be necessary to align the bearings in the sleeve to facilitate mounting on the ball screw 5 Screw the clamp nut on the bearing support end of the ball screw two or three turns but do not tighten 6 Pull the ball screw through the motor mount and loosely install the clamp nut on the opposite end 7 Install and tighten the SHCS on the bearing sleeve and torque to 15 ft lb EC 1600 Place a drop of blue Loctite on each of the SHCS before inserting and torque to 30 ft lb 8 Install the two outer SHCS of the five SHCS that secure the ball nut to the nut housing Torque to 15 in lb 9 Loosen the SHCS on the bearing sleeve approximately 1 4 turn do not remove 10 Hand turn the ball screw until the ball nut is at the motor end of travel Retighten the SHCS on the bearing sleeve torquing them to 15 ft lb EC 1600 torque to 30 ft lbs 11 Torque the remaining SHCS that secure the ball nut to the nut housing Place a drop of blue Loctite on each of the SHCS befo
418. tate the carousel by hand to the next pocket Line up the pocket mounting finger with the actuator shaft or micro switch on the flat spot on the carousel cam Mechanical Service 78 96 0189 rev L June 2005 TOOL CHANGER ASSEMBLY REMOVAL INSTALLATION Removal 1 Power off machine 2 Remove all ATC assembly sheet metal covers and fasteners 3 Remove the tool changer amphenol connection at the control box and tool pocket air line at the top of the carousel Wrap and tie the amphenol connector to the top of the carousel cam box 4 Insert an eyebolt into the threaded 1 2 13 hole at the top of the carousel housing Attach the lifting device to the eyebolt and support the ATC assembly Remove the five carousel mounting SHCS from the ATC mounting bracket and move ATC assembly away from the column 5 Carefully raise the ATC assembly until it is out of the machine Avoid catching the double arm on other machine parts 6 Lower the ATC assembly with the back side of the cam box towards the ground TC Lift Bracket 6X Hex Head Bolt 5X SHCS Horiz ATC Mounting Bracket 7X SHCS Mounting Pins EC 1600 3000 only Tool Changer Assembly Lifting Position Tool Changer Installation 1 Power Off machine 2 Clean mounting surfaces of the ATC mounting bracket and the ATC 3 Align the ATC with the mounting bracket and attach with SHCS Only snug the SHCS 4 Reconnect the tool changer amphenol connector to
419. th serial number 51004 and later See the end of this section for information specific to machines built before 51004 The Air Valve Assembly has three main components 3 Way Air Valve High Pressure Fixed Regulator Low Pressure Regulator THEORY OF OPERATION The Air Valve Assembly actuates the Rotary Table brake Supplied air flows though the high pressure regulator 45 PSI to supply the high side of the Brake Valve Pressure Booster This supplies 40 1 hydraulic pressure boost to expand the hydraulic pump When the clamp is released a valve switches the supplied air into the low side of the Pressure Booster This action returns the Pressure Booster piston to its original position and refills the hydraulic cylinder from the reservoir This is a closed hydraulic system A 45 20 PSI pressure differential is used to prevent air leaking into the Pressure Booster ASSEMBLY Individual assembly of the 3 Way Air Valve the High Pressure Regulator and the Low Pressure Regulator component parts is necessary and is not detailed in this Service Manual 1 Apply a small amount of thread sealant to the threads of the High Pressure Regulator Assembly and attach to the 3 Way Air Valve Orient the Regulator to match the position of the part removed 2 Apply a small amount of thread sealant to the threads of the Low Pressure Regulator Assembly and attach to the 3 Way Air Valve Orient the Regulator to match the position of the part removed 3 Attach t
420. the Cable Box into the Table Tighten 3 Apply Sikaflex around any gaps to prevent the Encoder cable from popping out when it is pushed down into the box after installation 154 Mechanical Service 96 0189 rev L June 2005 3 204TH AXIS BRAKE ASSEMBLY The Brake Assembly has five main components Brake Ring Brake Arm Pivot Block Pivot Pin Bearing ASSEMBLY 1 Orient the Pivot Block so that you will be inserting the Bearings Step 2 from the 20 degree chamfered side 2 Insert one Bearing into each bore of the Pivot Block When installing the Bearings orient the seam in the bearing out of phase of the direction of load Proper Bearing Orientation 3 Clean the Pivot Pin with alcohol and a lint free rag Insert one Pivot Pin through each Bearing 4 Place one Brake Arm over each end of the Pivot Pins Secure each Pivot Pin with supplied E Clips 5 Insert the remaining two Bearings into the legs of the Brake Ring Clean the remaining two Pivot Pins 6 Place the Pivot Block assembly between the legs of the Brake Ring Insert the Pivot Pins through the Brake Arms of the Pivot Block assembly Secure each Pivot Pin with supplied E Clips See the following figure 155 96 0189 rev L June 2005 Mechanical Service Brake Ring Pivot Pin Brake Arm Pivot Block INSTALLATION BRAKE ASSEMBLY 1 Clean the threaded holes in the table to remove all oil Apply Red Loctite onto the 6 Studs 49 0024 and thread into t
421. the driver motor or the slide being run into the mechanical stops On machines with servo based tool changer chains the chain was unable to move On Machines with servo based tool changer arms the arm was unable to move possibly due to a stuck tool 188 B SERVO OVERLOAD Excessive load on B axis motor This can occur if the load on the motor over a period of several seconds or even minutes is large enough to exceed the continuous rating of the motor The servos will be turned off when this occurs This can be caused by running into the mechanical stops It can also be caused by anything that causes a very high load on the motors 189 B AXIS MOTOR OVERHEAT Servo motor overheat The temperature sensor in the motor indicates over 150 degrees F This can be caused by an extended overload of the motor such as leaving the slide at the stops for several minutes 190 B MOTOR Z FAULT Encoder marker pulse count failure This alarm usually indicates that the encoder has been damaged and encoder position data is unreliable This can also be caused by loose encoder connectors 191 B LIMIT SWITCH Normally disabled for rotary axis 36 Alarms 96 0189 rev L June 2005 192 B AXIS Z CH MISSING Z reference signal from encoder was not received as expected Can be caused by loose connections encoder contamination or parameter error 193 B AXIS DRIVE FAULT Current in B servo motor beyond limit Possibly caused by a stalled or overloaded motor The servos are turne
422. the oil line at the ball nut 11 Loosen the SHCS and remove the bearing sleeve from the motor mount Push on the column or the opposite end of the ball screw to loosen CAUTION Do not pry the bearing sleeve away from the housing Damage to the sleeve bearing or ball screw will result 12 Loosen and remove the five SHCS attaching the ball nut to the nut housing 13 Hand turn the ball screw toward the rear towards the front for EC 400 EC 1600 of the machine until the ball screw clears the bearing by aproximately 6 Mechanical Service 110 96 0189 rev L June 2005 14 EC 300 Carefully push the ball screw towards the front of the machine and above the support bearing EC 400 Carefully push the ballscrew to the side of the bearing support and then remove by pulling the ballscrew towards the spindle EC 1600 Carefully push the ball screw back and under the column until the front of the ball screw clears the nut housing and remove Installation 1 Ensure all mating on the bearing sleeve motor housing nut housing and ball nut are free of dirt burrs grease or other contaminants CAUTION Mating surfaces must be clean or misalignment may occur seriously affecting the proper operation of the machine 2 EC 300 Slide the motor end of the ball screw from the front of the machine over the bearing housing taking care not to damage the screw threads EC 400 Slide the bearing support end of the ball screw past the rotary
423. the parameter 43 bit 3 to 1 Note This will disable the rotary table position encoder and enable the drive motor encoder The drive motor gear will now hold position allowing backlash to be measured between the ring and pinion gear 3 Loosen the 3 4 11 hex head bolts that secure the cam backlash adjuster motor plate to the underside of the table It is not required to remove these bolts completely only loosen them The 2 SHCS that bolt through the plate are shoulder bolts and do not need to be loosened 4 Loosen the backlash adjusting screw lock nuts on both of the adjusting screws See the following figure Loosen the left adjusting bolt and thread it back away from the plate Tighten the right bolt three turns This will increase the backlash between the drive and ring gear Note As this bolt is driven in it may start to bind If this happens back the bolt off slightly and then continue tightening 170 Mechanical Service 96 0189 rev L June 2005 Tightening this screw will backlash reduce Tightening this screw will backlash increase Backlash Adjusting Screws 5 Verify the brake is disengaged and that backlash exists by manually moving the platter back and forth At times additional force is required to overcome friction Use platter lifting plates or a fixture on the platter with a cheater bar between them if necessary to move the platter within the allow able backlash 6 Back the right bolt all the way out 7 Set up
424. there are no travel limits Thus you can jog into the hard stops in either direction for X Y or Z After a ZERO RETURN has been performed the travel limits will operate unless an axis hits the limit switch When the limit switch is hit the zero returned condition is reset and an AUTO ALL AXES must be done again This is to ensure that if you hit the limit switch you can still move the servo back away from it The limit switches are normally closed When a search for zero operation is being performed the X Y and Z axes will move towards the limit switch unless it is already active open then they will move away from the switch until it closes again then they will continue to move until the encoder Z channel is found This position is machine zero What Can Go Wrong With Limit Switches If the machine is operated without connector P5 a LOW LUBE and DOOR OPEN alarm will be generated In addition the Home search will not stop at the limit switch and will instead run into the physical stops on each axis If the switch is damaged and permanently open the zero search for that axis will move in the negative direction at about 0 5 in min until it reaches the physical travel stops at the opposite end of travel If the switch is damaged and permanently closed the zero search for that axis will move at about 10 in min in the positive direction until it reaches the physical stops If the switch opens or a wire breaks after the zero search compl
425. till be used to synchronize output When more than one HAAS controller is daisy chained data sent from the PC goes to all of the controllers at the same time That is why an axis selection code Parameter 21 is required Data sent back to the PC from the controllers is OR ed together so that if more than one box is transmitting the data will be garbled Be cause of this the axis selection code must be unique for each controller RS 232 Remote Command Mode Parameter 21 must be non zero for the remote command mode to operate as the controller looks for an axis select code defined by this parameter The controller must also be in RUN mode to respond to the interface Since the controller powers on in RUN mode remote unattended operation is thus possible RS 232 LINE NOISE To minimize line noise on the serial port reroute the cables route them straight up the left hand side of the control to the processor stack Do not run them above the I O PCB or up the center wire channel to the processor The best way to minimize transmission errors is to have a good common ground between the PC and CNC control Electrical Service 192 96 0189 rev L June 2005 4 5 FRONT PANEL Please read this section in its entirety before attempting to replace any component of the control panel LCD ASSEMBLY REPLACEMENT CAUTION Use an electro static discharge ESD strap on wrist when working inside the pendant 1 Turn the power off and disconnect
426. ting beneath the spindle head casting Lower the spindle head Y axis until it rests on the wood 5 POWER OFF the machine 6 EC 300 Remove the right spindle head cover looking at the spindle from the inside of the machine 7 Remove the motor coupling cover and loosen the SHCS on the motor coupling at the ball screw 4X BHCS Coupling Housing Cover Coupling Bumper 4X SHCS Y Axis Motor Key 4X BHCS Coupling Housing Cover Coupling Key Y Axis Motor 4X SHCS Y axis motor and coupling EC 300 Y axis motor and coupling EC 400 8 Remove the SHCS and remove the motor from the coupling housing 9 Disconnect all wiring from the motor 10 Remove the motor Installation 1 Inspect the motor coupling and replace it if required Visually inspect the flex plates to ensure they are parallel to the coupling halves Slide the new coupling onto the motor shaft until the coupling half is flush to the end of the shaft NOTE The slot in the locking collar must be positioned 45 degrees between the bolt hole pattern of the coupler If improperly aligned the coupler will not have enough clamping force on the ball screw or motor shaft Refer to diagram in Coupling Replacement section 2 Reconnect all wiring to the motor Mechanical Service 98 96 0189 rev L June 2005 3 Align the key on the motor shaft Slide the motor into the motor housing inserting the end of the ball screw into the motor
427. tion for correct amount to add or remove 4 Tighten the retaining plate screws ADJUSTMENT OF SWITCHES Unclamp Switch 1 Drawbar height must be set properly before adjusting switches Add or subtract shim washers to the tool release piston until proper height is achieved In line drive machines must have the precharge pressure verified See the previous Setting Pre Charge section 2 Push the PARAM DGNOS twice to enter the diagnostic mode and confirm that DB OPN 0 and DB CLS 1 3 Using the same set up for setting the drawbar height jog the Z axis to 0 06 above from where the tool holder was resting on the aluminum block 4 Change Parameter 76 Low air Delay to 45000 to eliminate a low air pressure alarm 5 In order to limit the spindle head deflection during this next part of the procedure the air pressure will need to be reduced to lower the output force of the TRP Reduce the air regulator to about 60 psi Place a 0 0005 test indicator between the table and front face of spindle head to measure axial deflection when the tool release piston is energized Press and hold the tool release button and check that the block is tight and the head deflection is between 0 002 and 0 004 If the head deflection is too high reduce the air pressure If the head deflection is too low or no deflection increase the air pressure Once the head deflection is between 002 and 0 004 proceed to the next step Indicato
428. to the proper level at the oil fill breather where shown EC Series Remove the plug and feel for oil with your finger If no oil is felt add oil until the oil starts to come out of the oil Replace plug SMTC Oil Types Mobilgear 632 or equivalent for standard tool changers Mobil SHC 630 or equivalent for high speed tool changers HS 3 4 6 7 38 TOOL TOOL CHANGER MAINTENANCE Six Months Lubricate the following parts using red grease Magazine Drive Gear Tool Pot Changer Slide Rack Lubricate the Arm Shaft using Moly grease Annually Lubricate the Changer Slide Linear Guide with red grease Tool Pot Chain Tension The tool pot chain tension should be checked regulary as a preventative maintenance procedure Chain tension adjustment is performed in the lower left area of the magazine Loosen the four 12x50 SHCS from the front of the magazine This will allow the plate to move Loosen the hex lock nut on the shaft and tighten the shaft using the hex bolt Lock in the adjustment with the hex lock nut and retighten the four 12x50 SHCS Tensioning will not change the indexed pot location but check the alignment between the manual tool push cylinder and the tool pot 258 96 0189 rev L June 2005 EC 1600 AND HS 3 4 6 7 TRANSMISSION OIL Oil Fill Oil Drain Oil Level View Oil Fill Port Oil Drain Plug Oil Sight Glass EC 1600 HS 3 4 6 7 Oil Check Remove the sheet metal necessary to gain access to the transm
429. to the receiver 4 Remove the 14 BHCS that fasten the rear of the waycover to the column 5 Remove the waycover Installation 1 POWER ON the machine 2 Replace the waycover The end with the smallest section goes toward the receiver 3 Fasten the column end using fourteen 14 BHCS 4 Fasten the receiver end using fourteen 14 BHCS Left Way Cover Removal 1 Jog the Z axis receiver all the way in the Z direction toward the spindle 2 Rotate the H frame 45 counter clockwise 3 Remove the thirteen 13 BHCS that fasten the rear way cover to the receiver assembly 4 Remove the rear waycover through the door Install the way cover in the reverse order above however make sure that all necessary gaskets and sealants are replaced and repaired as necessary EC 300 X AXIS WAY COVER ADJUSTMENT The front of the column on either side of the spindle is covered by heavy shades kept taut by spring loaded canisters If the shades should need adjusting refer to the following procedure 61 Mechanical Service 96 0189 rev L June 2005 Shades 1 Clamp the shaft at the flat with clamping pliers or other such clamping device to hold the shaft when adjusting of the spring tension 2 Loosen the set screw so that the spring tension may be adjusted 3 Rotate the shaft one complete revolution against the force of the spring counter clockwise for the left canister and clockwise for the right canister
430. travel of the fourth auxiliary W axis in the negative direction 248 SMTC RLY ON OFF DLY Vertical mills with sidemount tool changers only It specifies the time needed in milliseconds between turning off one relay and turning on the other one when reversing the carousel 249 TOOL CLAMP DELAY This parameter provides a delay after the tool has been clamped and before retraction of the tool carousel at the end of a tool change For most mills this parameter should be set to zero Units are millisec onds 250 TOOL UNCLAMP DELAY This parameter provides a delay after the tool has been unclamped and before the spindle is backed away at the beginning of a tool change For most mills this parameter should be set to zero Units are in milliseconds 251 A DOOR OPEN ERRTIME This parameter supports the Auto Door feature It is used for several things 1 It specifies the number of 50ths of a second for the motor to run to open the door 2 The value of this parameter plus one second specifies the number of 50ths of a second for the motor to run to close the door 3 If at the end of the door close time the door has not yet reached the switch alarm 238 DOOR FAULT is generated If an automatic door is installed this parameter should be set to 5500 5 5 seconds nominally otherwise it should be set to zero 252 GEAR MOTOR TIMEOUT This parameter supports the Auto Door feature It specifies the length of time in ms that is allowed for the door to be
431. trol behaves as before 10 PALLET HARDCODE This bit supports the hard coded APC pallet changer function It must be set to 1 when an APC is present that is wired for two APC door switches On all other machines it must be set to 0 11 M50 CLOSES DOOR The MDC 1 pallet changer station auto door closes before an M50 pallet rotate and opens afterward provided that this parameter bit is set to 1 If the bit is set to zero a flashing message directing the operator to close the pallet changer door manually or by pushing the PART READY button will be displayed and the pallet change will not occur until the door is closed Note that the door will not close automatically if the Pallet Schedule Table is used to schedule a pallet 12 MANUAL JOG TRM TRL This parameter bit enables the manual jog feature for the Tool Room Mill s handwheels 13 SAFTY SWITCH When set to zero the control behaves as normal When it is set to 1 the Toolroom Mill s safety switch must be pressed by the operator for controlled motion to start or continue 14 FOURTH AXIS This parameter bit prevents unauthorized use of the 4th A axis It can only be set to 1 with a magic code When it is set to zero it prevents the user from altering setting 30 and prevents the user from zeroing the parameter 43 DISABLED bit When this parameter bit is changed to zero setting 30 will be returned to OFF and the parameter 43 DISABLED bit will be set to 1 15 FIFTH AXIS This parameter bit prev
432. ube 3 If the lube is wet and black the lube system has been contaminated by metal particles Inspect the Ball Screws for wear Contamination of the lube and or coolant systems can be caused by a wearing Ball Screw or by metal chips entering the systems through open or loose way covers Check all way covers and seals for excessive clear ances Machine Crash A hard machine crash can cause a Ball Screw to lock up The static overload created during a machine crash can break apart the ball nut balls denting the thread surfaces Turning the nut by hand will result in an obvious grinding feeling and or sound 1 Check the screw for straightness 2 Look for ball dents at the ends of the screw length These indents will be a sure sign of a hard machine crash The inertia of the table is transferred due to the sudden stop directly to the balls inside the ball nut creating impressions on the screw surface Troubleshooting 19 96 0189 rev L June 2005 BALL SCREW CLEANING In most cases a thorough cleaning of the suspect Ball Screw will resolve bad screw issues including noise complaints 1 Manually jog the ball nut to one end of the screw 2 Visually inspect the screw threads Look for metal flakes dark or thick lube or contaminated coolant See the Ball Screws Visual Inspection Contamination section 3 Use alcohol or other approved cleaning agents to wash the screw CAUTION Do not use detergents d
433. um RPM available to the spindle When this speed is programmed the D to A output will be 10V and the spindle drive must be calibrated to provide this 132 Y SCREW COMP COEF This is the coefficient of heating of the ball screw and is used to decrease or shorten the screw length 133 Z SCREW COMP COEF This is the coefficient of heating of the ball screw and is used to decrease or shorten the screw length 134 X EXACT STOP DIST 135 Y EXACT STOP DIST 136 Z EXACT STOP DIST 226 Parameters 96 0189 rev L June 2005 137 A EXACT STOP DIST These parameters control how close each axis must be to its end point when exact stop is programmed They apply only in G09 and G64 They are in units of encoder steps A value of 34 would give 34 138718 0 00025 inch NOTE To change the values of parameters 134 137 permanently the machine must be rebooted 138 X FRICTION COMPENSATION 139 Y FRICTION COMPENSATION 140 Z FRICTION COMPENSATION 141 A FRICTION COMPENSATION These parameters compensate for friction on each of the four axes The units are in 0 004V 142 HIGH LOW GEAR CHANG This parameter sets the spindle speed at which an automatic gear change is per formed Below this parameter low gear is the default above this high gear is the default 143 DRAW BAR Z VEL CLMP This parameter sets the speed of the Z axis motion that compensates for tool motion during tool clamping Units are in encoder steps per second 144 RIG TAP FINIS
434. unning the axis into a mechanical stop A short in the motor or a short of one motor lead to ground can also cause it 694 ATC SWITCH FAULT Conflicting switch states detected such as shuttle at spindle and shuttle at chain simulta neously or tool pocket up and down simultaneously Check for damaged or sticking switches damaged wiring or debris build up Use Tool Changer Restore to recover the ATC then resume normal operation 695 ATC DOUBLE ARM CYLINDER TIME OUT The ATC double arm did not complete extending or retracting within the time allowed by Parameter 61 Check for proper spindle orientation correct alignment of the double arm with the chain or spindle adequate air supply mechanism binding air leakage excessive tool weight debris build up adequate chain tension correct chain guide strip adjustment and interference between the tool holder set screw and the chain or tool gripper Use Tool Changer Restore to recover the ATC then resume normal operation 696 ATC MOTOR TIME OUT The ATC shuttle motor or double arm motor failed to complete the commanded move ment within the time allowed by Parameter 60 Check for mechanism binding correct motor and switch operation damaged gear motor control board relays damaged electrical wiring or blown fuses on the gear motor control board Use Tool Changer Restore to recover the ATC then resume normal operation 697 ATC MOTOR FAULT The ATC shuttle motor or double arm motor was on unexpectedly Use
435. ur organization or otherwise obtain the necessary help BEFORE you con tinue WARNING WARNING WARNING WARNING WARNING The electrical panel should be closed and the three screws on the door should be secured at all times except during installation and service At those times only qualified electricians should have ac cess to the panel When the main circuit breaker is on there is high voltage throughout the electrical panel including the circuit boards and logic circuits and some components operate at high tempera tures Therefore extreme caution is required 177 Electrical Service 96 0189 rev L June 2005 4 1 SOLENOIDS Please read this section in its entirety before attempting to replace any solenoid assemblies TOOL RELEASE PISTON AIR SOLENOID ASSEMBLY REMOVAL 1 Turn machine power ON EC 300 Raise the spindle head to its highest position EC 400 lower the spindle head to the lowest position Turn power OFF 2 Remove the rear enclosure panel 3 Remove air supply from machine 4 Disconnect all air lines connected to the air solenoid assembly on the top front of the solenoid bracket 5 Unplug the solenoid wiring Locations of EC 300 and EC 400 TRP Solenoids 6 Remove the screws holding the assembly to the bracket and remove the assembly Electrical Service 178 96 0189 rev L June 2005 INSTALLATION 1 Replace the air solenoid assembly and attach to the bracket with the screws previousl
436. ur SHCS that mount the TRP to the spindle head 5 IMPORTANT Remove the wood brace from the spindle head 6 Replace the rear enclosure panel SETTING PRE CHARGE 1 Install an air gauge capable of reading 30 psi to the precharge assembly 2 Press MDI DNC to get to MDI screen 3 Type in 1120 1 and press WRITE ENTER and then Press CYCLE START 4 Set the pressure regulator so that 30 psi reads on the gauge Press the regulator knob in to lock the knob in place 5 Press RESET 6 Remove the gauge and replace the hose 69 Mechanical Service 96 0189 rev L June 2005 3 3 SPINDLE SPINDLE CARTRIDGE REMOVAL 1 Remove the six SHCS that mount the spindle to head casting 2 Slide the spindle out from the front side of machine INSTALLATION 1 Inspect the mating surface for high spots on the spindle and spindle head casting before installing spindle 2 Carefully install the new spindle into the bored sleeve of the head casting Apply grease to the inside of the through bore in the spindle head The oil drain hole must point down Failure to do so will cause the spindle to overheat fail adn will void the warranty 1 4 Tube X 1 8 NPT 1 4 Tube X 1 8 NPT 6X SHCS 6X Lockwasher Spindle Assembly EC 300 Spindle Head Assembly EC 400 Spindle Head Assembly Spindle must be installed with oil drain notch in spindle lock at the bottom 3 Evenly tighten the six mounting SHCS o
437. ure the resistance from terminal 1 to terminal 3 If the resistance is less than 100K the drive is faulty 11 With the REGEN load left disconnected power up the machine and command a spindle speed of 700 RPM 300 RPM for lathes in high gear Press lt RESET gt while monitoring the DC voltage between terminal 1 and terminal 3 The voltage should read 330 VDC and then drop to less than 50 VDC momentarily If not that drive is faulty If the voltage at RESET was okay and the alarm was resettable the REGEN load should be replaced even if the resistance appears to be ORIENTATION Spindle loses correct orientation Check alarm history Look for Spindle Z Fault or Spindle Reference Missing alarms If these alarms exist there may be a defective spindle encoder or a broken ground or shield connection Check parameters Check for a mechanical slip at the contact points of all components between the spindle encoder TOOLS STICKING IN TAPER This problem may occur after loading a cold tool into a hot spindle a result of thermal expansion of the tool holder inside the spindle taper It may also occur due to heavy milling milling with long tooling or cuts with heavy vibration This also is the result of thermal expansion If sticking only occurs during these situations check your application to ensure proper machining techniques are being used check the feeds and speeds for the tools and material being used If a tool is pulled out
438. value plus or minus the spindle will be considered locked Otherwise the spindle will not be locked 194 SPINDLE STOP FREQ The spindle is considered to be stopped discrete input SP ST 0 when the speed drops below this value Units are encoder steps millisecond 195 C START STOP DELAY This delay is used at the start of motion to magnetize the rotor before acceleration starts When the motor comes to a stop it remains energized for this amount of time Units are in milliseconds 196 C ACCEL LIMIT LOAD This parameter is used when a Vector Drive is installed This is the load limit during acceleration If the load reaches this limit during acceleration the control slows down the acceleration If a Vector Drive is not installed this parameter is called C axis EXACT STOP DISTANCE and is not used 197 SWITCH FREQUENCY Unit Hz This is the frequency at which the spindle motor windings are switched Note that there is a hysteresis band around this point defined by parameter 198 198 SWITCH HYSTERESIS UNIT Hz This defines the hysteresis band around parameter 197 For example if parameter 197 is 85 Hz and parameter 198 is 5Hz the switching will take place at 90Hz when the spindle is speed ing up and at 80 Hz when the spindle is slowing down 199 PRE SWITCH DELAY UNIT ms This is the amount of time allowed for the current in the motor to drop before the winding change contactors are switched 200 POST SWITCH DELAY UNIT ms This is t
439. wed machine range Machine coordi nates are in the negative direction This condition indicates either an error in the user s program or improper offsets 601 V OVER TRAVEL RANGE Commanded V axis move would exceed the allowed machine range Machine coordi nates are in the negative direction This condition indicates either an error in the user s program or improper offsets 602 W OVER TRAVEL RANGE Commanded W axis move would exceed the allowed machine range Machine coordinates are in the negative direction This condition indicates either an error in the user s program or improper offsets 603 U LIMIT SWITCH Axis hit limit switch or switch disconnected The stored stroke limits should stop the slides before they hit the limit switches Verify the value of parameter 373 Grid Offset and check the wiring to the limit switch and connector P5 at the side of the main cabinet Can also be caused by a loose encoder shaft at the back of the motor or coupling of motor to the screw 604 V LIMIT SWITCH Axis hit limit switch or switch disconnected The stored stroke limits should stop the slides before they hit the limit switches Verify the value of parameter 409 Grid Offset and check the wiring to the limit switch and connector P5 at the side of the main cabinet Can also be caused by a loose encoder shaft at the back of the motor or coupling of motor to the screw 605 W LIMIT SWITCH Axis hit limit switch or switch disconnected The stored stroke limits
440. y removed Tighten securely 2 Reconnect all air lines 4 Reconnect the wiring to the plugs on the solenoid bracket 5 Reconnect air supply to the machine and check for leaks 6 Replace the rear enclosure panel SPINDLE LUBE AIR SOLENOID 1 Turn the machine power off and remove the air supply from the machine 2 Disconnect the air lines from the spindle lube air solenoid assembly 3 Unplug the electrical leads at the quick disconnect You will have to slide the wiring channel cover back to disconnect the leads Figure 4 1 1 Top view of spindle lube air solenoid assembly 4 Unscrew the assembly from the T fitting 179 Electrical Service 96 0189 rev L June 2005 Figure 4 1 2 Top view of spindle lube air solenoid assembly 5 Replace the assembly ensuring it is approximately horizontal to the floor and tighten fittings securely 6 Reconnect all air lines 7 Reconnect wiring leads at the quick disconnect in the wiring channel Slide cover back into place 8 Restore air supply to the machine Electrical Service 180 96 0189 rev L June 2005 4 2 LINE VOLTAGE ADJUSTMENTS Please read this section in its entirety before attempting to adjust the line voltage TOOLS REQUIRED Large flat tip screwdriver Digital voltmeter ADJUSTING VOLTAGE NOTE The machine must have air pressure at the air gauge or a Low Air Pressure alarm will be present on power up LOW VOLT
441. yor will continue to run with the door open When 0 the conveyor will stop when the door is open but will resume when the door is closed For safety it is recommended that the bit be set to 0 18 DISABLE COOLANT IN If set to 1 low coolant input will not be used 19 UNUSED 20 REMOTE TOOL RELEASE If set to 1 allows use of remote tool release button on spindle head 21 FLOPPY ENABLE If set to 1 enables the optional disk drive 22 TL CHG RECOV KEYPAD If set to 1 enables tool changer restore button on keypad 23 MCODE RELAY BOARD If set to 1 allows for M code addressing This adds the availablility of additional outputs 24 TSC ENABLE When set to 1 DSBL CLNT IN bit is ignored M24 M54 and M64 are disabled and TSC will operate When set to zero the control functions normally 230 Parameters 96 0189 rev L June 2005 25 AUX JOG NACC If the jog handle is moved rapidly the auxiliary axis will not develope extremely large lags 26 ALIAS M PROGR START Alias M codes during program restart 27 DISABLE JOG TEST Disables the encoder test for the jog handle 28 NO ZERO CLAMP During zero return of the pallet changer the general sequence is 1 lift 2 home 3 lower When this bit is set to 1 only the first two steps are executed The pallet remains in the unclamp position This bit was added to prevent damage to the pallet changer prior to Grid Offset and Tool Change Offset zero return offset for the pallet changer axis set up
442. ys on the I O assembly the drawbar assembly or the wiring 131 TOOL NOT CLAMPED When clamping or powering up the machine the Tool Release Piston is not Home There is a possible fault in the air solenoids relays on the I O Assembly the drawbar assembly or wiring 132 POWER DOWN FAILURE Machine did not turn off when an automatic power down was commanded Check wiring to the Power Interface POWIF card on power supply assembly relays on the I O assembly and the main contactor K1 133 SPINDLE INOPERATIVE Spindle does not respond when spindle motion is commanded This can be caused by failure of encoder cables belts MOCON or vector drive 134 TOOL CLAMP FAULT While UNCLAMPING the tool did not release from spindle when commanded Check air pressure and solenoid circuit breaker CB4 This fault can also be caused by maladjustment of the drawbar assem bly 135 X AXIS MOTOR OVERHEAT Servo motor overheat The temperature sensor in the motor indicates over 150 degrees F 65 deg C This can be caused by an extended overload of the motor such as leaving the slide at the stops for several minutes 136 Y AXIS MOTOR OVERHEAT Servo motor overheat The temperature sensor in the motor indicates over 150 degrees F 65 deg C This can be caused by an extended overload of the motor such as leaving the slide at the stops for several minutes 137 Z AXIS MOTOR OVERHEAT Servo motor overheat The temperature sensor in the motor indicates over 150 degre
443. zero return position may not be consistent from one zero return to the next The encoder Z channel signal must occur between 1 8 and 7 8 revolution of where the home switch releases This will not turn the servos off but will stop the zero return operation 680 TT or B CABLE FAULT Cable from TT or B axis encoder does not have valid differential signals 681 TT or B PHASING ERROR Error occurred in phasing initialization of brushless motor This can be caused by a bad encoder or a cabling error 682 TT or B TRANSITION FAULT Illegal transition of count pulses in B axis This alarm usually indicates that the encoder has been damaged and encoder position data is unreliable This can also be caused by loose connectors at the MOCON or MOTIF 683 TT or B AXIS DISABLED Parameter has disabled this axis 684 TT or B AXIS LINEAR SCALE Z FAULT Encoder marker pulse count failure This alarm usually indicates that the Z Fault encoder has been damaged and encoder position data is unreliable This can also be caused by loose scale connectors 685 V MOTOR Z FAULT Encoder marker pulse count failure This alarm usually indicates that the encoder has been damaged and encoder position data is unreliable This can also be caused by loose encoder connectors 686 W MOTOR Z FAULT Encoder marker pulse count failure This alarm usually indicates that the encoder has been damaged and encoder position data is unreliable This can also be caused by loose encoder connectors

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