Haas VF Series Mill Service Manual PDF
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Summary of Content for Haas VF Series Mill Service Manual PDF
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.
VF-Series Service Manual 96-8100 RevC English June 2001
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COMMON ABBREVIATIONS USED IN HAAS MACHINES
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 Change Forward ATC REV Automatic Tool Changer Reverse AWG American Wire Gauge BHCS Button Head Cap Screw CAD Computer Assisted Design CAM Computer Assisted Machining CB Circuit Breaker CC Cubic Centimeter CCW Counter Clockwise 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 CW Clockwise DB Draw Bar DC Direct Current DGNOS Diagnostic DIR Directory DNC Direct Numerical Control DOS Disk Operating System 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 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
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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 PrintedCircuit Board PGM Program POR Power On Reset POSIT Positions PROG Program PSI Pounds Per Square Inch PWM Pulse Width Modulation RAM Random Access Memory REPT RIG TAP Repeat Rigid Tap 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 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 Through The Spindle Coolant VF Vertical Mill (very first) VF-E Vertical Mill- Extended VMC Vertical Machining Center WAN Wide Area Network
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1. TROUBLESHOOTING
This section is intended for 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 problems 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, dont expect the machine to correct the fault. Dont suspect machine accuracy if the vise bends the part. Dont claim hole mis-positioning if you dont 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 doesnt turn, remember that the spindle is connected to 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 dont replace the spindle drive if the belt is broken. Find the problem first; dont just replace the easiest part to get to.
DONT TINKER WITH THE MACHINE There are hundreds of parameters, wires, switches, etc., that you can change in this machine. Dont 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 processors 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 WONT 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.
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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").
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
Check IOPCB (see "Electrical Service").
Check POWER PCB (see "Electrical Service").
Machine can be powered on, but turns off by itself.
Check settings #1 and #2 for Auto Off Timer or Off at M30.
Check alarm history for OVERVOLTAGE or OVERHEAT shutdown.
Check AC power supply lines for intermittent supply.
Check wiring to POWER OFF button on front control panel.
Check connection between 24V transformer and K1 contactor.
Check IOPCB (see "Electrical Service").
Check Parameter 57 for Power Off at E-STOP.
Check MOTIF or MOCON PCB (see "Electrical Service").
Machine turns on, keyboard beeps, but no CRT display.
Check for power connections to CRT from IOPCB. Check for green POWER LED at front of CRT.
Close doors and Zero Return machine (possible bad monitor).
Check video cable (760) from VIDEO PCB to CRT.
Check for lights on the processor.
Machine turns on, CRT works, but no keyboard keys work.
Check keyboard cable (700B) from VIDEO to KBIF PCB.
Check keypad (see "Electrical Service").
Check KBIF PCB (see "Electrical Service").
Constant E-Stop Condition (will not reset)
Check Hydraulic counterbalance pressure, low pressure switches and cabling.
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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. Because the VF Series uses a gear head, it will be noisier than a direct drive or belt system. 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. We will assume that vibrations would be something that could be felt by putting your hand on the spindle covers. One crude method of measurement 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 is a tough one to call because 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 order 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/Leadscrews", and "Gearbox and Spindle Motor" sections.
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ACCURACY
Before you complain of an accuracy problem, please make sure you follow these simple dos and donts:
Ensure that the machine has been sufficiently warmed up before cutting parts. This will eliminate mispositioning errors caused by thermal growth of the leadscrews (see "Thermal Growth" section).
Do not use a wiggler test indicator for linear dimensions. They measure in an arc and have sine/cosine errors over larger distances.
Do not use magnetic bases as accurate test stops. The high accel/decel of the axis can cause them to move.
Do not attach magnetic base to the sheet metal of the spindle head or table.
Do not mount the magnetic base on the spindle dogs.
Do not check for accuracy/repeatability using an indicator with a long extension.
Ensure that test indicators and stops are absolutely rigid and mounted to machined casting surfaces (e.g. spindle head casting, spindle nose, or the table).
Do not 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.
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).
Check for backlash ("Servo Motors/Leadscrews" section).
Bored holes do not go straight through the workpiece.
Check that the machine is level (see "Installation" section).
Check for squareness in the Z axis.
Machine bores holes out-of-round.
Check that the machine is level (see "Installation" section).
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 leadscrew (see "Thermal Growth" section).
The spindle is not parallel to the Z axis. Check the spindle sweep to the table and the squareness of the Z axis with a cylinder square. If available use a spindle master bar and indicate the spindle to the Z axis.
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Machine mis-positions holes.
Check for thermal growth of the leadscrew (see "Thermal Growth" section).
Check that the machine is level (see "Installation" section).
Check for backlash (see "Servo Motors/Leadscrews" 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).
Check the sweep of the machine (see "Spindle Sweep Adjustment" section).
Cutter diameter too large for depth of cut.
Boring depth inaccurate
Check for thermal growth of the leadscrew (see "Thermal Growth" section).
Check the hydraulic counterbalance system. Check for: abnormal noises from counterbalance system, oil leaks (esp. at fittings and at filter at top of cylinder), bound cylinder.
FINISH
Machining yields a poor finish.
Check for gearbox vibration.
Check for backlash ("Accuracy/Backlash" section)
Check the condition of the tooling and the spindle.
Check spindle
Check the condition of the servo motors.
Check that the is machine level.
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THERMAL GROWTH
A possible source of accuracy and positioning errors is thermal growth of the leadscrew. As the machine warms up, the leadscrews expand in all three linear axes, causing accuracy and positioning errors, or inaccu- rate 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: On machines equipped with linear scales, thermal growth will not affect machine positioning or accuracy. However, it is still recommended that the machine be warmed up before cutting parts.
NOTE: The leadscrew will always expand away from the motor end.
VERIFY THERMAL GROWTH
There are a number of ways to verify the problem. The following procedure will verify thermal growth of the X- axis leadscrew 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.
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 direc- tion, feed the final .25 inches at 10 inches/min., and then repeat the X movement.
G00 G90 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 to be thermal growth.
7. A similar program can be written to test for thermal growth in the Y and Z axes, if necessary.
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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 leadscrews to warm up to the correct temperature and stabilize. Once the machine is at temperature, the leadscrews 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.
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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.
If motor turns but spindle does not, see "Belt Assembly" and "Spindle Motor & Transmission" sections.
Command spindle to turn at 1800 RPM and check spindle drive display. If display blinks bb, check spindle orientation switch ("Spindle Orientation" section). 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, replace MOCON PCB ("Electrical Service").
If spindle is still not turning, replace spindle drive ("Electrical Service").
Check for rotation of the gearbox (if applicable) or the motor (VF-0). If the motor or gearbox operates, check the drive belt ("Belt Assembly" section).
Disconnect the drive belt. If the spindle will not turn, it is seized and must be replaced ("Spindle Assembly" section).
NOTE: Before using the replacement spindle, the cause of the previous failure must be determined.
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NOISE
Most noises attributed to the spindle actually lie in the motor/gearbox or drive belt of the machine. Isolate the sources of noise as follows:
Excessive noise coming from the spindle head area.
On VF-1 through 6 models, first determine if the noise is related to the RPM of the motor or the RPM of the spindle. For example: If the noise appears at 2000 RPM in high gear, listen for a similar noise at 500 RPM in low gear. If the same noise persists, the problem lies with the gearbox. If the noise disappears, the problem could be either the gearbox or the spindle, and further testing is necessary.
NOTE: The gear ratio is 1:1.25 in high gear, and 3.2:1 in low gear.
Remove the head covers and check the machines drive belt tension ("Tension Adjustment" section). If the noise persists, turn the drive belt over on the pulleys. If the noise is significantly different, the belt is at fault. Replace the belt ("Belt Assembly" section). If the noise does not change, remove the belt and go on to the next step.
Check the pulleys for excessive runout (more than 0.003" axial or radial).
Run the motor (VF-0) or the gearbox (VF-1, VF-2, VF-3) with the drive belt disconnected. If the noise persists, the problem lies with the gearbox/motor. If it disappears, go on to the next step.
Check for the correct amount of lubrication to the spindle bearings (0.5-1.0 cc every two hours) in an air mist-lubricated spindle.
If the spindle is not getting lubrication, correct the problem per the lube and air diagram at the back of this manual and replace the spindle ("Spindle Assembly" section). If the spindle is getting lubrication, replace the spindle ("Spindle Assembly" section).
Note: Haas Automation does not honor warranty requests for gearbox or spindles without vibration analyzer signatures.
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OVERHEATING
When investigating complaints of overheating, a temperature probe must be used to accurately check the temperature at the top of the spindle taper. The temperature displayed in Diagnostics is not relevant. A machine that runs at high RPM continuously will have a much warmer spindle than a machine that runs at a lower RPM. New spindles tend to run much warmer than spindles that have already been run-in. In order to run a valid test on a new spindle, ensure that it is properly run-in.
To run-in a spindle, run the following program (it will take approximately 6 hours):
N100 S300 M03 G04 P900. N700 S6000 M03 G04 P900. M05 G04 P900. M05 G04 P900. M05 G04 P900. G04 P900. G04 P900. N200 S1000 M03 N500 S4000 M03 G04 P900. G04 P900. G04 P900. N800 S7500 M03 M05 M05 G04 P900. G04 P900. G04 P900. M05 N300 S2000 M03 G04 P900. G04 P900. G04 P900. N600 S5000 M03 G04 P900. M05 G04 P900. M99 G04 P900. M05 G04 P900. G04 P900. N400 S3000 M03 G04 P900.
NOTE: This program will step the spindle speed from 300 RPM up to 7500 RPM at regular intervals of time, stop the spindle and allow it to cool to room temperature, then restart it so the temperature can be monitored.
ALTERNATE SPINDLE RUN-IN PROGRAM
Run program #O02021 with the air pressure to the spindle set to 30 psi. (for all spindles). 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 override 50% for 5,000 RPM machines; Set at 100% for 7,500 and 10,000 RPM machines; Set at 150% for 15,000 RPM machines.
N100 S750M3 G04 P600.; S2500M3; G04 P600.; S5000M3; G04 P900.; N200 M97 P1000 L15 M97 P2000 L15 M30; N1000 S7500M3; G04 P30.; S500 M3; G04 P150.; M99;
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N2000 S10000M3; G04 P30.; S500M3; G04 P150.; M99; %
If at any time during this procedure the spindle temperature rises above 150 degrees (120 degrees for 50 Taper), start the procedure over from the beginning and follow the steps below.
NOTE: Once run-in program is complete reset the air pressure back to 17psi. (20psi. for 15K spindles, 25psi. Mini-Mill) 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.
Check the drive belt tension. Belts that are too tight will cause heating of the top bearing in the spindle housing.
Ensure that the correct oil is being used (refer to "Maintenance Schedule").
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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 machining, run very hot and very loud. Investigate machining prob- lems before concluding the problem exists with the spindle or spindle drive.
SPINDLE DRIVE
Low line voltage may prevent the spindle from accelerating properly. If the spindle takes a long time to acceler- ate, slows down or stays at a speed below the commanded speed with the load meter at full load, the spindle drive and motor are overloaded. High load, low voltage, or too fast accel/decel can cause this problem.
If the spindle is accelerated and decelerated frequently, the regenerative load resistor on top of the control may heat up. If this resistor heats beyond 1000C, a thermostat will generate an overheat alarm.
If the regen load resistors are not connected or open, this could then result in an overvoltage alarm. The overvoltage occurs because the regenerative energy being absorbed from the motor while decelerating is turned into voltage by the spindle drive. If this problem occurs, the possible fixes are to slow the decel rate or reduce the frequency of spindle speed changes.
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 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.
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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 be 8.6 ohms for machines with 20/15 Vector drives and HT10K mills equipped with 40/30 drives. All other machines with 40/30 drives 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), 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.
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 <RESET>. 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 6 ohms between the leads for machines with 40/30 Vector drives and 8.6 ohms between the leads on machines with 20/15 Vector drives and HT10K mills.
10. Measure 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 <RESET> 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 okay.
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ORIENTATION
Spindle loses correct orientation.
Non Vector Drive
Check the orientation ring for tightness. Ensure the shaft on which the ring mounts is clean and is free of grease and oil.
Check the orientation ring for cracks near the bolt holes or near the balancing holes. If there are cracks, replace the ring.
Check the shot pin on the gearbox for binding, damage, and proper operation. Replace it if it is damaged.
Vector Drive
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 and the spindle encoder.
TOOLS STICKING IN TAPER
Tool sticking in the taper causes ATC to be pulled up; accompanied by a popping noise as the tool holder pops out of the spindle taper.
NOTE: 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 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 does not create flex in the carousel or the need to remove the tool with a mallet.
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 instead to release the tool using the tool release button on the front of the spindle head. 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 or above).
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Check air supply. Max air pressure drop of 10psi. during a tool change is allowed. Check drawbar height adjustment. Does the tool tip to the spindle gauge line exceed 3.5? Are the correct pull studs being used?
Tool Holder / Spindle Fretting
Is fretting present on the tool holder or spindle?
Fretting is the result 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.
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1.3 SERVO MOTORS / LEADSCREWS
NOT OPERATING
All problems that are caused by servo motor failures should also register an alarm. Check the alarm history to determine the problems cause before any action is taken.
Servo motor is not functioning.
Check the power cable from rear electrical cabinet to ensure connection is tight.
Encoder is faulty or contaminated (Alarms 139-142, 153-156, 165-168, 182-185). Replace motor assembly on brushless machines, replace the encoder on brush machines.
Open circuit in motor (Alarms 139-142, 153-156, 182-185). Replace motor assembly ("Axis Motor Removal / Installation").
Motor has overheated, resulting in damage to the interior components (Alarms 135-138, 176). Replace motor assembly ("Axis Motor Removal/Installation").
Wiring is broken, shorted, or missing shield (Alarms 153-156, 175, 182-185).
Dust in the motor from brushes has shorted out the motor (VF-E only) (Alarms 153-156, 175, 182- 185). Replace motor assembly ("Axis Motor Removal/Installation").
Motor has overheated; no damage to the interior components. OVERHEAT alarm has been triggered. After thorough check of motor (DO NOT DISASSEMBLE!), take necessary steps to eliminate the problem and alarm to resume operation. If motor is still inoperable, replace motor assembly ("Axis Motor Removal/Installation").
Check for broken or loose coupling between the servo motor and the lead screw. Replace or repair the coupling ("Axis Motor Removal/Installation")
Check for a damaged lead screw, and replace if necessary ("Lead Screw Removal and Installation" section).
NOTE: If a lead screw fails, it is most often due to a failed bearing sleeve. When replacing the lead screw in an older machine, always replace the bearing sleeve with the current angular contact bearing sleeve ("Bearing Sleeve Removal and Installation" section).
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TROUBLESHOOTING
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June 2001
NOISE
Lead 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 lead screws or bearing sleeves without due consideration; they are extremely durable and reliable. Verify that customer complaints are not due to tooling, programming, or fixturing problems.
Servo motor noise.
Disconnect the servo motor from the lead screw and rotate by hand. If the noise persists, replace the motor assembly ("Axis Motor Removal/Installation" section).
Noise is caused by motor brushes (VF-E only). Remove and inspect brushes. Blow out brush dust and inspect the armature.
Lead screw noise.
Ensure oil is getting to the lead screw through the lubrication system (See Air and Oil Diagrams). Look 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 lead screw. Loosen the clamp nuts at both ends of the lead screw. If the symptom disappears, replace the bearing sleeve. Be certain to check for damage to the lead screw shaft where the bearing sleeve is mounted.
If the noise persists, the lead screw is damaged and must be replaced. When replacing the lead screw in an older machine, always replace the bearing sleeve with the current angular contact design bearing sleeve.
Misalignment in the lead screw itself will tend to cause the lead 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 lead screw ball nut mounts is indicated by heating up of the ball nut on the lead screw, and noise and tightness through out the travel of the lead screw. Misalignment at the yoke where the ball nut mounts is indicated by noise and tightness at both ends of the travel of the lead screw. The ball nut may get hot.
NOTE: Customer complaints of Lead Screw noise may not indicate a bad screw. Screws from different manufacturers produce varying levels of noise. Often machines are built with two or more different brands of 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.
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TROUBLESHOOTING
96-8100 rev C
June 2001
ACCURACY / BACKLASH
Accuracy complaints are usually related to tooling, programming, or fixturing problems. Eliminate these possibilities before working on the machine.
Poor mill table-positioning accuracy.
Check for backlash in the lead screw as outlined below:
Check parameters for that axis
Check for a loose encoder on the servo motor. Also, ensure the key in the motor or the lead screw is in place and the coupling is tight (Brush machines only).
INITIAL PREPARATION -
Turn the VMC ON. ZERO RET the machine and move the mill table to the approximate center of its travel in the X and Y directions. Move the spindle head to approximate center of the Z-axis travel, also.
CHECKING X-AXIS:
1. Set up a dial indicator and base on the mill table as shown in Fig. 1-1.
Figure 1-1. Dial indicator in position to check X-axis.
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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 button on the control panel. Press the HANDLE JOG button on the control panel. The Distance to go display on the lower right hand corner 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 in Fig. 1-1 and manually push on the mill table in both directions. The dial indicator should return to zero after releasing the table.
NOTE: The servos must be on to check backlash by this method.
CHECKING Y-AXIS:
1. Set up a dial indicator and base on the mill table as shown in Fig. 1-2.
Figure 1-2. 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 button on the control panel. Press the HANDLE JOG button on the control panel. The Distance to go display on the lower right hand corner should read: X=0 Y=0 Z=0.
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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.
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. 1-2 and manually push on the mill table in both directions. The dial indicator should return to zero after releasing the table.
NOTE: The servos must be on to check backlash by this method.
CHECKING Z-AXIS:
1. Set up a dial indicator and base on the mill table as shown in Fig. 1-3.
2. Manually push up and down on the spindle head while listening for a clunk. Also, watch for any rapid change in the dial indicator. Either of these indicate possible backlash.
NOTE: Servos must be on to check for backlash in the Z-axis.
NOTE: Do not mistake deflection for backlash in the system.
Figure 1-3 Dial indicator in position to check Z-axis.
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If backlash is found in the system, check for the following possible causes:
Loose SHCS attaching the ball nut to the nut housing. Tighten the SHCS as described in Mechanical Service.
Loose SHCS attaching the nut housing to the mill table, spindle 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. Tighten as described in "Lead Screw Removal and Installation".
Defective thrust bearings in the bearing sleeve. Replace the bearing sleeve as outlined in "Bearing Sleeve Removal and Installation".
Loose SHCS attaching the axis motor to the motor housing. If the SHCS are found to be loose, inspect the motor for damage and if none is found, tighten as described in "Axis Motor Removal/ Installation". If damage is found, replace the motor.
Incorrect backlash compensation number in the parameter in the machine. Check Parameters 13, 27, and 41.
Worn lead screw.
VIBRATION
Excessive servo motor vibration.
Swap the suspected bad servo motor with a known good driver and check to see if there is a driver problem. If needed, replace the DRIVER PCB ("Electrical Service" section).
Check all Parameters of the suspected axis against the Parameters as shipped with the machine. If there are any differences, correct those and determine how the Parameters were changed.
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 chassis. If the motor is open or shorted, replace.
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TROUBLESHOOTING
96-8100 rev C
June 2001
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 users application for excessive load or high duty cycle. Check the lead screw for binding ("Accuracy/ Backlash" section). If the motor is binding by itself, replace in accordance with "Axis Motor Removal/ Installation".
FOLLOWING ERRORS
FOLLOWING ERROR (Brush Machines only) or SERVO ERROR TOO LARGE alarms 103- 106, 187 occur on one or more axes sporadically.
Check DC bus voltage on diagnostics page #2 (brush machines only). 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 Manual.
Check motor wiring for a short.
Check driver card ("Electrical Service").
Check servo motor ("Axis Motor Removal/Installation").
Check encoder (brush machines only)
DRIVE FAULT / OVERCURRENT
Z-axis motor overcurrent.
Alarm not cleared
Low counterbalance pressure
Check Z axis parameters
Check the lead screw for binding
Check motor and cable for shorts
Check amplifier (drive card on a VF-E)
VF-6 with Z axis brake only
Brake power fuse blown
Brake power transformer blown
Brake power rectifier blown
Cabling pinched
Brake failed
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TROUBLESHOOTING
96-8100 rev C
June 2001
LEAD SCREWS - VISUAL INSPECTION
The three main causes of Lead 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 Lead Screw itself.
Loss of Lubrication:
The lubrication system of the machine provides a layer of oil for the Lead 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 Lead 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. Lead 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 Lead Screws is material fatigue. Material fatigue typically occurs at the end of the Lead Screw service life. Signs of material fatigue include black, contaminated coolant, pitting of the screw surface, loss of preload, and metal flakes on the Lead Screw. Lead Screws suffering from material fatigue are not repairable and are considered scrap.
Contamination:
Contamination of the lubrication and/or coolant systems of the machine will produce problems with the Lead Screws.
Check the condition of the lube on the Lead 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 lube.
3. If the lube is wet and black, the lube system has been contaminated by metal particles. Inspect the Lead Screws for wear.
Contamination of the lube and/or coolant systems can be caused by a wearing Lead Screw, or by metal chips entering the systems through open or loose way covers. Check all way covers and seals for excessive clear- ances.
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TROUBLESHOOTING
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June 2001
Machine Crash:
A hard machine crash can cause a Lead Screw to lock up. The static overload created during a machine crash can break apart the 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 Nut, creating impressions on the screw surface.
CLEANING
In most cases, a thorough cleaning of the suspect Lead Screw will resolve bad screw issues, including noise complaints.
1. Manually jog the 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 Visual Inspection - Contamination above.
3. Use alcohol, or other approved cleaning agents, to wash the screw.
CAUTION! Do not use detergents, degreasers, or solvents to clean Lead Screws or their components. Do not use water-based cleaners to avoid rust.
4. Jog the 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.
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TROUBLESHOOTING
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June 2001
1.4 AUTOMATIC TOOL CHANGER
DEFLECTION
Deflection is usually caused by ATC misalignment, and sometimes caused by damaged or poor quality tooling, a damaged spindle taper, or a damaged drawbar or poor air supply. Before beginning any troubleshooting, observe the direction of the ATC deflection.
During a tool change, ATC appears to be pushed down.
Check to see if pull studs on the tool holder are correct and tight.
Check the adjustment of the Z offset ("Setting Parameter 64").
NOTE: If the offset is incorrect a tool changer crash can occur and a thorough inspection of the ATC will be necessary.
Check the adjustment of the Z offset. Check parameters 71, 72, and 143 against the values that are in the documentation sent with the machine.
Ensure the tool holders are held firmly in place by the extractor forks.
Ensure the balls on the drawbar move freely in the holes in the drawbar when the tool release button is pressed. If they do not move freely, the ATC will be pushed down about 1/4" before the tool holder is seated in the taper, resulting in damage to the roller bolts on the ATC shuttle. Replace the drawbar.
Check Drawbar height adjustment.
If TSC, check for excessive coolant tip wear.
Tool holder sticking in the spindle taper causes the ATC to be pulled up as the spindle head is travelling the distance specified in parameter 71; accompanied by a popping noise as the tool holder pops out of the spindle taper.
NOTE: 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 in 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. If tool is pulled out of extractors due to a tool being stuck in the taper then the unclamp switch is not adjusted correctly or the switch could be bad.
Check the condition of the customers tooling, verifying the taper on the tool holder 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 different 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. See "Spindle Assembly" section for spindle cartridge replacement.
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TROUBLESHOOTING
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June 2001
Duplicate the cutting conditions under which the deflection occurs, but do not execute an auto- matic tool change. Try instead to release the tool using the tool release button on the front of the spindle head. If sticking is observed, the deflection is not caused by improper ATC adjustment, but is a problem in the spindle or tool release piston. See the "Spindle Assembly" section in Mechani- cal Service for spindle cartridge replacement.
Check air supply pressure it should be 85 psi (min). An air pressure drop of no more than 10 psi during tool release is acceptable. An air pressure drop greater than 10 psi is caused by a supply line restriction or an undersize supply line. Use of quick couplers (1/
4 ") can cause restriction.
Directly connecting the air hose to a barb fitting can help.
During a tool change, ATC appears to be pulled up; no popping noises.
Check the adjustment of the Z offset ("Setting Parameter 64" section).
NOTE: If the offset is incorrect, a tool changer crash can occurred, and a thorough inspection of the ATC will be necessary.
Ensure the roller bolts on the shuttle of the ATC are tight against the V-guides on the ATC holding arm. If the lower right roller bolt is loose against the V-guide, the upper right bolt is probably bent. See the following section ("ATC Crashing") or "Roller Bolt Replacement", for roller bolt replace- ment.
NOTE: Bent roller bolts are a symptom of another problem with the ATC. Repair the bent roller bolt and then isolate the ATC problem.
Check Parameter 71 against the values that are in the documentation sent with the machine.
Ensure the balls on the drawbar move freely in the holes in the drawbar when the tool release button is pressed. If they do not move freely, the ATC will be pushed down about before the tool holder is seated in the taper, resulting in damage to the roller bolts on the ATC shuttle. Replace drawbar.
Tool holders twist against extractor fork during a tool change.
Check the alignment of the ATC in the X and Y axes ("Automatic Tool Changer Alignment" section).
Tool holders spin at all pockets of the ATC when the ATC shuttle retracts.
ATC is misaligned in the Y axis. Realign ATC ("Automatic Tool Changer Alignment" section).
NOTE: Observe the direction the tool holder rotates, as this will be the direction in which the Y axis of the ATC needs to be moved.
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TROUBLESHOOTING
96-8100 rev C
June 2001
Tool holders spin only at certain pockets of the ATC when the ATC shuttle retracts.
Check all the extractor forks to ensure they are centered in the pocket of the ATC. Also, see above. See "Extractor Fork Replacement" section, if necessary.
NOTE: If the ATC shows the problem as described here, each extractor fork must be checked and centered to eliminate the possibility of the ATC being aligned against an incorrectly-centered fork.
CRASHING
The most common ATC crashes are outlined as follows:
Shuttle crashes into spindle when a tool change is commanded (tool holder is in the pocket facing the spindle head).
Rotate the carousel to an empty pocket. Refer to the Programming and Operation manual for correct operation.
NOTE: This crash is fairly common and is a result of operator error. If the ATC is stopped in the middle of tool change cycle, the operator must command the ATC to an empty pocket before the machine will operate correctly. Repeated crashes of this type can damage the I/O board, the slip clutch, and the shuttle motor in the ATC.
During a tool change spindle crashes into top of the tool holder after a turret rotation.
When the spindle head moves down over the top of the tool holder during a tool change, the pull stud will bind inside the drawbar bore of the spindle, forcing the ATC down, breaking the carousel. Bending the upper right roller bolt on the ATC shuttle or completely breaking it off is also possible. Tool holder is not held correctly in the extractor fork, possibly held only in one side of the extractor and at an odd angle.
Check all of the extractor forks on the ATC.
During a tool change spindle crashes into top of the tool holder after a turret rotation.
The balls in the drawbar do not move freely, causing the ATC to be forced down far enough to break the carou- sel. Bending the upper right roller bolt on the ATC shuttle or completely breaking it off is also possible.
Ensure the balls on the drawbar move freely in the holes in the drawbar when the tool release button is pressed. If this failure occurs, check all of the extractor forks on the ATC for damage and repair the spindle drawbar.
Check drawbar height and set according to the appropriate section, if necessary.
ATC properly deposits a tool holder in the spindle, but the tools are dropped onto the machine table when the shuttle retracts.
Inspect the balls and the Belleville springs in the drawbar. See appropriate section and replace drawbar.
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TROUBLESHOOTING
96-8100 rev C
June 2001
The part or fixture on the mill table crashes into long tooling or into the ATC itself when machining.
Either reposition the tools to remove the interference, or program the carousel to rotate long tooling out of the way of the part (USE THIS ONLY AS A LAST RESORT). CAUTION! If the carousel has to be programmed to rotate long tools clear of the part, the correct carousel position must be programmed back in before a tool change can be executed.
NOTE: If these crashes occur, thoroughly inspect the ATC for damage. Pay close attention to the extractor forks, the sliding covers on the ATC carousel, and the roller bolts on the ATC shuttle. See appropriate section for extractor fork replacement.
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TROUBLESHOOTING
96-8100 rev C
June 2001
SIDE MOUNT TOOL CHANGER RECOVERY FLOW CHART
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TROUBLESHOOTING
96-8100 rev C
June 2001
BREAKAGE
Breakage of the ATC is caused by either very hard and repeated crashes or excessive TSC coolant tip wear.
ATC shuttle is broken off of the holding plate.
Carefully inspect the bosses on the shuttle casting (where the roller bolts mount) for damage to the threads or cracks. If any of the bosses are cracked, replace the casting. Realign the tool changer after repairing the machine.
ATC extractor forks are damaged after breakage.
Check the condition of the mounting holes in the carousel. If the threads are damaged, they must be repaired or the carousel replaced. See appropriate section for extractor fork replacement.
NOISY OPERATION
To isolate noise(s) in the ATC, carefully observe the ATC in operation and look for the following:
ATC makes noise as the shuttle moves.
Check the adjustment of the roller bolts on the ATC ("Roller Bolt Replacement" section). Loose roller bolts can cause the ATC to make a clunking noise when the shuttle is commanded to move. Tight roller bolts can cause the shuttle motor to labor excessively, possibly damaging the motor or the I/O board. In this case, the shuttle may also move too slowly.
Check for damage to the trap door on the ATC cover. See appropriate section for trap door replacement.
Check for missing plastic riders on the ATC shutter. See "ATC Trap Door Replacement" for shutter replacement.
Ensure the guide pin mounted to the holding plate is not bent and does not scrape the ATC cover during movement. See "ATC Trap Door Replacement" for guide pin replacement.
Listen for damage to the gear train in the shuttle motor. If the motor is found to be the source of the noise, replace the motor ("Shuttle Motor Removal" section). DO NOT try to repair the motor or to further isolate the noise in the motor.
Check to ensure the Geneva driver on the turret motor is tight and properly adjusted ("Shuttle Motor Removal" section). If the Geneva driver is found to be loose, check for damage to the Geneva star. Any roughness in the slots will require that it be replaced ("Geneva Star Replace ment" section).
Check the adjustment of the Geneva driver in relation to the Geneva star ("Geneva Star Replace ment" section). If the adjustment is too loose, the carousel will vibrate heavily and make a loud clanking noise during carousel rotation. If the adjustment is too tight, the turret motor will labor excessively and the carousel may appear to move erratically.
NOTE: If the turret motor adjustment is tight for extended periods, the turret motor, Geneva star, and the I/O board may be damaged. If the adjustment of the Geneva star appears tight at some pockets and loose at others, the problem lies with the Geneva star. Check the concentricity of the star relative to the bearing housing on the carousel assembly. If the concentricity of the star is proven to within specification and the problem still persists, the Geneva star must be replaced ("Geneva Star Replacement" section).
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TROUBLESHOOTING
96-8100 rev C
June 2001
Ensure the screws holding the turret motor to the mounting plate are tight ("Turret Motor Removal" section).
Ensure the screws attaching the motor mounting plate to the shuttle casting are tight.
Check for excessive noise in the gear train of the turret motor. See appropriate section for turret motor replacement.
NOTE: If the motor is found to be the source of noise, replace the motor assembly (motor, mounting plate, and Geneva driver). DO NOT attempt to repair the motor or to further isolate the problem in the motor.
SPINDLE ORIENTATION
A switch is used to sense when the pin drops in to lock the spindle. When the pin drops the switch opens, indicating orientation is complete. The normally-closed side of this switch is wired to the spindle drive and commands it into the COAST STOP condition. This is done to make sure that the spindle motor is not pow- ered when the pin is locking the spindle. If, during a tool change, the dogs on the spindle shaft do not align with the keys on the ATC carousel, the spindle orientation may be at fault.
The orientation of the spindle is as follows:
1. If the spindle is turning, it is commanded to stop,
2. Pause until spindle is stopped,
3. Spindle orientation speed is commanded forward,
4. Pause until spindle is at orientation speed,
5. Command spindle lock air solenoid active,
6. Pause until spindle locked status is active and stable,
7. If not locked after time-out time, alarm and stop.
ATC out of orientation with the spindle. Incorrect spindle orientation will cause the ATC to crash as the shuttle moves. Alarm 113 will be generated.
Check the orientation of the spindle.
ATC will not run.
In all cases where the tool changer will not run, an alarm is generated to indicate either a shuttle in/out problem or a turret rotation problem. These alarms will occur either on an attempt to change tools (ATC FWD) or ZERO RETURN the machine (AUTO ALL AXES). Use the appropriate alarm to select one of the following problems:
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TROUBLESHOOTING
96-8100 rev C
June 2001
ATC shuttle will not move; shuttle is getting power (Command a tool change and check for power being applied to the shuttle motor).
Disconnect the slip clutch arm from the ATC shuttle and ensure the shuttle can move freely. If not, appropriate section for shuttle adjustment.
Command a tool change with the shuttle disconnected. If the shuttle cycles, check the slip clutch on the ATC. See "Shuttle Installation" section for slip clutch replacement.
NOTE: The slip clutch should move the shuttle with a fair amount of force, but not so much that the shuttle cannot be made to slip when holding it back by hand. If the slip clutch is frozen, replace it. It cannot be rebuilt in the field.
If the ATC shuttle does not cycle, the motor has failed and must be replaced. Turn the motor by hand and feel for binding in the gear train in the motor.
NOTE: The motor uses a large amount of gear reduction and should be hard to turn by hand.
ATC shuttle will not move; shuttle is not getting power.
Command a tool change check for power being applied to the shuttle motor.
Check that the TC IN/TC OUT LED on the I/O PCB is illuminated when a tool change takes place. If the LED lights, check the fuse FU5 on the POWER PCB or FU1 on the I/O PCB. Otherwise, check the I/O PCB ("Electrical Service"). If the LED does not light, check cables I/O-P1-510 and I/O-P2-520.
Check ATC shuttle relay
ATC turret will not rotate; turret motor is getting power.
Command a tool change check for power being applied to the turret motor.
If power is applied but the output shaft on the motor does not turn, check for binding between the turret motor assembly and the Geneva star ("Automatic Tool Changer" section). Check for damage to the Geneva star or the Geneva driver. Check for a broken turret motor ("Turret Motor Removal" section).
NOTE: Do not attempt to repair the motor or to further isolate the problem in the motor.
ATC turret will not rotate; turret motor is not getting power.
Command a tool change check for power being applied to the turret motor.
Check that the TC CW/ TC CCW LED on the I/O PCB is illuminated when a tool change takes place. If the LED lights, check the fuse FU5 on the POWER PCB or FU1 on the I/O PCB. Otherwise, replace the I/O PCB (Electrical Service). If the LED does not light, check cables I/O-P1-510 and I/O-P2-520.
Check ATC turret relay.
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TROUBLESHOOTING
96-8100 rev C
June 2001
1.5 GEARBOX AND SPINDLE MOTOR
The gearbox cannot be serviced in the field and must be replaced as a unit. NEVER remove a motor from a VF-Series mill that has a gearbox, as this will damage the gearbox and void the warranty.
NOISE
When investigating complaints of gearbox noise, also refer to "Spindle" troubleshooting section. Gearboxes can be damaged by, gearshift cylinders, or bearings, resulting in noisy operation. While gearbox vibration can cause a poor finish on a workpiece, noisy gearbox operation may not.
Excessive or unusual noise coming from the gearbox and/or spindle motor.
Operate the machine in both high and low gears. Monitor the gearbox for noise in both gear positions and if the pitch of the noise varies with the motor or the output shaft speed.
If the noise only occurs in one gear throughout the entire RPM range of that gear position, the problem lies with the gearbox, and it must be replaced ("Spindle Motor & Transmission" section).
If the noise occurs in both gear positions, disconnect the drive belt and repeat the previous step. If the noise persists, the gearbox is damaged and must be replaced, ("Spindle Motor & Transmission" section).
With the drive belt disconnected, run the machine at 1000 RPM in high gear. Command a change of direction and listen for a banging noise in the gearbox as the machine slows to zero RPM and speeds back up to 1000 RPM in reverse. If the noise occurs, the motor has failed and the gearbox must be replaced.
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TROUBLESHOOTING
96-8100 rev C
June 2001
GEARS WILL NOT CHANGE
Machine will not execute a gear change.
NOTE: Whenever a gear change problem occurs, an alarm will also occur. Refer ALARMS section to diagnose each problem before working on the machine.
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.
Check air supply pressure. If pressure is too low, the gears will not change.
Check the air solenoid assembly on the solenoid bracket (rear of gearbox). If the solenoid operates properly and the limit switches on the gearbox operate properly, the problem lies with the gear change piston. Replace the gearbox ("Spindle Motor & Transmission" section).
Check contactor CB4.
LOW PRESSURE ALARM
Alarm 179 (Low Pressure Transmission Oil) has been triggered.
Check for low oil supply in reservoir.
Check to see that pump motor is running.
Check for an air leak in the suction side of the pump.
Check for a bad pressure sensor.
Check for a broken or damaged cable.
Check for a worn pump head.
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June 2001
1.6 THROUGH THE SPINDLE COOLANT
COOLANT OVERFLOW
To begin troubleshooting, check the alarm history to determine the problems cause before any action is taken.
Coolant pouring out of spindle head covers.
Check the customer's tooling for through holes in the pull stud, holder and tool.
Check for seal failure. If failure is found, replace the seal housing (30-3286A). Refer to the appropriate steps in "TSC-Tool Release Piston Replacement" section for procedure.
Check that the TSC drain and purge lines are intact. If necessary, replace with 5/32" O.D. nylon tubing.
Check for coolant flowing from a failed fitting or check valve.
Check precharge pressure in accordance with TSC "Pressure Regulator Adjustment' section and reset if necessary. Low precharge pressure can cause coolant to dump into the spindle head.
Check the coolant pump pressure (should be 300 psi. for high pressure TSC , and 140 psi. for old system), with a standard (non-TSC) tool holder in spindle. If pump pressure is above 310 psi. (above 140 psi for old system), reset the pump relief valve in accordance with the "Setting TSC Pump Relief Valve" section.
Excessive coolant flow out of drain line. Pulsating flow through tool and drain line.
Check precharge pressure in accordance with TSC "Pressure Regulator Adjustment" section. Reset precharge pressure if necessary. Low precharge pressure will cause heavy or pulsating flow from the drain line.
Ensure the coolant pump relief valve has not been tampered with (yellow paint band is intact). Check the coolant pump pressure (should be 300psi. for high pressure TSC, and 140 psi. for old system), with a standard (non-TSC) tool holder in spindle. If pump pressure is above 310 psi (above 140 psi. for old system), reset pump relief valve in accordance with "Setting Pump Relief Valve" section.
38
TROUBLESHOOTING
96-8100 rev C
June 2001
LOW COOLANT
Alarm 151, "Low Thru Spindle Coolant"
Check coolant tank level.
Check for slow coolant drainage from machine enclosure.
Read the filter gauges and check the intake strainer to ensure there is no clogging. Read gauges with TSC running with no tool in spindle. Check coolant lines for any clogging or kinking. Clean or replace as needed.
If received at start-up, check that the breaker hasn't tripped and that the pump is turning. Check the electrical continuity of cables.
Check for overheating TSC motor. Single phase motors have a built in thermal cut out. Three phase TSC motors have a thermal circuit that interrupts power to the relay coil.
For old TSC system, if the drawbar was replaced, check that the hole through the drawbar is 0.156 dia. not 0.190 dia. Replace if it is 0.190.
Check for pressure switch failure (refer to "Testing the Coolant Pressure Switch" section), and replace if necessary. Check "LO CLNT" bit in the diagnostics display (0 = pressure on, 1= pres sure off). Leaking pressure switches can also give intermittent alarms.
Check the pump pressure with TSC running and no tool in the spindle. Normal pressure is 75-95 PSI. Replace the pump if pressure is 60 psi or less.
Another alarm generated during TSC operation can cause this alarm.
COOLANT TIP WEAR
The carbide coolant tip should last for the life of the machine. The old bronze coolant tip should be checked every 1000 hours of TSC operation.
Coolant tip is wearing quickly and needs frequent replacement.
Check the filtration system and that the coolant is not contaminated.
Check precharge pressure (refer to the TSC Pressure Regulator Adjustment" section). Heavy wear will occur if this pressure is too high.
Main air supply below 85 psi can cause excessive precharge pressure and heavy coolant tip wear.
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 the warranty. Notify HAAS Service Dept. if machine is being used for this application.
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TROUBLESHOOTING
96-8100 rev C
June 2001
PRE-CHARGE FAILURE
Alarm 198, "Precharge Failure"
NOTE: This alarm only applies to the TSC system. This alarm does not apply to 50 taper spindle machines. If this alarm is received on a 50 taper TSC machine, check that parameter 235 is set to zero. A non-zero value will cause the control to act as a 40 taper TSC.
Check for broken or disconnected precharge air line, and replace if necessary.
Check if the "Tool Clamped" limit switch is sticking, and replace if necessary.
Check the "Tool Clamped" limit switch adjustment (refer to "Tool Clamp/Unclamp Switch Adjust ment").
Check for low precharge pressure (refer to "Pressure Regulator Adjustment" section).
Check precharge solenoid for proper operation.
May be generated if another alarm occurs during TSC operation.
40
TROUBLESHOOTING
96-8100 rev C
June 2001
1.7 CHIP CONVEYOR
Chip conveyor does not turn
Check that Parameter 209 bit switch ENA CNVR is enabled.
Check that the front enclosure door is completely closed and door switches function properly.
Check that hub is connected to auger with bolt.
Check that all conveyor fuses are intact. [Single phase motor uses 2 fuses (VF-0,1/2 ; Three phase motor uses 3 fuse (VF-3,4,6,8)]
Check thermal reset button on conveyor motor body.
NOTE: Thermal reset indicates further problems: Ensure conveyor is not jammed, all necessary fuses are intact, check motor connector and I/O Board conveyor relays
Chip conveyor is moving in the wrong direction
Toggle Parameter 209 bit switch REV CNVR to reverse direction of conveyor.
Check I/O Board conveyor relays.
Chip conveyor reverses, then shuts down
Check that the conveyor is free of obstruction.
Check that Parameters are at Default settings.
Check that Discrete Input CNVYR (conveyor overload) cycles from 0 - 1 or 1 - 0 (0 means overload condition).
NOTE: If it does cycle check the motor for burnout or binding. If it does not cycle check the I/O board.
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TROUBLESHOOTING
96-8100 rev C
June 2001
1.8 HYDRAULIC COUNTERBALANCE
0
2 0
4 0
6 0
8 0
1 0
0
1 2
0
1 4
0
1 6
0
p s
i
Hydraulic Tank
Pressure Gauge
Pressure Switch Cable
Pressure ManifoldOutlet
Pressure Switch
Fill Valve
Hydraulic Tank Assembly
TOP OF TRAVEL PRESSURE
A reference table is listed below indicating top of travel pressure and switch setting pressure for each machine.
Machine Top of Travel Pressure (PSI) Switch Setting Pressure (PSI)
VF-E-2 750 600 VF-3, 4 1150 900 VF-5/40 875 750 VF-5/50 1100 1000 VF-6/40 11/40 750 600 VF-6/50, 7/50, 10/50 1150 900 VF-8/50, 9/50, 11/50 1550 1400 VR-11 1100 1000 VB-1 1550 1400 HS-1, 15AXT, 1R, 1RP 600 450 HS-3, 3R 1150 1000
TROUBLESHOOTING
The table below lists observable machine conditions and their probable cause. Find the appropriate corrective action step to fix the observed faults.
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TROUBLESHOOTING
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June 2001
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1 2 2
Corrective Action
Tools Required Hand tools. Charge/Discharge Kit P/N 35-4050A Hydraulic Hand Pump Kit P/N 93-0206
1. Check for sufficient oil in system: Block spindle head at top of travel. Attach charge/discharge kit to schrader valve, slowly turn t-handle clockwise to begin releasing pressure and make one of the following observations:
a) If oil is immediately present stop discharging, there is sufficient oil in the system. There are two courses of action at this point; add nitrogen to system to obtain top of travel pressure specification. This step may last indefinitely depending on the severity of the leak, or what caused it. The second course of action is to proceed to Corrective Action 2 if it is felt that the leak is substantial.
b) If nitrogen gas is immediately present stop discharging and proceed to Corrective Action 2. There is not enough oil in the system.
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TROUBLESHOOTING
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2. Block spindle head at bottom of travel (if the cylinder is to be replaced block the head in the lowest position that will permit access to the rod attachment).
a) Carefully drain remaining gas and oil.
b) Replace faulty component(s). (SAE straight thread o-ring fittings are to be lubricated with a film of hydraulic oil prior to install) Note that machines built after August, 1999 use straight thread fittings with o-rings, and sealed connectors on the switch wires. Earlier machines have pipe thread connections. Replacing older style components with newer style requires that all components of the counter balance system be changed as well as the cable back to the control.
c) Pump new Mobil DTE-25 oil (see chart for qty.) into system using Hydraulic Hand Pump Kit. (see Hydraulic Hand Pump Instructions below).
Machine Quarts of Mobile DTE-25 # of Pump Strokes VF-E-11, VR-11, HS-1 2 per tank 93 VB-1, HS-3 3 per tank 0140
d) Pressurize with nitrogen using charge/discharge kit to spec. at top of travel.
3. Add 50 psi of nitrogen to the system at top of travel.
Does the alarm clear?
Yes: Now check if the head drifts up more than 1 upon E-stop at the bottom of travel. If it does then replace the switch as described in corrective action 2.
No: Add another 50 psi to the system at top of travel. If the alarm still does not clear replace the switch as described in corrective action 2. If the alarm clears check if the head drifts up more than 1 upon E-stop at the bottom-of-travel. If it does then replace the switch as described in corrective action 2.
4. If the counter balance system pressure is ok and there is an E-stop alarm that wont reset check the cable for dirty contacts. Loose connections or broken wire can be tested by disconnecting the cable at the switch and adding a jumper across the connector pins of the cable and clear the alarm. If the alarm does not clear the cable is defective. Repair or replace the cable if necessary.
5. Check I/O board and replace if necessary.
6. Test for short in cable. Repair or replace if necessary.
7. Does spindle head drift down from top of travel upon E-stop?
Yes: Replace switch as described in corrective action 2. No: Replace pressure gauge as described in corrective action 2.
8. Invert tank to bleed about 50 psi of nitrogen gas. Re-evaluate machine condition.
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TROUBLESHOOTING
96-8100 rev C
June 2001
LEAK FAILURES
Leaks can occur at any fitting connection, at the hydraulic cylinders rod seal (where the rod enters the cylinder), at the cylinders piston seal, or through hose failures. Inspections for leaks are visual although rod seal leaks may be inconclusive because of way oil spatter. Piston seal leaks, if ad- vanced, exit the top end of the cylinder and oil can be seen at the vent area. Early piston leaks accumulate over time on top of the piston to about high before they are pushed out the cylinder at top of travel. Leaks are normally very slow and machines can operate until the pressure switch sends an E-stop alarm.
MECHANICAL DIAGNOSIS
Important! Hydraulic counterbalance oil contains red dye for easier recognition.
Noise in the system
Slight moan or creaking at slow speeds is normal for rubber seals.
While Z-axis is in motion a whistle sound at tank location is normal fluid flow.
Verify cylinder is seated correctly in counterbore. If not then reseat the cylinder.
Bumping or grinding noise indicates a mechanical cylinder failure. Replace cylinder assembly.
Look for galling and wear on cylinder shaft. If so replace the cylinder assembly.
System is not holding pressure and/or has an E-STOP (Alarm 107) that cannot be reset.
Check for accurate pressure readings. If low then the following items need to be checked:
Check for leaks at all cylinder fittings. If leaking then replace cylinder assembly.
Collapse the lower Z-axis waycover and look for any red oil pooled at the bottom of the base. If so, then fittings or seals could be damaged. Replace cylinder assembly.
Remove cylinder vent fitting. If there is red oil inside the vent cavity then the cylinder assembly needs replacement.
Check for leaks at all hydraulic tank fittings. If leaking then tank assembly needs replacement.
Over Current alarms
Pressure is set too high.
Pressure is set too low.
Too much oil has been added. (Insufficient gas volume causes large pressure rise)
Hydraulic cylinder is binding or is misaligned. Replace cylinder assembly.
Length of replacement cylinder incorrect.
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TROUBLESHOOTING
96-8100 rev C
June 2001
1.9 LINEAR SCALES
If any linear scale faults (alarms 279-290) are detected, contact the Haas service Department.
The following information is needed in order to properly diagnose the machine: List of the faults and the dates Any pertinent information on the conditions and circumstances surrounding the fault All machine parameters Software version Machine serial number
Do not attempt to adjust or inspect the scale without notifying the service department.
1.10 AUTOMATIC PALLET CHANGER
Checking pallet repeatability on to the receiver.
Maximum tolerance is .+/-0005.
Pallets are not considered repeatable from one to the other. Pallets should use separate offsets.
If pallet is out of tolerance check the alignment pins on the receiver base and bushings on the bottom side of the clamp rails for damage.
Check the height of the alignment pins on the receiver base, the top of the pin should be .450 to .490 above the receiver base.
If the alignment pins are out of the receiver body, check the depth of the hole. Depth should be .510 to .550.
Sticking Pallet.
Check for chips around the alignment pins or pallet clamp rail bushings.
Check the torque on the bolts that fasten the clamp rails to the pallet. If the bolts are loose realign the pallet according to the instructions in the APC section of Mechanical Service.
APC not responding to controller commands.
If the APC does not run but the mill does, check the APC control cable.
Make sure the E-Stop jumper is removed and that the APC control cable is plugged into the 5th axis port tightly.
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TROUBLESHOOTING
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June 2001
Recovery from an E-Stop initiated during a pallet change
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TROUBLESHOOTING
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June 2001
Figure 1 Pallet known locations. Pallet 1 is on the receiver and engaging the Pallet Clamped switch. Pallet 2 is on the APC and engaging
the Pallet Home Switch under the control panel.
Figure 2 Alignment Pin and Bushing alignment must be verified
when manually positioning a pallet on the receiver.
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TROUBLESHOOTING
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June 2001
Pin Clear Switch
Pallet Drive Leg
Pin Clear Switch
Pallet Home Switches
Trip Block
Chain/Sprocket Rotation Tool
Figure 3 With pallet 2 clamped on the receiver, the trip block must be engaging the switch as shown.
Figure 4 Press and hold the solenoid actuation buttons to
keep air pressure flowing to unclamp the receiver and hold the door open. If the buttons are released
the door will close and the receiver will clamp.
49
TROUBLESHOOTING
96-8100 rev C
June 2001
1.11 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, which is very rare.
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. Replace amplifier. 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, which is very rare.
Axis Overload
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.
50
TROUBLESHOOTING
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June 2001
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 alarm 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.
Alarm 101, "MOCON Comm. Failure"
During a self-test of communications between the MOCON and main processor, the main processor 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.
Alarm 222, C Phasing Error
If this alarm occurs on a VB-1, it is probably because parameter 176 bit 3 (SP AXIS DISABLED) is set to 0. It should be set to 1.
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 alarm. Change the bit and Setting 30 back to their original values. Press Reset to clear the alarms or cycle power to the machine.
51
TROUBLESHOOTING
96-8100 rev C
June 2001
Alarm 354 - Aux Axis Disconnected
When this alarm is generated, do not press RESET. Turn Setting 7 OFF. Enter DEBUG mode, then view the Alarms/Messages page. On the Messages page, a code will appear similar to WO1. The list of codes and their descriptions appears below:
WO1 Power was just turned on or failed. Check the ribbon cables from the Aux Axis PCB to the proces- sor for correct routing. Check for communication problems between the processor and the Aux Axis PCB.
WO2 Servo following error too large. Check the encoder for contamination or dirt. Check for an intermit- tent connection at both ends of the motor cable.
WO3 Emergency Stop. The E-STOP button was pressed, or an E-STOP condition occurred.
WO4 High load. Check for binding in the tool changer gearbox and motor. Rotate the carousel by hand and feel for any binding. Make sure the tool holders are the correct weight.
WO5 Remote RS-232 commanded off. Check the ribbon cable and the voltage to the Aux Axis PCB. Check for 115VAC (minimum) to the Aux Axis PCB from the main transformer. Check the fuse holder and the fuse that is protecting this circuit.
WO6 Air or limit switch or motor overheat. Check that the motor is not hot. Check for any binding in the motor. Check for overweight tooling.
WO7 Z channel fault. Either the encoder or the cable is bad. Change the encoder first, as it is easier to change than the cable. If the problem persists, change the cable.
WO8 Over-current limit, stalled or PCB fault. Check for binding in the tool changer gearbox. Make sure the belt is not too tight. Ohm out the motor cable, checking pins G to F (should be open), G to H (should be open), and F to H (should read between 2.5 and 5 ohms). Check all the connections on the Aux Axis PCB and motor cable.
WO9 Encode ES. Z channel is missing. Bad encoder or cable. See WO7.
WOA High voltage. Check the incoming voltage to the Aux Axis PCB. Incoming voltage must be 115 VAC. See WO5.
WOB Cable fault. Check the cable from the motor to the Aux Axis PCB. Check for loose connections at each end.
52
TROUBLESHOOTING
96-8100 rev C
June 2001
PROCESSOR STACK DIAGNOSTIC
(DISCONNECT CABLES FROM A NORMAL OPERATING SYSTEM)
Remove low voltage cable from the Video & Keyboard PCB
Processors LED's are normal
Runs fine and the CRT is Normal
No keypad beep
Remove low voltage cable from the MOTIF PCB
Processors LED's are normal then RUN goes out
No screen
Remove the Data & or Address buss from the Video & Keyboard PCB
Processors LED's Normal - then Run goes out
Remove the Data & or Address buss from the MOTIF PCB
Processors LED's Normal - then Run goes out
Remove the Data & or Address buss from the Micro Processor PCB
Processors LED's - CRT and Run are out
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TROUBLESHOOTING
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June 2001
KEYBOARD DIAGNOSTIC
NOTE: Refer to the "Cable Locations" section of this manual for a drawing of the Keyboard Interface PCB.
NOTE: This Keyboard Grid is for machines with a Keyboard Interface only. This Keyboard Grid is not for machines with a Serial Keyboard Interface.
The following is an example of how to troubleshoot the keypad:
NOTE: Keypad Diodes 1-24 correspond to chart numbers 1-24.
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TROUBLESHOOTING
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June 2001
Example
1. Pressing the RESET button will cause diodes 1 and 17 to conduct.
With the POWER OFF read across diode 1.
A typical reading is between .400-.700 ohms, note your reading.
2. Press and hold the RESET button. If the diode is conducting, the reading should drop about .03 ohms.
(If your reading was .486 and it dropped to .460, for a difference of .026; the diode is good).
The same will hold true for diode 17 in this example. If the reading stays the same or there is no change, the diode is not conducting. Pull P2 and read between pins 1 and 17.
Press and hold <RESET>. The meter should read a short (0 ohms) if not the keypad is bad.
ETHERNET
Error 53 The computer name specified in the network path cannot be located
This error usually happens when NET USE C: \\SERVER\HAAS/PERSISTENT: NO /YES is entered during the setup phase.
To fix this error first verify the following:
1. A 10 Base-T network is present. 2. The network cable is coming from a hub (not the server). 3. The server name that you specified in your NET USE command is correct. 4. Your network is running IPX/SPX protocol.
If all of the above is correct and communications between the Haas CNC and the network are not established, there may be compatibility issues between an older Novell network and an NT 4.0 server. If the NWLink IPX/ SPX Compatible Transport on the NT server is set to auto detect the protocols frame, the NT server may be detecting the Novell server first and setting the NWLink IPX/SPX Compatible Transport frame protocol to 802.3 The NWLink IPX/SPX Compatible Transport required for the mills to connect to an NT server is 802.2. Since these two frame protocols are different the mill would never connect to the desired NT server. To remedy this check the following:
1. On the Ethernet boot disk, edit the protocol.ini file in the NETI directory. 2. Find the line FRAME=ETHERNET_802.2 and change it to FRAME=ETHERNET_802.3 3. Save the file 4. Insert the boot disk back into the CNC and cycle the power.
If an Error 53 is still present, restore the protocol.ini file to its previous state and do the following to the NT server:
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TROUBLESHOOTING
96-8100 rev C
June 2001
1. Open the control panel 2. Double click on the Network icon 3. Select the Protocols tab. 4. Highlight NWLINK IPX/SPX Compatible Transport. 5. Select properties. 6. Select Manual Frame Type Detection. 7. Click on Add. 8. Select Ethernet 802.2 9. Click on Add. 10. Click OK. 11. Close all windows and reboot the NT server.
Once the NT server is rebooted the NWLINK IPX/SPX Compatible Transport Frames is set to 802.2 and the mill will be able to see the desired server.
Mill code will not work
Make sure the command in the server routes back to the mill.
56
ALARMS June 2001
96-8100 rev C
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 corrected by first correcting any mechanical problem, pressing RESET until the alarms are clear, selecting ZERO RET mode, and selecting AUTO ALL AXES. Some messages 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.
Alarm number and text: Possible causes:
101 Comm. Failure with MOCON During a self-test of communications between the MOCON and main processor, the main processor does not respond, one of them is possibly bad. Check cable connections and boards.
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 faults, tool changer problems, or power fail.
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 a parameter. 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 Same as alarm 103.
105 Z Servo Error Too Large Same as alarm 103.
106 A Servo Error Too Large Same as alarm 103.
107 Emergency Off EMERGENCY STOP button was pressed. After the E-STOP is released, the RESET button must be pressed once to correct this to clear the E-STOP alarm. This alarm will also be generated if there is a low pressure condition in the hydraulic counterbalance system. In this case, the alarm will not reset until the condition has been corrected.
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ALARMSJune 2001
96-8100 rev C
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 but not much past them. It can also be caused by anything that causes a very high load on the motors.
109 Y Servo Overload Same as alarm 108.
110 Z Servo Overload Same as alarm 108.
111 A Servo Overload Same as alarm 108.
112 No Interrupt Electronics fault. Call your dealer.
113 Shuttle In Fault Tool changer is not completely to 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 not completely to left. During a tool change operation the tool in/out shuttle failed to get to the OUT 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, failed to stop 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. 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. This is either a vector drive problem or a mechanical problem on machines without a vector drive. During a spindle orientation function, the spindle is rotated until the lock pin drops in; but the lock pin never dropped. Parameters 66, 70, 73, and 74 can adjust time-out timers. This can be caused by a trip of circuit breaker CB4, a lack of air pressure, or too much friction with the orientation pin.
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, circuit breaker CB4,the circuit breaker for the air pressure solenoids, and the spindle drive.
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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 solenoids circuit breaker CB4, and the spindle drive.
119 Over Voltage Incoming line voltage is above maximum. 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 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 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.
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.
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 solenoids circuit breaker CB4, 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 turret motor only stops in one position indicated by a switch and cam on the Geneva mechanism. This alarm is only generated at power-on. The AUTO ALL AXES button will correct this but be sure that the pocket facing the spindle afterwards does not contain a tool.
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129 M Fin Fault M-Fin was active at power on. Check the wiring to your M code interfaces. This test is only performed 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, relays on the I/O assembly, the drawbar assembly, or in the wiring.
131 Tool Not Clamped When clamping or powering up the machine, the Tool Release Piston is not HOME. This is a possible fault in the air solenoids, relays on the IO 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 POWIF card on power supply assembly, relays on the IO assembly, and the main contactor K1.
133 Spindle Locked Shot pin did not release. This is detected when spindle motion is commanded. Check the solenoid that controls the air to the lock, relay K16, the wiring to the sense switch, and the switch.
134 Tool Clamp Fault When UNCLAMPING, the tool did not release from spindle when commanded. Check air pressure and solenoid circuit breaker CB4. Can also be caused by misadjustment of drawbar assembly.
135 X Motor Over Heat 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.
136 Y Motor Over Heat Same as alarm 135.
137 Z Motor Over Heat Same as alarm 135.
138 A Motor Over Heat Same as alarm 135.
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 Same as alarm 139.
141 Z Motor Z Fault Same as alarm 139.
142 A Motor Z Fault Same as alarm 139.
143 Spindle Not Locked Vector drive orientation lost or shot pin not fully engaged when a tool change operation is being performed. Check air pressure and solenoid circuit breaker CB4. This can also be caused by a fault in the sense switch that detects the position of the lock pin.
144 Time-out- Call Your Dealer Time allocated for use prior to payment exceeded. Call your dealer.
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145 X Limit Switch Axis hit limit switch or switch disconnected. This is not normally possible as the stored stroke limits will stop the slides before they hit the limit switches. Check the wiring to the limit switches 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 Same as alarm 145
147 Z Limit Switch Same as alarm 145
148 A Limit Switch Normally disabled for rotary axis.
149 Spindle Turning Spindle not at zero speed for tool change. 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 Changer not at home and either the Z or A or B axis (or any combination) is not 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, spindle 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. If no problems are found with any of these, and none of the coolant lines are clogged or kinked, call your dealer. Verify proper pump and machine phasing.
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 at the top left of the control. Call your dealer.
153 X-axis Z Ch Missing Z reference signal from encoder was not received as expected. Likely encoder contamination or parameter error.
154 Y-axis Z Ch Missing Same as alarm 153.
155 Z-axis Z Ch Missing Same as alarm 153.
156 A-axis Z Ch Missing Same as alarm 153.
157 MOCON Watchdog Fault The self-test of the MOCON has failed. Replace the MOCON.
158 Video/Keyboard PCB Failure Internal circuit board problem. The VIDEO PCB in the processor stack is tested at power-on. This could also be caused by a short in the front panel membrane keypad. Call your dealer.
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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 a short distance into a mechanical stop. It can also be caused by a short in the motor or a short of one motor leads to ground.
162 Y-Axis Drive Fault Same as alarm 161.
163 Z-Axis Drive Fault Same as alarm 161.
164 A-Axis Drive Fault Same as alarm 161.
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 Same as alarm 165.
167 Z Zero Ret Margin Too Small Same as alarm 165.
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.
170 Phase Loss Problem with incoming line voltage. This usually indicates that there was a transient loss of input power to the machine.
173 Spindle Ref Signal Missing The Z channel pulse from the spindle encoder is missing for hard tapping synchronization.
174 Tool Load Exceeded The tool load monitor option is selected and the maximum load for a tool was exceeded in a feed. This alarm can only occur if the tool load monitor function is installed in your machine.
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.
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176 Over Heat Shutdown An overheat condition persisted longer than the interval specified by parameter 296 and caused an automatic shutdown.
177 Over Voltage Shutdown An overvoltage condition persisted longer than the interval specified by parameter 296 and caused an automatic shutdown.
178 Divide by Zero Software Error; Call your dealer.
179 Low Pressure Transmission Oil Spindle coolant oil is low or low pressure condition in lines.
180 Pallet Not Clamped The APC pallet change was not completed for some reason (pressing E-stop, reset, or feedhold), and an attempt was made to run the spindle. Run M50 pallet change to reset the machine.
182 X Cable Fault Cable from X-axis encoder does not have valid differential signals.
183 Y Cable Fault Same as alarm 182.
184 Z Cable Fault Same as alarm 182.
185 A Cable Fault Same as alarm 182.
186 Spindle Not Turning Status from spindle drive indicates it is not at speed when expected.
187 B Servo Error Too Large Same as alarm 103.
188 B Servo Overload Same as alarm 108.
189 B Motor Overheat Same as alarm 135.
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 Same as alarm 148.
192 B Axis Z Ch Missing Z reference signal from encoder was not received as expected. Likely encoder contamination or parameter error.
193 B Axis Drive Fault Same as alarm 161.
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 Same as alarm 182.
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196 Coolant Spigot Failure Vertical mills only. Spigot failed to achieve commanded location after two (2) attempts.
197 100 Hours Unpaid Bill 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. If received, check all air lines and the air supply pressure.
199 Negative RPM A negative spindle RPM was sensed.
201 Parameter CRC Error Parameters lost. Check for a low battery and low battery alarm.
202 Setting CRC Error Settings lost. Check for a low battery and low battery alarm.
203 Lead Screw CRC Error Lead screw compensation tables lost. Check for low battery and low battery alarm.
204 Offset CRC Error Offsets lost. Check for a low battery and low battery alarm.
205 Programs CRC Error Users program lost. Check for a low battery and low battery alarm.
206 Internal Program Error Possible corrupted program. Save all programs to floppy disk, delete all, then reload. Check for a low battery and low battery alarm.
207 Queue Advance Error Software Error; Call your dealer.
208 Queue Allocation Error Software Error; Call your dealer.
209 Queue Cutter Comp Error Software Error; Call your dealer.
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 floppy disk, delete all, then reload.
212 Program Integrity Error Possible corrupted program. Save all programs to floppy 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.
215 Free Memory PTR Changed Indicates the amount of memory used by the programs counted in the changed system disagrees with the variable that points to free memory. Possible processor board problem.
216 EPROM Speed Failure Possible processor board problem.
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217 X Axis Phasing Error Error occurred in phasing initialization of motor. This can be caused by a bad encoder, or a cabling error.
218 Y Axis Phasing Error Same as alarm 217.
219 Z Axis Phasing Error Same as alarm 217.
220 A Axis Phasing Error Same as alarm 217.
221 B Axis Phasing Error Same as alarm 217.
222 C Axis Phasing Error Same as alarm 217.
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 count pulses in X 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 PCB.
225 Y Transition Fault Same as alarm 224.
226 Z Transition Fault Same as alarm 224.
227 A Transition Fault Same as alarm 224.
228 B Transition Fault Same as alarm 224.
229 C Transition Fault Same as alarm 224.
231 Jog Handle Transition Fault Illegal 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 Enc. 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.
236 Spindle Motor Overload This alarm is generated in machines equipped with a Haas vector drive, if the spindle motor becomes overloaded.
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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 Door Fault The control failed to detect a low signal at the Door Switch when the door was commanded to close, or a high signal at the Door Switch when the door was commanded to open after the time allowed.
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 No End Check input file for a number that has too many digits
243 Bad Number Data entered is not a number.
244 Missing ) Comment must end with a " ) ".
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 Software Error; Call your dealer.
248 Number Range Error Number entry is out of range.
249 Prog Data Begins Odd Possible corrupted program. Save all programs to floppy disk, delete all, then reload.
250 Program Data Error Same as alarm 249.
251 Prog Data Struct Error Same as alarm 249.
252 Memory Overflow Same as alarm 249.
253 Electronics Overheat The control box temperature has exceeded 135 degrees F. This can be caused by an electronics problem, high room temperature, or clogged air filter.
254 Spindle Overheat The 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.
257 Program Data Error Possible corrupted program. Save all programs to floppy disk, delete all, then reload. Possible processor board problem.
258 Invalid DPRNT Format Macro DPRNT statement not structured properly.
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259 Language Version Possible processor board problem.
260 Language CRC Indicates FLASH memory has been corrupted or damaged. Possible processor board problem.
261 Rotary CRC Error Rotary table saved parameters (used by Settings 30, 78) have a CRC error. Indicates a loss of memory - possible processor board problem.
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. Indicates a loss of memory. Possible processor board problem.
266 Tool Changer Fault Run Toolchanger Recovery.
267 Tool Door Out of Position Horizontal mills only. Alarm will be generated during a tool change when parameter 278 TC DR SWITCH is set to 1, and the tool carousel air door and the tool carousel air door switch indicates that the door is open after commanded to be closed, or closed after it was commanded to be 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 toolchanger arm is not in position. Run Toolchanger Recovery.
270 C Servo Error Too Large Same as alarm 103.
271 C Servo Overload Same as alarm 108.
272 C Motor Overheat Same as alarm 135.
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 Same as alarm 145.
275 C Axis Z Ch Missing Z reference signal from encoder was not received as expected. Likely encoder contamination or parameter error.
276 C Axis Drive Fault Same as alarm 161.
277 C Zero Ret Margin Too Small Same as alarm 165.
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278 C Cable Fault Same as alarm 182.
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 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.
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 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 Incomming line voltage is above maximum. The servo will be turned off and the spindle, tool changer, and coolant pump will stop. If this persists, an automatic shutdown will begin after the interval specified by parameter 296.
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297 ATC Shuttle Overshoot The ATC shuttle has failed to stop within the standby position window during a tool change. Check for a loose drive belt, damaged or over heated motor, sticking or damaged shuttle standby switch or shuttle mark switch, or burned ATC 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, mechanism binding, damaged motor, or debris build up. Use tool changer restore to recover the ATC, then resume normal operation.
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 within an accuracy of 0.0010 inches.
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 Cycle 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 Feed Rate 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 of 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 M97, M98, or G65 In M97, M98 or G65 a subprogram number must be put in the P code. G47 must have P0 for text engraving or P1 for sequential serial numbers.
314 Subprogram or Macro Not In Memory Check that a subroutine is in memory or that a macro is defined.
315 Invalid P Code In M97, M98 or 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. G47 must have P0 for text engraving or P1 for sequential serial numbers.
316 X Over Travel Range Commanded X-axis move would exceed the allowed machine range. Machine coordinates are in the negative direction. This condition indicates either an error in the users program or improper offsets.
317 Y Over Travel Range Same as alarm 316.
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318 Z Over Travel Range Same as alarm 316.
319 A Over Travel Range Commanded A-axis move would exceed the allowed machine range. Machine coordinates are in the negative direction. This condition indicates either an error in the users program or improper offsets.
320 No Feed Rate Specified Must have a valid F code for interpolation functions.
321 Auto Off Alarm Occurs in debug mode only.
322 Sub Prog Without M99 Add an M99 code to the end of program called as a subroutine.
324 Delay Time Range Error P code in G04 is greater than or equal to 1000 seconds (over 999999 milliseconds).
325 Queue Full Control problem; call your dealer.
326 G04 Without P Code Put a Pn.n for seconds or a Pn for milliseconds.
327 No Loop For M Code Except M97, M98 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 Parameters have disabled this axis. Not normally possible in VF Series CNC Mill.
334 Y-Axis Disabled Same as alarm 333.
335 Z-Axis Disabled Same as alarm 333.
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).
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 comp. must begin on a linear move.
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341 Cutter Comp End With G02 or G03 Disable cutter comp later.
342 Cutter Comp Path Too Small Geometry not possible. Check your geometry.
343 Display Queue Record Full Software error. Call your dealer.
344 Cutter Comp With G18 and G19 Cutter comp only allowed in XY plane (G17).
346 Illegal M Code There was an M80 or M81 commanded. These commands are not allowed while Setting 51 DOOR HOLD OVERRIDE is OFF. Also check Setting 131 for Auto Door and Parameter 57 for DOOR STOP SP.
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 W/O Cancel 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 comp 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.
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. Status from control was LOST.
354 Aux Axis Disconnected Aux axes not responding. Check auxiliary axes and RS-232 connections.
355 Aux Axis Position Mismatch between machine and aux axes position. Check aux axes and Mismatch 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 auxiliary axis at a time.
359 Invalid I, J, or K In G12 or G13 Check your geometry.
360 Tool Changer Disabled Check Parameter 57. Not a normal condition for VF Series CNC Mill.
361 Gear Change Disabled Check Parameter 57. Not a normal condition for VF Series CNC Mill.
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362 Tool Usage Alarm RESET. Tool life limit was reached. To continue, reset the usage count in the Current Commands display and press
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.
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 Cutter 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.
381 G43 or G44 Not Allowed in G36 or G136 Auto work offset probing must be done without tool offset.
382 D Code Required in G35 A Dnnn 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 G10 was used to change offsets but L, P, or R code is missing or Code In G10 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 comp cannot be used.
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388 Cutter Comp Not Allowed With G10 Coordinates cannot be altered while cutter comp is active. Move 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 an 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).
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 Same as alarm 316.
395 No G107 Rotary Axis A rotary axis must be specified in order to perform cylindrical mapping Specified (G107).
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, G36, G37, G136) was found during program restart.
403 RS-232 Too Many Progs Cannot have more than 200 programs in memory.
404 RS-232 No Program 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 Onnnnn and must be at beginning of a block.
406 RS-232 Missing Code A receive found bad data. 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 RS-232 Invalid N Code Bad Parameter or Setting data. User was loading settings or parameters and something was wrong with the data.
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410 RS-232 Invalid V Code Bad parameter or setting data. User was loading settings or parameters and something was wrong with the data.
411 RS-232 Empty Program 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. This alarm is not normally possible as this control can keep up with even 115200 bits per second. Computer sending data may not respond to X-OFF
415 RS-232 Overrun Data sent too fast to CNC. This alarm is not normally possible as this control can keep up with even 115200 bits per second.
416 RS-232 Parity Error Data received by CNC has bad parity. Check parity settings, number of data bits and speed. Also check your wiring.
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 code entered at the keyboard. Warning only.
421 No Valid Pockets Pocket Table is full of dashes.
422 Pocket Table Error If the machine is equipped with a 50 taper spindle there must be 2 dashes between Ls (large tools). Ls must be surrounded by dashes.
429 Disk Dir Insufficient Memory Disk memory was almost full when an attempt was made to read the disk directory.
430 Disk 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.
431 Disk No Prog Name Need name in programs when receiving ALL; otherwise has no way to store them.
432 Disk Illegal Prog Name Check files being loaded. Program must be Onnnnn and must be at the beginning of a block.
433 Disk Empty Prog Name Check your program. Between % and % there was no program found.
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434 Disk Load Insufficient Memory Program received does not fit. Check the space available in the LIST PROG mode and possibly delete some programs.
435 Disk Abort Could not read disk.
436 Disk File Not Found Could not find disk file.
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 Paren. 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. Call your dealer.
506 Operand Stack Error The macro expression operand stack pointer is in error. Call your dealer.
507 Too Few Operands On Stack An expression operand found too few operands on the expression stack. Call your dealer.
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 Var. Ref. 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 A macro variable was used incorrectly with an alpha address. Same as 513.
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 outside of an IF-THEN, WHILE, or M99 block.
517 Exprsn. Not Allowed With N Or O A macro expression cannot be linked to N or O. Do not declare O[#1], etc.
518 Illegal Macro Exprsn Reference An alpha address with expression, such as A[#1+#2], evaluated incorrectly. Same as 517.
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519 Term Expected In the evaluation of a macro expression an operand was expected and not found.
520 Operator Expected In the evaluation of a macro expression an operator was expected and 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 Reqd Prior To THEN 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 parameters.
530 Too Many I, J, or Ks 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 amount 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 and 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.
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539 Illegal Goto Expression after GOTO not valid.
540 Macro Syntax Not Allowed A section of code was interpreted by the control where macro syntax is not permitted.
541 Macro Alarm This alarm was generated by a macro command in a program.
600 U Over Travel Range Same as alarm 316.
601 V Over Travel Range Same as alarm 316.
602 W Over Travel Range Same as alarm 316.
603 U Limit Switch Same as alarm 145.
604 V Limit Switch Same as alarm 145.
605 W Limit Switch Same as alarm 145.
609 U Servo Error Too Large Same as alarm 103.
610 V Servo Error Too Large Same as alarm 103.
611 W Servo Error Too Large Same as alarm 103.
612 U Servo Overload Same as alarm 108.
613 Command Not Allowed In Cutter Comp. A command (m96, for example) in the highlighted block cannot be executed while cutter comp. Is invoked.
614 V Servo Overload Same as alarm 108.
615 W Servo Overload Same as alarm 108.
616 U Motor Over Heat Same as alarm 135.
617 V Motor Over Heat Same as alarm 135.
618 W Motor Over Heat Same as alarm 135.
619 U Motor Z Fault Same as alarm 139.
620 C Axis Disabled Parameters have disabled this axis
621 C Over Travel Range C-axis will exceed stored 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.
The following alarms apply only to the Vertical Mills with a sidemount tool changer:
622 Tool Arm Fault This alarm supports the side mount tool changers. It is generated if the arm is not at the Origin position, or the arm motor is already on when a tool change process is started.
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623 Side Mount Carousel Error This alarm supports the side mount tool changers. It is generated if the carousel motor is still on when the tool pocket is unlocked and lowered prior to a tool change.
624 Invalid Tool This alarm is generated by a side mount tool changer if the tool specified by the G-code program is not found in the POCKET- TOOL table, or the searching pocket is out of range.
625 Carousel Positioning Eror This alarm is generated by a side mount tool changer if conditions are not correct when: The carousel or tool arm was started and one or more of the following incorrect conditions existed: The carousel or arm motor already on, arm not at Origin, tool carousel not at TC mark. The tool carousel was in motion and Tool One Mark was detected but the current pocket facing the spindle was not at pocket one, or the current pocket was at pocket one but Tool One Mark was not detected.
626 Tool Pocket Slide Error This alarm is generated by a side mount 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 Position Timeout This alarm supports the side mount tool changers. It is generated if the tool arm has not moved after the allowed time or has not stopped after the allowed time. Refer to Parameter 309 MOTOR COAST TIME.
628 ATC ARM Positioning Error This alarm supports the side mount tool changers. It is generated 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 moved 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 Carousel Position Timeout This alarm supports the side mount tool changers. It is generated if the tool carousel has not moved after the allowed time or has not stopped after the allowed time specified by parameter 60 TURRET START DELAY and parameter 61 TURRET STOP DELAY, respectively.
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.
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631 APC-Pallet Not Clamped Or Home DO NOT ATTEMPT TO MOVE X OR Y AXES OR MILL UNTIL APC IS IN A SAFE CONDITION. CAUTION- The APC is not in a safe operating condition. One pallet is at home but the other pallet is neither clamped nor at home. Locate the unclamped pallet, go to the lube/air panel at rear of mill and continuously press both white buttons in center of solenoid air valves while an assistant pulls the pallet off the receiver.
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 air line, or a mechanical problem.
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 VMC 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 air line is blocked or kinked.
634 APC-Mislocated Pallet A pallet is not in the proper place on the APC. The pallet must be pushed back against the hard stop by hand.
635 APC-Pal Num Conflict Rec & 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-Switch Missed Pal 1 Pallet #1 did not return from the receiver to the APC in the allowed time. This can be caused by the chain switch block missing the limit switch, or from another mechanical problem, such as clutch slippage.
637 APC-Switch Missed Pal 2 Pallet #2 did not return from the receiver to the APC in the allowed time. This can be caused by the chain switch block missing the limit switch, or from another mechanical problem, such as clutch slippage.
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 air line, or a mechanical problem.
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 or kinked air line, or a mechanical problem.
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 the receiver (against the hard stop) then run M18 to clamp the pallet.
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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.
CAUTION! The pallets weigh 300 lbs. each, and can cause serious injury. Use extreme caution when moving them.
642 APC- Incorrect Chain Location Chain not in position to load or unload pallets when necessary. To correct this, the mislocated pallet must be moved back into the proper position by hand.
CAUTION! The pallets weigh 300 lbs. each, and can cause serious injury. Use extreme caution when moving them.
643 RP-Index Station Unlocked (Verify Lever Up) Or Front Doors Open The index station is not in the correct orientation for a pallet change or the front doors are open. Check whether the handle is in the fully up position, close the front doors, check the function of the front door switches.
644 RP-Pallet Changer Will Not Rise, Verify Air Supply To The Lift Cylinder The pallet did not begin to lift within a reasonable time after command, or did not complete lifting within a reasonable time. Verify air supply to the pallet changer valve assembly, verify proper adjustment of the lift cylinder regulator (40 PSI), verify the function of the lift cylinder air valve and solenoid, verify the operation of the lift cylinder position sense switches.
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
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.
647 RP-Up/Down Switch Illegal Condition, Lift Cylinder The switches that sense 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.
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ALARMS June 2001
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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.
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 the current limiting resistors.
650 RP-Pallet Not Engaging RP Main Drawbar This alarm occurs when the pullstud 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.
651 Z Axis Is Not Zeroed The Z-axis has not been zeroed. In order to continue the Toolchanger Recovery the Z-axis must be zeroed. Once the Z- axis has been zeroed, continue with the Toolchanger Recovery.
652 U ZERO RET MARGIN TOO SMALL Same as alarm 168.
653 V ZERO RET MARGIN TOO SMALL Same as alarm 168.
654 W ZERO RET MARGIN TOO SMALL Same as alarm 168.
655 U CABLE FAULT Same as alarm 182.
656 V CABLE FAULT Same as alarm 182.
657 W CABLE FAULT Same as alarm 182.
658 U PHASING ERROR Same as alarm 217.
659 V PHASING ERROR Same as alarm 217.
660 W PHASING ERROR Same as alarm 217.
661 U TRANSITION FAULT Same as alarm 224.
662 V TRANSITION FAULT Same as alarm 224.
663 W TRANSITION FAULT Same as alarm 224.
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ALARMSJune 2001
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664 U AXIS DISABLED Same as alarm 336.
665 V AXIS DISABLED Same as alarm 336.
666 W AXIS DISABLED Same as alarm 336.
667 U AXIS LINEAR SCALE Z FAULT Same as alarm 279.
668 V AXIS LINEAR SCALE Z FAULT Same as alarm 279.
669 W AXIS LINEAR SCALE Z FAULT Same as alarm 279.
670 TT OVER TRAVEL RANGE Same as alarm 316.
671 TT LIMIT SWITCH Same as alarm 145.
673 TT SERVO ERROR TOO LARGE Same as alarm 103.
674 TT SERVO OVERLOAD Same as alarm 108.
675 TT MOTOR OVER HEAT Same as alarm 135.
676 TT MOTOR Z FAULT Same as alarm 273.
677 TT AXIS Z CH MISSING Same as alarm 275.
678 TT AXIS DRIVE FAULT Same as alarm 161.
679 TT ZERO RET MARGIN TOO SMALL Same as alarm 168.
680 TT CABLE FAULT Same as alarm 182.
681 TT PHASING ERROR Same as alarm 217.
682 TT TRANSITION FAULT Same as alarm 224.
683 TT AXIS DISABLED Same as alarm 336.
684 TT AXIS LINEAR SCALE Z FAULT Same as alarm 279.
685 V MOTOR Z FAULT Same as alarm 273.
686 W MOTOR Z FAULT Same as alarm 273.
687 U MOTOR Z FAULT Same as alarm 273.
688 U AXIS Z CH MISSING Same as alarm 275.
689 V AXIS Z CH MISSING Same as alarm 275.
690 W AXIS Z CH MISSING Same as alarm 275.
691 U AXIS DRIVE FAULT Same as alarm 161.
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ALARMS June 2001
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692 V AXIS DRIVE FAULT Same as alarm 161.
693 W AXIS DRIVE FAULT Same as alarm 161.
694 ATC SWITCH FAULT Conflicting switch states detected, such as shuttle at spindle and shuttle at chain simultaneously. Check for damaged or sticking switches, damaged wiring, or debris build up.
695 ATC AIR 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, and correct chain guide strip adjustment. 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 movement within the time allowed by Parameter 60. Check, for mechanism binding, correct motor and switch operation, damaged ATC control board relays, damaged electrical wiring, or blown fuses on the ATC 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 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.
699 ATC CHAIN OUT OF POSITION An incorrect tool change position was detected during a tool change. Use tool changer restore to recover the ATC, then resume normal operation.
900 Par No xxx Has Changed. Old Value Was xxx. 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 file has been loaded from floppy 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 RS-232 When a 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.
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904 TOOL CHANGER 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.
NOTE: Alarms 1000-1999 are user defined by macro programs.
The following alarms only apply to horizontal 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 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 it's 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 it's 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.
MECHANICAL SERVICE
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June 2001
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
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.
* 3/8-16 SHCS used on tool release piston torqued to 35 ft. lb.
3.1 HEAD COVERS REMOVAL / INSTALLATION
Please read this section in its entirety before attempting to remove or replace covers.
REMOVAL -
NOTE: This procedure is for the VF-3/4. However, the procedure varies only slightly for other models.
10-32 x 3/8" SHCS Remove side covers from
top side
Figure 3.1-1 View of VF-3/4 head covers.
MECHANICAL SERVICE
8596-8100 rev C
June 2001
1. Zero return (ZERO RET) all axes, then HANDLE JOG to center X- and Y-axes under spindle. Protect table surface with a piece of cardboard.
2. Remove the top and rear covers.
3. Pull front cover from the bottom until you can disconnect the tool release cable (quick disconnect), then remove cover .
4. Remove the side covers. Jog Z-axis as necessary to make screw removal easier.
INSTALLATION -
1. Protect table surface with a piece of cardboard.
2. Replace each side cover from the top. Jog Z-axis as necessary to make access to screws easier.
3. Reconnect tool release cable, if equipped, then replace front cover from the bottom.
4. Replace rear cover and top cover.
MECHANICAL SERVICE
86 96-8100 rev C
June 2001
3.2 TOOL RELEASE PISTON (TRP) ASSEMBLY
Please read this section in its entirety before attempting to replace tool release piston assembly.
Overview
The Tool Release Piston is actuated by air. It forces the Tool Draw Bar down against the spring stack, releasing the old tool and permitting the new tool to be inserted. Normally the piston is in the upper, retracted position. During a tool change cycle the piston is forced down by air pressure, pushing the draw bar down until the pull stud on the top of the tool is released.
As the piston finishes its downward stroke a hole in the side of the Tool Release Shaft comes clear of the Cylinder Housing and is exposed to the compressed air within the cylinder. The air flows down through the Shaft to the Tool Release Nut at the lower end of the shaft. This nut presses on the end of the Tool Draw Bar and the air flows through a central hole drilled through both the Tool Release Nut and the Tool Drawbar to blow any chips out of the tapered area of the Spindle Shaft.
The Spring Retainer captures the compression spring that returns the Tool Change Piston and Shaft to the normal position when the air is released from the cylinder. The Upper and Lower Limit Switches are actuated by the Spring Retainer. The position of these switches is monitored by the computer control system during the tool change cycle.
There is different tool release piston for the 40 and 50 taper spindles. In addition The tool change pistons have different subassemblies that will need to be adjusted, or may need replacing. The section(s) that follow the installation instructions must be completed as well or serious damage to the machine could result.
40 TAPER SPINDLE TRP REMOVAL
1. If machine is equipped with Through the Spindle Coolant (TSC), place a tool holder in the spindle.
2. Remove cover panels from the headstock area.
3. Remove the four 3/8-16 x 1" SHCS holding the tool release piston assembly to the head casting.
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 tool release air hose and precharge hose at the fitting shown in Fig. 3.2-1 If machine is equipped with TSC, also remove the coolant hose.
7. Remove entire tool release piston assembly.
MECHANICAL SERVICE
8796-8100 rev C
June 2001
NOTE: Steps 8 and 9 apply only to machines with TSC.
8. Remove the drain and purge lines from the seal housing.
9. Remove the seal housing from the TRP.
CAUTIO N
3/8" - 16 X 1 3/4" SHCS
TSC Fitting (Optional)
3/8" Air Hose Fitting
1/4" Air Hose Fitting
Unclamp switch
Clamp switch
Figure 3.2-1 Tool Release Piston with Optional TSC fitting.
Figure 3.3-2 Mounting location for tool release piston assembly
MECHANICAL SERVICE
88 96-8100 rev C
June 2001
40 TAPER SPINDLE TRP INSTALLATION
The following sections must be completed after installation:
Set Pre-Charge
Adjust the Tool Clamp/Unclamp Switches
Set the Drawbar Height
1. Ensure drive belt has been properly replaced as described in "Belt Assembly" section.
2. Verify spindle sweep adjustment is correct (as shown in "Spindle Assembly" section) before proceeding. If not correct, re-shim as necessary.
3. Reinstall tool release piston assembly loosely if the machine is equipped with TSC. Otherwise tighten the four mounting bolts securely.
4. Reconnect the air hoses at the applicable fittings on the tool release piston assembly.
5. Reconnect the clamp/unclamp cables and solenoid wire to the sides of the solenoid bracket.
6. Connect the 5/32" drain line and 5/32" purge line to the seal housing and install the seal housing on the TRP (use Loctite on the screws). The drain line connector should point toward the rear of the machine.
NOTE: The drain line must run straight through the cable clamp guide on the transmission, and must not interfere with the pulley or belts. On VF-0/0E machines, the drain line must go straight down through the cable clamp on the bracket.
NOTE: Steps 6, 7 and 8 apply only to machines with TSC.
7. Apply precharge pressure several times to allow the seal to center itself with the drawbar. While holding down precharge, tighten the bolts.
8. Install the coolant hose. A wrench must be used, tighten snug. Do not overtighten!!
9. Adjust the clamp/unclamp switches in accordance with the appropriate section.
MECHANICAL SERVICE
8996-8100 rev C
June 2001
Setting Pre-Charge
NOTE: Do not perform this procedure on machines equipped with Through the Spindle Coolant (TSC). It will damage the machine. Refer to the "Precharge Regulator Adjustment" section and perform those adjustments.
10. Turn the air pressure regulator down to zero (0). The knob must be pulled out to unlock before adjusting.
NOTE: At "0" pressure on the precharge regulator, the adjustment knob is out as far as it will turn.
SPINDLE LOCKED
STATUS SW
ITCH
W ITHOUT
GEARBOX
H IG
H G
E A R
S T A T U
S S W
IT C
H
LO W
G E
A R
S TAT
U S
S W
IT C
H
JU M
P E
R W
IT H
O U
T
G E
A R
B O
X
TO O
L C
LAM PED
STATU S
SW ITC
H
Figure 3.2-3. Air pressure regulator adjustment knob.
11. Ensure Parameter 149, Precharge DELAY, is set to 300. If not, set it at this time.
12. Execute a tool change. A banging noise will be heard as the tool release piston contacts the drawbar.
13. Turn the air pressure regulator turn in. Execute a tool change and listen for the noise described previously. If it is heard, repeat this step until no noise is heard. There should be no noise with or without a tool in the spindle.
CAUTION! Only increase the pressure to the point where tool changes become obviously quiet. Any further pressure increases are not beneficial. Exces- sive pressure to the precharge system will cause damage to the tool changer and tooling in the machine.
14. Replace the head covers.
MECHANICAL SERVICE
90 96-8100 rev C
June 2001
TOOL CLAMP/UNCLAMP SWITCH ADJUSTMENT - INITIAL PREPARATION
Please read this section in its entirety before adjusting clamp/unclamp switches or setting drawbar height.
TOOLS REQUIRED
Machined aluminum block (2" x 4" x 4")
6" flexible ruler or .020" shim
1" diameter pipe (approx. 1' long)
1. Remove cover panels, as described in "Head Covers Removal".
2. Place a sheet of paper under the spindle for table protection, then place a machined block of aluminum (approximately 2" x 4" x 4") on the paper.
Aluminum Block
Tool Holder
Sheet of paper
Figure 3.2-4 Placement of aluminum block under spindle.
3. Power on the VMC.
4. Insert a tool holder WITHOUT ANY TYPE OF CUTTER into the spindle taper.
5. Go to the HANDLE JOG mode. Choose Z-axis and set jog increments to .01.
MECHANICAL SERVICE
9196-8100 rev C
June 2001
6. Jog Z-axis in the negative (-) direction until the tool holder is approximately .03 from the block. At this point, stop jogging the spindle and push the TOOL RELEASE button (top left). You will notice that the tool holder comes out of the taper.
NOTE: The clearance from the tool holder to the block should be zero (0).
7. To accomplish this, set the jog increments to .001 and jog in the negative (-) Z direction a few increments of the hand wheel at a time. Between these moves, push the tool release button and feel for movement by placing your finger between the tool holder and the spindle. Do this until no movement is felt. You are now at zero (0).
CAUTION! Do not jog too far in the negative (-) direction or else it will cause an overload of the Z-axis.
SETTING DRAWBAR HEIGHT
1. Press MDI and turn hand wheel to zero (0).
2. Press HANDLE JOG button and set increments to .01. Jog the Z-axis in the positive (+) direction 0.100".
3. Press and hold the TOOL RELEASE button, grasp the block and try to move it. The block should be tight at .100 and loose at .110. If block moves at .100, jog the Z-axis in the negative (-) direc- tion one increment at a time. Press the TOOL RELEASE button and check for movement between increments until block is tight.
NOTE: The increments jogged in the Z negative (-) direction are the amount of shim washers that must be added to the tool release bolt (or coolant tip for TSC). Refer to the "Shim Washers" section.
4. 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 block is loose.
The increments jogged in the Z positive (+) direction are the amount of shim washers that must be removed. (Refer to the "Shim Washers" section).
MECHANICAL SERVICE
92 96-8100 rev C
June 2001
SHIM WASHERS
1. To add or subtract shim washers, remove tool release piston assembly ("Tool Release Piston" section) from head casting.
2. Check the condition of the tool release coolant tip and the draw bar. Repair or replace these items before setting the drawbar height.
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.
Figure 3.2-5 Tool release piston assembly (TSC shown).
3. Remove tool release bolt. If machine is equipped with TSC, loosen the three set screws and remove the TSC coolant tip.
4. Add or subtract required shim washers (See previous section for correct amount to add or remove).
5. Before installing tool release bolt, put a drop of serviceable (blue) Loctite on the threads and install. If replacing TSC coolant tip, put a drop of Loctite on the threads of the three set screws before installing.
6. Install tool release piston assembly in accordance with the "Tool Release Piston - Installation" section and recheck settings. If within specifications, continue; if not, readjust.
MECHANICAL SERVICE
9396-8100 rev C
June 2001
ADJUSTMENT OF SWITCHES
LOWER (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.
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.
CAUTIO N
3/8" - 16 X 1 3/4" SHCS
TSC Fitting (Optional)
3/8" Air Hose Fitting
1/4" Air Hose Fitting
Unclamp switch
Clamp switch
Figure 3.2-6 Tool release piston assembly.
4. Using the pressure regulator on the air/lube panel to reduce the inlet pressure to 75 PSI. Be sure to back regulator down past 75 PSI then adjust back up to 75 PSI. This will decrease the amount of upward deflection on the spindle head from TRP force.
5. Press the tool release button and hold it in. Adjust the switch in or out until the switch just trips (DB OPN =1).
6. Check the adjustment. 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.
7. Re-adjust and repeat steps 1-6 if necessary.
8. Set the pressure regulator back to 85PSI.
MECHANICAL SERVICE
94 96-8100 rev C
June 2001
UPPER (CLAMP) SWITCH -
1. Remove the tool holder from the spindle.
2. Delete everything in MDI mode and write #1120=1.
3. Start with the upper switch all the way in. Place a 0.02 shim between the tool release piston adjustment bolt and the drawbar.
4. Push the PARAM/DGNOS button twice to enter the diagnostics mode.
5. Press CYCLE START.
6. 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).
7. Press RESET. Replace the 0.02 shim with a 0.04 shim. Press CYCLE START. See that DB CLS=1. Readjust and repeat steps 1-7 if necessary.
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.
Figure 3.2-7 Placement of shim before checking switch adjustment.
MECHANICAL SERVICE
9596-8100 rev C
June 2001
50 TAPER SPINDLE TRP REMOVAL
1. For TSC equipped machines, place a tool holder in the spindle.
2. Remove cover panels from the headstock area in accordance with "Head Covers Removal and Installation".
3. For TSC equipped machines the rotary union and extension tube must be removed before proceed- ing. They both have left handed threads.
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. Remove the four shoulder screws holding the tool release piston assembly to the head casting. Make sure to keep all the washers and shims.
8. Remove entire tool release piston assembly, by sliding it forward then lifting it upward. The assem- bly is heavy so use great care when removing it.
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.
MECHANICAL SERVICE
96 96-8100 rev C
June 2001
10. Remove the lower TRP 50T piston.
11. Remove the TRP sub plate.
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. lbs.
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.
MECHANICAL SERVICE
9796-8100 rev C
June 2001
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)
Figure 3-10.. Shim and spacer location diagram.
1. Place the TRP on the machine. The TRP will rest on the spindle lift fork. Caution: Be careful of the spindle lift fork. Place the assembly toward the front of the machine before lowering it. The assem- bly is heavy so use great care when replacing it.
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.
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.)
MECHANICAL SERVICE
98 96-8100 rev C
June 2001
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.
Purge Air Hose
Check Valve Assy
Drain hose
High Pressure Coolant Hose
Rotating Union
Extension Tube
TRP
a) Put a tool holder in the Spindle (this is absolutely required!).
b) Prevent Spindle from rotating to allow for tightening of Extension Tube (inserting a bolt into one of the holes in the pulley and bracing a bar against the inside of the spindle head is one way of doing this).
c) Apply grease lightly to the O-ring on the end of the extension tube.
d) Apply blue Loctite to end of extension tube threads.
e) Insert the extension tube into drawbar. The Extension Tube has left hand threads. Tighten the Extension Tube and turn until the reference marks line up (there should be a paint line on the extension tube and on the drawbar).
f) Check the runout of the extension tube with a dial indicator at the top of the extension tube. If the runout is greater than 0.010 TIR max., follow the instructions for Adjusting Extension Tube Runout.
g) Slip Support Bracket over Rotating Union (check that the edge strip is intact).
h) Lightly grease the O-ring on the Rotating Union, and install the union onto the top of the extension tube (it has left hand threads). Tighten using two wrenches.
i) Install the (4) support bracket screws loosely. Allow the Rotating Union to find its own center. Tighten the screws carefully so the bracket does not pull to one side.
MECHANICAL SERVICE
9996-8100 rev C
June 2001
j) Apply grease to the surface of the Rotating Union that passes through the Support Bracket.
k) Connect the hose to the check valve assembly and the drain line hose (secure the hose with a cable tie so coolant drains downward to protect rotating union).
4. Plug the 3 air hoses in the TRP.
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. Place machined aluminum block onto machine table. Place a clean sheet of paper under the block to protect the table.
Aluminum Block
Tool Holder
Sheet of paper
Figure 3.2-9 Pushout Adjustment.
3. Jog Z-Axis down until tool holder is about 0.030 above the aluminum block. Switch to 0.001 increments. Jog down one increment at a time until no movement can be felt in the block. This is our zero point. Do not press the tool release button now, this can cause a Z-Axis overload!
MECHANICAL SERVICE
100 96-8100 rev C
June 2001
Figure 3.2-10 Fork shim location.
4. 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 upward 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 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.
MECHANICAL SERVICE
10196-8100 rev C
June 2001
5. 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.
6. Apply red grease to the shoulder bolts used to mount the TRP when the shim adjustments are complete. Use blue Loctite on the threads.
Figure 3.2-11 TRP shim location
MECHANICAL SERVICE
102 96-8100 rev C
June 2001
SETTING TRP SWITCHES
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.
2. Setting the lower 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) Put a jumper across the air switch to prevent a low pressure alarm. c) Back off the air pressure to around 65 psi (75 psi for old style TRPs). 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 remove jumper.
MECHANICAL SERVICE
10396-8100 rev C
June 2001
COOLANT UNION
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
Coolant Union Removal
1. 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.
2. 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.)
3. Remove the coolant union from the Extension Tube (bottom arrow in diagram) using two wrenches (7/8 and 15/16). THIS IS A LEFT HAND THREAD.
4. 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.
Coolant Union Installation
1. 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.
2. 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.
3. Thread the black coolant hose onto the connector on the check valve assembly. Tighten with a wrench. Do not over-tighten!
MECHANICAL SERVICE
104 96-8100 rev C
June 2001
EXTENSION TUBE
Special Tools Required: 5/8 Allen Wrench
Molybdenum Grease
Wrench or Pliers large enough to tighten a 2 nut.
1) Place a Tool Holder in the Spindle.
2) Remove the Rotating Union.
3) Remove the old Extension Tube (It has left hand threads).
4) Remove the Tool Release Piston, and lay it on its side with the air connectors facing up.
5) Insert a 5/8 Allen wrench into the lower end of the piston shaft. Loosen off 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.
6) Screw the Bearing Holder (20-7655) onto the piston shaft, and tighten using a large wrench or pliers.
7) Wipe clean the hole in the end of the Drawbar.
8) Replace the Tool Release Piston.
MECHANICAL SERVICE
10596-8100 rev C
June 2001
9) Apply a light layer of Molybdenum Grease to the inside of the Bearing Holder. Insert the Wave Spring (59-0176) into the Bearing Holder.
10) 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).
11) Block Spindle rotation with a bolt, bar or socket inserted into one of the Pulley holes. It will stop against the TRP Fork.
12) Tighten the Extension Tube to 15-20 ft-lbs. Remove the bolt from the Spindle Pulley.
13) Re-install the Rotating Union. Lightly grease the O-ring. DO NOT put Loctite on the threads.
14) Measure the runout at the top of the rotating union with a dial indicator. Record the measurement on the Service Report.
15) Check the Tool Clamp and Unclamp switches. They should not have moved.
16) Test run the TSC system to check for leaks before putting the head covers back on.
MECHANICAL SERVICE
106 96-8100 rev C
June 2001
3.3 BELT ASSEMBLY
Please read this section in its entirety before attempting to replace the drive belt.
BELT REMOVAL
NOTE: For easier removal, place transmission in high gear before beginning.
1. Remove cover panels from headstock area in accordance with "Head Covers Removal and Installa- tion".
Figure 3.3-1 Spindle head casting disconnect points.
MECHANICAL SERVICE
10796-8100 rev C
June 2001
2. Remove tool release piston assembly in accordance with "Tool Release Piston Assembly Re- moval".
3. For all VMC's except VF-0, remove the six SHCS holding the transmission to the head casting and pull the transmission forward enough (" to " max.) to allow the drive belt to be pulled upward over the spindle pulley.
4. For the VF-0, remove the four SHCS holding the mounting plate to the spindle head casting. Slide the assembly forward enough to allow the drive belt to be pulled up over the spindle pulley.
Shifter
Drive Belt
Spindle Pulley
Head Casting
Transmission (Except VF-0)
Figure 3.3-2 Head casting area showing belt location.
5. Remove the inspection cover from the bottom of the spindle head casting and carefully slide the drive belt between the sump tank and the web in the casting.
6. First, pull the belt up over the spindle pulley, then push the other end down to clear the shifter and pull out.
NOTE: DO NOT bend or kink the belt in any way; damage to the fibers in the belt may result, and the belt will fail soon after installation.
MECHANICAL SERVICE
108 96-8100 rev C
June 2001
BELT INSTALLATION
1. For all VMC's except VF-0, slide the replacement belt(s) under the sump tank and onto the pulley.
NOTE: DO NOT wrap the belts over the pulley. The pulley can be rather sharp, and may cut the belts. DO NOT bend or kink the belt in any way; damage to the fibers in the belt may result, and the belt will fail soon after installation.
2. Ensuring the belt is properly seated, push the transmission back, tightening the belt. Pull belt forward from rear of head casting. Pull belt over spindle pulley.
3. Tighten the drive belt in accordance with the following section.
4. Set the spindle orientation in accordance with appropriate section.
NOTE: The following step is necessary only if the spindle or transmission was exchanged prior to belt replacement.
5. Double-check the spindle sweep to assure that nothing has moved during the previous steps. If sweep is within tolerance, continue; if not, sweep must be readjusted.
NOTE: Drive belt tension must be adjusted after every installation.
TENSION ADJUSTMENT
NOTE: The drive belt tension should be adjusted after every service on the transmis- sion or spindle of the machine.
1. Turn the machine ON. Jog the spindle head down to a level that will allow you to work on the drive belt comfortably.
2. Remove the cover panels from the head stock area as shown in "Head Covers Removal" section.
3. Remove the tool release piston assembly in accordance with appropriate section.
FOR THE VF-1 THROUGH 9
4. Loosen the six SHCS holding the transmission to the spindle head casting.
NOTE: Ensure the transmission is broken free by moving it slightly by hand.
5. Set the belt tension tool in place as shown in Figure 3.3-3. Mount it to the head casting by insert- ing the two SHCS into the two front TRP mounting holes. Tighten the SHCS finger tight.
MECHANICAL SERVICE
10996-8100 rev C
June 2001
6. Turn the handle until the tool is flat against the transmission casting.
NOTE: Ensure the transmission is straight, and not cocked, before tensioning belt.
7. Turn the handle until the edge of the tool's plunger and the outer tube are flush. This will set the belt at the proper tension.
NOTE: A belt that is correctly tensioned will whine slightly, and requires approximately 12 hours of break-in time.
8. Check if the belt is too loose or too tight. If the belt is set too tight, the belt will whine excessively when the assembly is at speed; and if it is set too loose, it will vibrate during accelerations and decelerations.
9. With the tool still in place, tighten the six SHCS holding the transmission to the spindle head casting.
10. Loosen the two SHCS and remove the belt tension tool.
Outer Tube
Plunger
Belt Tension Tool
Figure 3.3-3 Belt tension tool.
MECHANICAL SERVICE
110 96-8100 rev C
June 2001
FOR THE VF-0:
4. Loosen the four SHCS holding the motor mounting plate to the head casting.
NOTE: Ensure the motor is broken free by moving it slightly by hand.
5. Set the belt tension tool in place as shown in Figure 3.3-3. Mount it to the head casting by insert- ing the two SHCS into the two front TRP mounting holes. Tighten the SHCS finger tight.
6. Turn the handle until the tool is flat against the motor mounting plate.
NOTE: Ensure the motor is straight, and not cocked, before tensioning belt.
7. Turn the handle until the edge of the tool's plunger and the outer tube are flush, and then 1/2 turn more. This will set the belt at the proper tension.
NOTE: A belt that is correctly tensioned will whine slightly, and requires approximately 12 hours of break-in time.
8. Check if the belt is too loose or too tight. If the belt is set too tight, the belt will whine excessively when the assembly is at speed; and if it is set too loose, it will vibrate during accelerations and decelerations.
9. With the tool still in place, tighten the four SHCS holding the mounting plate to the head casting.
10. Loosen the two SHCS and remove the belt tension tool.
MECHANICAL SERVICE
11196-8100 rev C
June 2001
3.4 SPINDLE ASSEMBLY
Please read this section in its entirety before attempting to replace spindle.
WARNING!
The current pulley is shrink-fitted onto the spindle and is not field- serviceable. It is identified by many holes on top of the spindle pulley. Should any attempt to remove the pulley damage the spindle or its components, the service warranty will be voided.
NOTE: The drive belt's tension should be adjusted after every transmission or spindle service.
SPINDLE CARTRIDGE REMOVAL
NOTE: VMCs equipped with a 15K Spindle must remove the spindle and drawbar as a unit. Do not remove the drawbar separately.
1. Ensure the VMC is ON. You will need to raise and lower the head stock to remove the spindle. Place the cardboard on the mill table to protect the surface.
2. Put the tool into the spindle.
3. Remove cover panels from head stock area as described in "Head Covers Removal" section.
4. Remove the tool release piston assembly in accordance with appropriate section.
5. Remove the spindle drive belt from the spindle pulley as shown in previous section. It is not possible to completely remove the belt at this time.
6. Drawbars are held in the spindle shaft by a spiral ring (newer assemblies). Remove the spiral ring with a small screwdriver. Wedge the tip of the screwdriver to take out one end of the ring from the shaft groove. Force the ring end to stay open and simultaneously rotate the screwdriver all the way around so the entire ring comes out of the groove.
7. Put the tool release piston on and remove the tool.
8. First disconnect the oil line from the fitting at the oil injection cover, then remove the brass fitting.
NOTE: When replacing a new design spindle in any vertical machine, it is important to note that the cavity between the housing and the spindle cartridge will be filled with either oil or grease. An oil filled spindle is identified by the oil fill hole to the left side of the spindle head near the spindle bore as viewed from the top.
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9. Ensure oil plug is inserted into oil injection port of spindle before removing spindle or oil may spill into the spindle cartridge.
10. With the 5/16" hex wrench, loosen approximately two turns the six SHCS holding the spindle to the underside of the head casting.
11. Place the block of wood (minimum 6" thick) on the table directly under the spindle.
Wood Block
Covered Table6" min.
Z-Axis
Figure 3.4-1. Position wood block under spindle.
12. At the panel, go to the JOG mode and choose Z-axis. Slowly jog in the negative (-) direction until the spindle rests on the block, then remove the screws that were previously loosened (step 7).
13. Jog Z-axis in the positive (+) direction until spindle is half way out of the head casting.
14. Grasp spindle with one hand and continue to jog in Z in the positive (+) direction until it is com- pletely free of the casting.
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SPINDLE CARTRIDGE INSTALLATION
Tool Drawbar
Spindle Pulley
Spindle Housing
Figure 3.4-2. Spindle cartridge.
1. Thoroughly clean all mating surfaces of both the cartridge and the head casting, lightly stone if necessary to remove burrs or high spots.
2. Place spindle on wood block making sure both spindle dogs contact the block. Align the two 10- 32 holes located on the spindle lock so they are approximately 90 degrees from the front of the spindle on the right side.
Front
10 - 32 Holes
Figure 3.4-3 Underside view of spindle cartridge.
3. Slowly jog the Z-axis in the negative (-) direction until the top portion of spindle is inside of head casting. At this point, align spindle to spindle bore. While performing this operation, you must make sure the spindle cartridge is straight to the spindle bore.
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4. If the spindle moves to one side, use a rubber mallet and/or jog in the X or Y directions to straighten it. The spindle must go in easy. If it does not, check your alignment. Do not force it!
5. Install and torque the six SHCS.
6. Reattach the brass fitting to the oil injection cover and connect the oil line to the fitting.
CAUTION! Do not overtighten the fittings when replacing on the oil injection cover. Overtightening may result in damage to the spindle cartridge.
NOTE: If replacing copper tubing to spindle, thoroughly clean out with filtered air.
7. Fill the cavity between the housing and the spindle cartridge with oil. The oil fill hole is to the left side of the spindle head near the spindle bore, as viewed from the top.
WARNING!
Never pour oil into the spindle housing.
8. Reinstall the drive belt and adjust the tension as needed.
9. Reinstall the tool release piston assembly.
10. Remove the tool release piston. Carefully install the spiral ring on the spindle shaft. Feed one end of the spiral ring into the shaft groove. Rotate the ring until the entire ring is in the groove.
11. Check the spindle sweep, as described later in this section. Check the clamp/unclamp switch adjustment.
NOTE: Refer to the appropriate sections and check the spindle orientation and ATC alignment.
DRAWBAR REPLACEMENT - 40 TAPER
REMOVAL -
NOTE: VMCs equipped with a 15K Spindle must remove the spindle and drawbar as a unit. Do not remove the drawbar separately.
1. Place a tool holder with no cutter in the spindle.
2. Remove head cover panels as shown in "Head Covers Removal'.
3. Remove the tool release piston in accordance with appropriate section.
4. Remove the snap ring from the top of the spindle shaft.
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5. Reinstall the tool release piston.
6. Remove the tool holder from the spindle.
7. Remove bolts from the transmission and use 2x4 blocks of wood, placed underneath the front of the housing, to keep it from falling forward.
8. Angle the transmission back and remove the drawbar from the spindle.
NOTE: VF-D does not require movement of the drive assembly to access/remove the drawbar.
INSTALLATION -
9. 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.
10. If machine is equipped with Through the Spindle Coolant option, grease the O-rings.
11. Insert four 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 force 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.
12. The tool release piston will have to be reinstalled at this time.
13. Install a tool holder with no cutter into the spindle taper.
14. Remove the tool release piston.
15. Install the spiral ring on the spindle shaft.
16. Reinstall the tool release piston.
17. Set the drawbar height, and clamp and unclamp switches as described in the following section.
18. Reinstall the head covers.
19. Test-run the machine and perform the necessary ATC adjustments in the "Automatic Tool Changer" section.
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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 force 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.
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SPINDLE SWEEP ADJUSTMENT
NOTE: The machine must be properly leveled for the spindle sweep adjustment to be accurate.
1. To check spindle sweep, place a .0005 indicator on a suitable holder, place on spindle nose and jog the Z-axis in the negative (-) direction enough so that you can adjust the indicator to sweep a 5" radius from the center of X and Y axes' travels. Slowly jog Z-axis in the negative (-) direction to zero out indicator.
2. Establish reference zero at rear of the table. Sweep the three remaining points (left, front, and right) and record the reading.
Figure 3.4-4 Spindle sweep area
3. Shim the spindle if necessary to correct the spindle sweep to specifications.
4. Recheck sweep. It must be within .0005 in both X/Z and Y/Z planes, as stated in the inspection report supplied with the VMC.
5. Replace the Tool Release Piston Assembly in accordance with the "Tool Release Piston Assembly Installation" and "Setting Pre-Charge" sections.
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3.5 SPINDLE ORIENTATION
Please read this section in its entirety before attempting to orient the spindle.
NOTE: If machine is equipped with a vector drive, skip to the next section.
Orientation of the spindle is automatically performed for tool changes and can be programmed with M19. Orientation is performed by turning the spindle slowly until an air pressure driven pin drops into a detent and locks the spindle in place. This pin is located behind the spindle motor and above the gear box. If the spindle is oriented and locked, commanding spindle forward or reverse will release the lock.
ORIENTATION - SPINDLE DRIVE WITH SHOT PIN ORIENTATION
1. Remove cover panels from the head stock area ("Head Covers Removal"), and tool changer front cover.
2. In MDI mode, press the ORIENT SPINDLE button.
3. Loosen the four 1/4"-20 bolts on the orientation ring. Remove two of these bolts and insert them into the two threaded holes on the ring. Evenly tighten these two bolts until the taper lock is broken.
4. Remove the two 1/4"-20 bolts and place them into their original holes. Tighten them finger tight, then 1/2 of a turn more. Ensure that the orientation ring is snug, but not tight.
NOTE: If replacing the orientation ring, clean the shaft and the ring bore thoroughly with alcohol. They must be free of grease and oil.
5. Set up a magnetic base with a 0.0005" indicator on the table. Zero the indicator on the spindle dog in the X- plane.
6. Jog the indicator across the spindle dogs and note the indicator reading. The spindle dogs should be parallel to the X axis within 0.030".
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(2) Threaded Holes
(4) SHCS
Orientation Ring Detent
Figure 3.5-1 Top view of spindle orientation components.
Figure 3.5-2 VF-0 motor with orient ring location.
7. There is a 0.015"-0.030" backlash in the spindle system when it is oriented. Be certain to com- pensate for this backlash when performing the adjustment.
8. Using a 5/8" open end wrench, rotate the spindle until the appropriate alignment is attained. If the spindle is very difficult to rotate, STOP and return to Step 4.
9. Disconnect the main air line to the machine.
10. Manually turn the orientation ring and push the shot pin until it drops into the orient ring detent.
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11. Tighten the orient screws (evenly) to 15 ft-lbs. Verify that spindle alignment has not changed.
NOTE: It is vital that the orient screws be tightened evenly. If not, the top of the orientation ring will run out and the ring will slip.
NOTE: Ensure the orientation ring has an adequate layer of grease around the circumference before starting operation.
12. Make at least 50 tool changes to test the spindle orientation.
ORIENTATION - VECTOR DRIVE
1. Place the machine in low gear.
2. Adjust Parameter 257, "SPINDL ORIENT OFSET", until the spindle dogs are parallel to the X-axis. Ensure that the dogs are within 0.030" using a dial indicator.
For 50 taper mills with an offset tool changer, add 5 degrees of offset (111 encoder steps) to Parameter 257 to match the tool changer arm offset.
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3.6 SETTING PARAMETER 64 (TOOL CHANGE OFFSET)
Please read this section in its entirety before attempting to set Parameter 64.
NOTE: Setting 7 must be "unlocked" before setting Parameter 64.
1. WITHOUT a tool in the spindle taper, initiate a tool change and stop the tool changer using the EMERGENCY STOP button (when the Z-axis moves above the carousel, but before the carousel rotates). Insert a tool holder into the pocket facing the spindle.
2. Using a .0005 indicator and suitable 18" mag base, zero off of bottom left edge A of tool holder (looking directly into pocket). Move indicator to bottom right edge B of tool holder. Any difference between these edges should be equally divided. For example: if a difference of .002 from left side to right side edge, adjust indicator dial so that indicator reads .001 when it is on either edge. This gives you the tool offset reference.
Figure 3.6-1 Checking tool offset reference.
3. Carefully (so as not to disturb relative position) move the indicator to one side. Remove tool from the tool changer and place it in the spindle.
4. Press Z SIGL AXIS to zero return the Z-axis only.
5. Carefully (so as not to disturb relative position) place indicator under spindle and indicate on bottom left edge of the tool holder.
If spindle head is too far in the negative (-) or the positive (+) direction, go to JOG mode and choose Z-axis. Jog Z-axis in the necessary direction until it reads zero (0).
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6. Push the help button twice. This will put the machine in the calculator mode.
Figure 3.6-2 Screen showing calculator.
7. Take the number in the Z-axis machine display (center left of page) and multiply it by Parameter 33, which is Z RATIO (STEPS/UNIT).
If Z-axis work display is negative (-), add the number to the number that you calculated to Parameter 64. If the number is positive (+), subtract it from Parameter 64.
8. To insert the calculated new number, place the cursor at Parameter 64, type in new number and push WRITE key. ZERO RET Z-axis to initialize the new Parameter 64.
9. Recheck the offset with the indicator (Steps 1-5).
10. Insert tool holder in spindle taper and initiate a tool change.
When the Parameter 64 is changed, the tool offsets must be reset.
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3.7 SPINDLE MOTOR & TRANSMISSION
Please read this section in its entirety before attempting to remove or replace transmission.
NOTE: The drive belt tension should be adjusted after every service on the transmis- sion or spindle.
MOTOR REMOVAL (VF-0)
1. Ensure the VMC is ON. You will need to raise and lower the head stock to remove the transmis- sion. At this time, raise the Z-axis to the full up position.
2. Remove the cover panels from head stock area ("Head Stock Removal" section).
3. Remove the tool release piston assembly ("Tool Release Piston Assembly" section).
4. Press the POWER OFF button on the control panel and turn the main breaker off. If there is an external breaker box, turn it off and lock it out.
5. Disconnect the air supply from the back panel of the machine.
6. Disconnect all of the electrical and pneumatic lines from the solenoid bracket on top of the spindle motor assembly. Mark any connections that have not been previously labeled for reassembly.
7. Remove the two SHCS holding the cable carrier to the solenoid bracket and position the cable carrier so as to not interfere with removal of the motor. It may be necessary to tie the cable carrier back to the Z-axis motor to keep it in place.
8. If machine is equipped with Through the Spindle Coolant option, remove the pressure regulator and bracket from the old transmission and install them on the new transmission.
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Figure 3.7-1 VF-0 with lifting eyeholes.
9. Remove the four SHCS and carefully lift the spindle motor assembly off the spindle head. Take care to not damage the drive pulley during removal.
NOTE: It is recommended that the HAAS Transmission Hoist be used in this operation (Refer to the "Hoist Pre-Assembly" section for assembly and setup).
INSTALLATION (VF-0)
1. Carefully lower the motor assembly down to just above the spindle head casting, taking care not to damage the drive pulley or pinch the drive belt.
2. Place the drive belt on the motor's drive pulley and lower the motor down onto the spindle head casting.
3. Insert and tighten down the four SHCS attaching the motor to the spindle head casting. Adjust the drive belt as noted in "Belt Assembly" before tightening down completely.
4. Refer to the appropriate section and set the spindle orientation.
5. Check for proper orientation of the machine and be aware of any unusual noises or vibration that may occur because of incorrect belt tension.
6. Reattach the cable carrier to the solenoid bracket and reconnect all electrical and fluid lines. Replace any leaking or damaged lines at this time, if necessary.
NOTE: Ensure the orient ring has an adequate layer of grease around the circumfer- ence before starting operation.
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HOIST PRE-ASSEMBLY
1. Attach the mast support to the support base, using the four 3/8-16 x 1" SHCS, four 3/8" flat washers, four split washers, and the four 3/8-16 hex nuts. Ensure the bolts are securely tightened.
2. Attach the boom modification plates to the mast using the three -13 x 4" HHB, three " split washers, three -13 hex nuts, and the three spacers.
Figure 3.7-2 Support base/mast support assembly.
Figure 3.7-3 Exploded view of boom modification plate components.
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3. Assemble the boom assembly as follows: A. Lubricate the components of the assembly:
1) Using a grease brush, apply grease to the through-hole and the side surface of the pulley wheel. 2) Wipe a thin coat of oil on the entire cable. 3) Lubricate all clevis pins with a thin layer of grease. 4) Oil all bearings on the winch and apply grease to the gear teeth.
B. Place the pulley wheel inside the cable guide and place this subassembly into the end of the boom. Ensure the clevis pin through-hole is toward the top of the boom and the rounded end of the cable guide is toward the outside. Slide the clevis pin through the hole and fasten with the 1/8" x 1" cotter pin. C. Attach the winch base to the boom with the two 3/8-16x1" SHCS, two 3/8" lock washers, and the two 3/8" hex nuts. See owner's manual for mounting of left-or right-handed operation. D. Feed the free end of the cable (without hook) between the pulley and cable guide and through the inside of the boom.
Figure 3.7-4 Mounting cable guide and pulley wheel to boom.
E. Attach the cable to the winch as follows: 1) FOR LEFT-HAND OPERATION - Pass the cable under the winch drum and through the hole in the drum flange. Form a loop of cable and securely anchor it in place using the tie-down clasp, carriage bolt, and hex nut. The cable must be underwound on the winch drum. 2) FOR RIGHT-HAND OPERATION - Pass the cable between the frame rod and the countershaft of the winch, over the winch drum, and through the hole in the drum flange. Form a loop of cable and securely anchor it in place using the tie-down clasp, carriage bolt, and hex nut. The cable must be over wound on the winch drum.
F. Ensure all hex nuts and cap nuts are securely tightened and all cotter pins are properly bent to secure them in place. Make sure all pivots and rotation points are well-lubricated and refer to the winch owner's manual for proper lubrication before operating.
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4. Place the transmission lift fixture on top of the transmission, with the rod at each end in the two lifting eyeholes of the transmission. Tighten the fixture onto the transmission by turning the handle at the end. Do not overtighten.
Figure 3.7-5 View of transmission lift fixture.
TRANSMISSION REMOVAL
NOTE: This procedure is not for VF-O.
1. Ensure the VMC is ON. You will need to raise and lower the head stock to remove the transmis- sion. At this time, raise the Z-axis to the full up position.
2. Remove the cover panels from head stock area ("Head Covers Removal" section).
3. If machine is equipped with the Through the Spindle Coolant option, remove the pressure regulator, check valve assembly, and bracket from the old transmission, so they can be installed later on new transmission.
4. Remove the tool release piston assembly ("Tool Release Piston" section).
5. Loosen the six SHCS holding the transmission to the head casting. Slide the transmission forward enough to release the drive belt from the transmission and spindle pulleys.
6. Press the POWER OFF button on the control panel and turn the main breaker off. If there is an external breaker box, turn it off and lock it up.
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7. Disconnect all electrical lines and air lines from the transmission solenoid bracket. Disconnect the electrical and oil lines from the oil pump. Plug the oil lines to prevent contamination. Most of the lines should be marked and identified. If not marked, do so as it is removed.
Figure 3.7-6 Solenoid bracket with all lines connected.
8. Remove the two SHCS holding the cable carrier to the solenoid bracket and position the cable carrier so as to not interfere with the transmission removal. It may be necessary to tie the cable carrier back to the Z-axis motor to keep it in place.
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9. Remove the protective cardboard from the mill table and install the support base assembly on the table, using the four SHCS, four " flat washers, and the four T-nuts.
CAUTION! Ensure the protective rubber pads on the bottom of the mounting base are in place and in good condition, or damage to the mill table may result.
Figure 3.7-7 Support base/mast support assembly location.
10. With the boom modification plate in place, insert the mast into the mast support. Using the two clevis pins, attach the boom to the mast.
Figure 3.7-8 Mounting boom assembly to mast.
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11. Place the hoist directly over the transmission and attach the hook to the cradle's eye bolt.
Figure 3.7-9 Fully assembled hoist in position
12. Remove the six SHCS holding the transmission to head casting. Raise the transmission, ensuring the hoist is being lifted in the locking position, clearing the enclosures. Swing the boom toward the front of the machine and lower onto the wood blocks.
Figure 3.7-10 Lifting position for VF-1 through 4.
13. For VF-1-4: Place the hoist hook in the bar's lifting eye and place the two hooks on either end of the bar into diagonally opposite lifting holes in the motor shroud. Lift just enough to ensure the hooks are seated properly, then carefully lift the motor and transmission assembly up enough to clear the VMC. Swing the boom toward the front of the machine and lower onto the wood blocks.
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TRANSMISSION INSTALLATION
1. If machine is equipped with Through the Spindle Coolant option, reinstall the pressure regulator, check valve assembly, and bracket. Install two cable ties on the replacement transmission as follows:
Place one cable tie around the limit switch cable. Place the second cable tie through the first one, forming a loop. Tighten the first cable tie. NOTE: The loop of the second cable tie must allow the drain line to slip through.
2. Place cradle under new transmission and lift just enough to put tension on the cables.
3. Ensure new transmission is seated securely and lift. Only lift high enough to clear the enclosure and to swing into place.
4. Slowly swing boom around to center the cradle and transmission over the spindle head.
NOTE: Inspect the gearbox isolators to ensure the spacer is flush with the bushing on the underside of the housing.
5. Lower the transmission carefully to just above the spindle head. Place the drive belt onto the transmission pulley.
6. Lower the transmission into the spindle head, taking care not to crush or bind the drive belt as you lower.
7. Insert and tighten down the six SHCS attaching the transmission to the spindle head. If these screws include gearbox isolators, ensure the 3/8" fender washer is NOT touching the gearbox housing.
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Figure 3.7-11 Gearbox isolators.
8. Adjust the drive belt tension as noted in "Belt Assembly" section before tightening screws down completely.
9. Reattach the cable carrier to the solenoid bracket and reconnect all electrical and fluid lines. Replace any leaking lines at this time, if necessary.
10. Fill the transmission.
NOTE: The hoist must be disassembled before removing from the mill table. Break down the hoist by removing the boom assembly, then the mast. It will not be necessary to completely break down the hoist after the first assembly.
NOTE: Ensure the positioning ring has an adequate layer of grease around the circumference before starting operation.
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TRANSMISSION AND MOTOR REPLACEMENT - 50 TAPER
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 extension 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.
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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). Use a universal swivel joint and hex-head socket for these SHCS.
12. Break loose the four large SHCS that attach the transmission mount plate to the spindle head. Remove the SHCS and set aside. Pull the transmission/motor assembly towards the front of the machine slightly. This will remove the tension on the drive belts.
13. Remove the Encoder belt and the drive belts.
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 plate using the removed SHCS.
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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.
14. Replace sheetmetal.
15. Set spindle orientation. Refer to the Spindle Orientation section.
16. Check Toolchanger function.
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3.8 AXIS MOTOR REMOVAL / INSTALLATION
Please read this section in its entirety before attempting to remove or replace the motors.
Tool Required
Z-Axis: Cylinder shaft stop (P/N 99-7562 - VF-0 through 4, P/N 93-9962 - VF-6 through 11)
X-AXIS MOTOR REMOVAL
1. Turn the VMC ON. ZERO RETURN all axes and put the machine in HANDLE JOG mode.
Figure 3.8-1 X-axis motor and components.
2. Move the table to the far left position. Loosen the SHCS and remove the right way cover.
3. Move the table to the far right position. Loosen the SHCS and remove the left way cover.
4. Remove the side enclosure panels.
5. On the motor housing, remove the four BHCS and remove the cover plate.
6. Loosen the SHCS on the motor coupling at the lead screw.
7. Turn the machine power OFF.
8. On the motor housing, loosen the four SHCS and remove the motor from the housing.
9. Disconnect all wiring from the motor.
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INSTALLATION -
1. Slide motor into motor housing, inserting the end of the lead screw in the motor coupling.
Figure 3.8-2 Motor coupling components.
2. Reinstall and tighten down the four SHCS that hold the motor to the housing.
3. Reconnect the motor wiring.
4. Visually inspect the coupler flex plates to ensure they are parallel to the coupling halves.
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 leadscrew or motor shaft.
Tighten the SHCS on the motor coupling at the lead screw. (Place a drop of blue Loctite on the screw before inserting.)
5. Replace the cover plate and fasten with the four BHCS.
6. Move the table to the far right position. Replace the left way cover with the SHCS.
7. Move the table to the far left position. Replace the right way cover with the SHCS.
8. Reinstall the side enclosures.
9. Check for backlash in the X-axis lead screw (Troubleshooting section) or noisy operation.
10. Zero X axis and set grid offset.
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Y-AXIS MOTOR REMOVAL
1. Turn the machine power ON. ZERO RETURN all axes and put the machine in HANDLE JOG mode.
2. Move the table to the farthest forward position. Using a 5/32" hex wrench, remove the SHCS on the way cover at the rear of the saddle.
3. Slide the way cover back against the machine. Remove the two roller brackets from the base. Pull the way cover forward and off of the base.
4. If the bearings are to be serviced, move the table to the rear of its travel and remove the SHCS holding the front way covers to the saddle. Slide the way cover to the forward position.
Figure 3.8-3 Y-axis motor and components.
REMOVING LUBE / AIR PANEL -
5. Turn the machine off and disconnect all air lines to panel.
6. Disconnect the spindle air/lube line.
7. Using a 3/8" open-end hex wrench, disconnect the oil line connecting the base to the lubrication system panel.
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8. Disconnect the two air lines from the panel (quick-disconnect fittings) by hand.
9. Disconnect the three connections labeled 'limit switches' and remove the cords from the panel.
10. Disconnect the limit switch connection and the Y-axis connection at the side of the control panel.
11. While holding the lube/air panel assembly at the bottom edge, loosen the two SHCS and remove the panel assembly.
CAUTION! On machines with only two SHCS, remove one screw at a time. Replace the screw to hold the cabinet in place before removing the other screw. Failure to do this will result in damage to the cabinet.
12. On the motor housing, remove the four BHCS and remove the cover plate.
13. Loosen the SHCS on the motor coupling at the lead screw.
14. On the motor housing, loosen the 4 SHCS, remove all wiring from the motor and remove the motor from the housing.
Figure 3.8-4 Lube/Air Panel.
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June 2001
INSTALLATION -
1. Slide motor into motor housing, inserting the end of the lead screw in the motor coupling.
2. Replace and tighten down the four SHCS that hold the motor to the housing and reconnect the cables to the motor.
3. Visually inspect the flex plates to ensure they are parallel to the coupling halves.
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 leads screw or motor shaft.
Tighten the SHCS on the motor coupling at the lead screw. (Place a drop of blue Loctite on the screw before inserting.)
4. Replace the cover plate and fasten with the four BHCS.
5. Replace the lube system panel with the two SHCS that mount it.
6. Plug in the limit switch connection and Y-axis connection at the side of the control panel.
7. Reconnect the three connections labeled "limit switches" to the panel.
8. Reconnect the two air lines to the panel, and the solenoid to the front of the panel.
9. Reconnect the oil line that connects the lube system panel to the base.
10. If the front way cover was removed, slide it back into position, and replace the SHCS that holds it to the saddle.
11. Move the table to the fully forward position. Replace the rear way cover.
12. Replace the two roller brackets onto the base.
13. Slide the way cover back into place, and attach to the saddle with the SHCS.
14. Check for backlash in the Y-axis lead screw (Troubleshooting section) or noisy operation.
15. Zero return the Y axis and set grid offset according to section.
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June 2001
Z-AXIS MOTOR REMOVAL
Machines are currently equipped with either a hydraulic counterbalance system or an electric brake motor. Care must be taken, in either case, to avoid damaging the machine or severely injuring yourself. Heed all warnings and cautions and read all the steps of the procedure before starting any disassembly.
WARNING! MACHINES WITHOUT A COUNTER BALANCE
If debug is on and the Z -axis is disabled the spindle head will fall. This is extremely dangerous and should be avoided at all costs.
CAUTION! Always block the hydraulic cylinder with shaft stop block before servicing any Z-axis components.
1. Turn the machine power ON. Zero return (ZERO RET) all axes and put the machine in HANDLE JOG mode.
2. Loosen the six SHCS that attach the rear head cover to the side covers, and remove from the spindle head.
NOTE: If machine is equipped with a hydraulic counterbalance, remove entire spindle head cover for VF-O/OE/1/2, VCE 500/550/700/750, or right side spindle head cover for VF-3/4, VCE 1000/1250.
3. Remove the SHCS attaching the Z-axis way cover to the spindle head and slide the cover to the bottom position. VF 0-4 remove the rear spindle head cover.
4. Lower the spindle head to its lowest position.
5. a. If the machine is equipped with a hydraulic counterbalance, install cylinder shaft stop (See Fig. 3.8-6). HANDLE JOG Z-axis up until shaft stop blocks axis.
b. Machine with Brake motors: Position table under the spindle head and insert a 4 x 4 x 14 wood block under the spindle head and lower head casting on to it. Emergency stop the machine.
6. At the motor housing, loosen the four BHCS and remove the cover plate.
7. Visually check the motor coupling. Align the coupler so that SHCS on the lead screw can be easily accessed. This can be done by turning the ball screw manually.
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Way Cover
Lead Screw Support Bearing
Nut Housing
Motor Housing
Motor
Figure 3.8-5 Z-axis motor and components.
Figure 3.8-6 Z-axis motor and components for machines equipped with hydraulic counterbalance.
8. Disconnect electrical power. Caution: If the machine is equipped with a Z-axis brake motor the spindle head may drop slightly.
9. On the motor housing, loosen the four SHCS and remove the motor from the housing.
10. Disconnect the Z-axis connection from the control panel.
11. Remove cableing from the motor.
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INSTALLATION -
1. Slide motor into motor housing, inserting the end of the lead screw in the motor coupling.
2. Replace and tighten down the four 5/16-18 x 1" SHCS that hold the motor to the housing and connect cables to the motor.
3. Visually inspect the flex plates to ensure they are parallel to the coupling halves.
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 leads screw or motor shaft.
Tighten the SHCS on the motor coupling at the lead screw. (Place a drop of blue Loctite on the screw before inserting.)
4. Replace the cover plate and fasten with the four BHCS.
5. Reconnect electrical power.
6. Remove shaft stop, if necessary.
7. If the front way cover was removed, slide it back into position, and replace the 10-32x3/8" SHCS that holds it to the saddle.
8. Move the table to the fully forward position. Replace the rear way cover.
9. Replace the two roller brackets onto the base.
10. Slide the way cover back into place, and attach to the saddle with the 10-32x3/8" SHCS.
11. Check for backlash in Z-axis lead screw (Troubleshooting section), or noisy operation.
12. Zero return Z axis and set grid offset and parameter 64 (section 3.6).
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June 2001
COUPLER REPLACEMENT
WARNING! MACHINES WITHOUT A COUNTER BALANCE
If debug is on and the Z -axis is disabled the spindle head will fall. This is extremely dangerous and should be avoided at all costs.
1. Remove the axis motor in accordance with "Axis Motor Removal/Installation" section.
2. Loosen the 10-32 x " SHCS on the two coupling rings and remove the coupling.
3. For installation: 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 leads screw or motor shaft.
Tighten the SHCS on the motor coupling at the lead screw. (Place a drop of blue Loctite on the screw before inserting.)
4. Reinstall the axis motor.
Figure 3.8-7 Motor coupling.
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3.9 LEAD SCREW REMOVAL AND INSTALLATION
Please read this section in its entirety before attempting to remove or replace the lead screws.
TOOLS REQUIRED
Spanner wrench (32 mm or 40/50 mm) 2" x 4" wood block (21"-231/ 2 " long)
Shaft lock (32 mm or 40/50 mm) Torque tester
Z-Axis: Cylinder shaft stop (P/N 99-7562 - VF-O through 4, P/N 93-9962 - VF-6 through 10)
NOTE: Certain steps in the following procedures apply only to 40 and 50 mm lead screws.
X-AXIS LEAD SCREW REMOVAL
1. Turn the machine ON. ZERO RETURN all axes and put the machine in HANDLE JOG mode.
2. Remove the side enclosures.
3. Loosen the SHCS and remove the chip tray from the mill table.
4. Jog the table to the far right position. Loosen the SHCS and remove the right way cover.
5. Jog the table to the far left position. Loosen the SHCS and remove the left way cover.
6. If applicable, remove the hard stop from the bearing housing on the lead screw.
Figure 39-1. X-axis lead screw and components.
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7. Disconnect the oil line from the ball nut.
8. Loosen the 10-32 x " SHCS and remove the clamp nut on the lead screw support bearing end.
Figure 3.9-2 Lead screw assembly.
9. Remove the axis motor in accordance with "X-Axis Motor Removal".
NOTE: The motor's electrical connections do not need to be removed for this operation. After removing motor from the housing, set it to one side.
10. Loosen the 10-32 x " SHCS and remove the clamp nut on the lead screw in the motor housing.
11. For 32 mm lead screws: Loosen the six -20 x 1" SHCS and remove the bearing sleeve from the motor housing. Push on the mill table or the opposite end of the lead screw to loosen. Push the mill table towards the motor end until the lead screw clears the bearing support. Remove the SHCS from the ball nut and remove the lead screw by pulling from the bearing support end.
CAUTION! Do not pry the bearing sleeve away from the housing. Damage to the sleeve, bearing, or lead screw will result.
For 40 and 50 mm lead screws: Loosen the SHCS that mount the bearing support to the saddle, and remove. Remove the pull pins from the bearing support. Loosen the five SHCS in the ball nut and remove the lead screw by pulling from the bearing support end.
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THIS PROCEDURE ASSUMES THAT THE NUT AND MOTOR HOUSING WILL NOT BE REMOVED.
INSTALLATION -
1. Center the mill table on the saddle.
2. 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.
3. Insert the lead screw through the nut housing and motor housing (See Fig. 3.9-3), taking care not to make contact with the screw threads, which will cause possible damage.
Figure 3.9-3 Install lead screw from right side.
4. If 40 or 50 mm lead screw: Mount the bearing support to the saddle with six SHCS, but do not tighten completely. Replace the pull pins in the bearing support. Install the spacer ring on the motor end of the lead screw. Insert the 5/16-18 x 3/4" (or M10 x 25 mm) SHCS, attaching the ball nut to the nut housing, but do not tighten completely. (Place a drop of blue Loctite on each of the SHCS before inserting.). Skip to Step 8.
5. Place the bearing sleeve in the motor housing as shown. (It may be necessary to align the bear- ings in the sleeve to facilitate mounting on the lead screw.)
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Figure 3.9-4 Bearing sleeve mounting location.
6. Insert the six -20 x 1" SHCS attaching the bearing sleeve to the motor housing. (Place a drop of blue Loctite on each of the SHCS before inserting.) Tighten to torque specification.
CAUTION! Do not use more than one drop of Loctite. An excessive amount will cause a film between the sleeve and housing, which could result in backlash.
7. Move mill table as far right as possible. Insert, but DO NOT TIGHTEN, the five -20 x 1" (or -20 x ") SHCS attaching the ball nut to the nut housing. (Place a drop of blue Loctite on each of the SHCS before inserting.)
CAUTION! Do not run mill table pads past the end of the linear guides! If this occurs, cease all operations and contact the manufacturer at once.
8. The following sequence is important to ensure proper installation of the lead screw: Tighten the clamp nut, hand tight, on the motor end. Install and tighten clamp nut on bearing support. Ensure the nut does not touch the support bearing. Install the shaft lock onto the bearing support end of the lead screw. This will keep the lead screw from turning while torquing the clamp nut. Place a spanner wrench on the clamp nut at the motor end of the assembly. Torque the clamp nut to 15 FT-LBS.
NOTE: The 40/50 mm leadscrew clamp nut should be torqued to 50 FT-LBS.
Tighten the clamp nut screw and mark with yellow paint on motor support end. Remove the shaft lock. Torque support mounting bolts to proper specifications. Loosen the clamp nut screw and clamp nut at the bearing support end and tighten to 4 IN-LBS against the bearing. Retighten the clamp screw.
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June 2001
9. For 40 and 50 mm lead screws only: Move the table all the way to the right. Tighten down completely the SHCS that mount the bearing support to the saddle. Loosen the clamp nut on the bearing support end. Adjust the nut until it seats on the bearing. Retighten the clamp nut hand-tight, then 1/8 turn more (If you have a torque screwdriver, torque the clamp nut to 4 in-lbs).
10. Reinstall the motor according to "Axis Motor Removal and Installation".
11. Torque the SHCS attaching the ball nut to the nut housing.
12. Reconnect oil line to the ball nut
13. Check lead screw torque at bearing support end with torque tester. Jog the table all the way to the right. Check the lead screw torque again. It should be the same as the previous reading.
14. Reinstall the way covers and chip tray. If applicable, replace the hard stop.
15. Check for backlash in the lead screw ("Accuracy/Backlash" section) or noisy operation.
16. Zero return X axis and set grid offset.
MECHANICAL SERVICE
150 96-8100 rev C
June 2001
Y-AXIS LEAD SCREW REMOVAL
1. Turn the machine ON. ZERO RETURN all axes and put the machine in HANDLE JOG mode.
2. If applicable, remove the hard stop from the lead screw support bearing end of the lead screw.
3. Disconnect the oil line at the ball nut.
4. Loosen the 10-32 x " SHCS and remove the clamp nut on the lead screw bearing support end.
Figure 3.9-5 Y-axis lead screw and components.
5. Remove the motor in accordance with "Y-Axis Motor Removal".
NOTE: The motor's electrical connections do not need to be removed for this operation. After removing motor from the housing, set it to one side.
6. Loosen the 10-32 x 1/2" SHCS and remove the clamp nut on the lead screw in the motor housing.
7. For 32 mm lead screws: Loosen the six -20 x 1" SHCS and remove the bearing sleeve from the motor housing. Push on the mill table or the opposite end of the lead screw to loosen.
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CAUTION! Do not pry the bearing sleeve away from the housing. Damage to the sleeve, bearing, or lead screw will result.
Remove the five SHCS attaching the ball nut to the nut housing. Hand-turn the lead screw toward the rear of the machine until the front end of the lead screw clears the bearing by approximately six inches (6"). Carefully pull the lead screw forward, to the right of the support bearing, under the front way cover until the rear of the lead screw clears the nut housing. Shift the rear end of the lead screw to the right side of the nut housing and move the lead screw to the rear of the machine until it clears the front way cover. Remove lead screw from the machine.
For 40 and 50 mm lead screws:
Loosen the SHCS that mount the bearing support to the saddle, and remove. Remove the pull pins from the bearing support. Loosen the five SHCS in the ball nut and remove the lead screw by pulling from the bearing support end.
Figure 3.9-6 Pull lead screw forward around bearing support,...
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...push back into the machine, then pull out forward.
THIS PROCEDURE ASSUMES THAT THE NUT AND MOTOR HOUSING WILL NOT BE REMOVED.
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. Slide the motor end of the lead screw under the saddle, taking care not to damage the screw threads. Position the lead screw to the right side of the nut housing and slide toward the rear of the machine as far as it will go.
3. Pull the lead screw forward until it is against the front way covers. Place the motor end of the lead screw through the nut housing and push the lead screw toward the back of the machine until the ball nut is seated in the nut housing.
4. If 40 or 50 mm lead screw: Mount the bearing support to the saddle with six SHCS, but do not tighten completely. Replace the pull pins in the bearing support. Install the spacer ring on the motor end of the lead screw. Insert the 5/16-18 x 3/4" (or M10 x 25 mm) SHCS, attaching the ball nut to the nut housing, but do not tighten completely. (Place a drop of blue Loctite on each of the SHCS before inserting.). Skip to Step 8.
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5. Place the bearing sleeve in the motor housing as shown. (It may be necessary to align the bear- ings in the sleeve to facilitate mounting on the lead screw.)
6. Insert the six -20 x 1" SHCS attaching the bearing sleeve to the motor housing. (Place a drop of blue Loctite on each of the SHCS before inserting.) Tighten to torque specifications.
CAUTION! Do not use more than one drop of Loctite. An excessive amount will cause a film between the sleeve and housing, which could result in backlash.
7. Move mill table as far forward as possible. Insert, but DO NOT TIGHTEN, the five 1/4-20 x 1" (or 1/ 4-20 x 3/4") SHCS attaching the ball nut to the nut housing. (Place a drop of blue Loctite on each of the SHCS before inserting.)
CAUTION! Do not run mill table pads past the end of the linear guides! If this occurs, cease all operations and contact the manufacturer at once.
8. The following sequence is important to ensure proper installation of the lead screw: Tighten the clamp nut, hand tight, on the motor end. Install and tighten clamp nut on bearing support. Ensure the nut does not touch the support bearing. Install the shaft lock onto the bearing support end of the lead screw. This will keep the lead screw from turning while torquing the clamp nut. Place a spanner wrench on the clamp nut at the motor end of the assembly. Torque the clamp nut to 15 FT-LBS.
NOTE: The 40/50 mm leadscrew clamp nut should be torqued to 50 FT-LBS.
Tighten the clamp nut screw and mark with yellow paint. Remove the shaft lock. Torque support mounting bolts to proper specifications. Loosen the clamp nut screw and clamp nut at the bearing support end and tighten to 4 IN-LBS. against the bearing. Retighten the clamp screw.
9. Move the mill table to the far back position (motor end). Tighten down completely the five SHCS attaching the ball nut to the nut housing.
10. For 40 and 50 mm lead screws only: Move the table all the way forward. Tighten down completely the SHCS that mount the bearing support to the base. Loosen the clamp nut on the bearing support end. Adjust the nut until it seats on the bearing. Retighten the clamp nut hand-tight, then 1/8 turn more (If you have a torque screwdriver, torque the clamp nut to 4 in-lbs).
11. Reinstall the motor according to "Axis Motor Removal and Installation". If applicable, replace the hard stop from the lead screw support bearing end of the lead screw.
12. Reconnect oil line to the ballnut.
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13. Check lead screw torque at bearing support end with torque tester. Jog the table all the way to the front. Check the lead screw torque again. It should be the same as the previous reading.
14. Check for backlash in the lead screw ("Accuracy/Backlash" section) or noisy operation.
15. Zero return Y axis and set grid offset.
Z-AXIS LEAD SCREW REMOVAL
Machines are currently equipped with either a hydraulic counterbalance system or an electric brake motor. Care must be taken, in either case, to avoid damaging the machine or severely injuring yourself. Heed all warnings and cautions, and read all the steps of the procedure before starting any disassembly.
WARNING!
IF THE MACHINE IS EQUIPPED WITH A HYDRAULIC CYLINDER, A SHAFT STOP BLOCK MUST BE USED TO SECURE THE SPINDLE HEAD.
DO NOT MOVE THE SPINDLE DURING LEAD SCREW SERVICE.
WARNING! MACHINES WITHOUT A COUNTER BALANCE
If debug is on and the Z -axis is disabled the spindle head will fall. This is extremely dangerous and should be avoided at all costs.
1. Turn the machine ON. ZERO RETURN all axes and put the machine in HANDLE JOG mode.
2. Loosen the six SHCS that attach the rear cover to the side covers, and remove from the spindle head. Remove the three SHCS attaching the Z-axis way cover to the spindle head and slide the cover to the bottom position.
3. a. Machines with hydraulic counter balance cylinders: Lower the spindle head to its lowest position. Install cylinder shaft stop. Handle jog Z-axis up until the shaft stop blocks the axis.
b. Machine with Brake motors: Remove the rear Y-axis way cover and brace the spindle head up with a 4 x 4 x 14 block of wood.
4. Disconnect electrical power.
5. If applicable, remove the hard stop from the bearing housing on the lead screw.
6. Disconnect the oil line at the ball nut.
7. Loosen the 10-32 x " SHCS and remove the clamp nut on the lead screw support bearing end.
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8. Remove the axis motor in accordance with "Z-Axis Motor Removal".
NOTE: The motor's electrical connections do not need to be removed for this operation. After removing motor from the housing, set it to one side.
9. Loosen the 10-32 x " SHCS and remove the clamp nut on the lead screw in the motor housing.
10. For 32 mm lead screws: Loosen the six -20 x 1" SHCS and remove the bearing sleeve from the motor housing. Push on the opposite end of the lead screw to loosen.
CAUTION! Do not pry the bearing sleeve away from the housing. Damage to the sleeve, bearing, or lead screw will result.
Hand-turn the lead screw to move the screw up until the bottom end clears the support bearing by approximately six inches (6"). Remove the SHCS from the ball nut and lower the lead screw down and to the right of the support bearing, past the Z-axis way cover. For the VF-6, remove the lead screw from top of column.
CAUTION! Do not damage the threads on the lead screw.
For 40 and 50 mm lead screws: Loosen the SHCS that mount the bearing support to the column, and remove. Remove the pull pins from
the bearing support. Loosen the five SHCS in the ball nut and remove the lead screw by pulling from the bearing support end.
Figure 3.9-7 Z-axis lead screw and components.
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156 96-8100 rev C
June 2001
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. If 40 or 50 mm lead screw: Insert the lead screw into the bearing support. Screw the clamp nut on a few turns. Insert the lead screw, with the bearing support attached, into place on the column. Ensure the lead screw goes through the ball nut housing and the bearing sleeve. Mount the bearing support to the column with SHCS, but do not tighten completely. Replace the pull pins in the bearing support. Install the spacer ring on the motor end of the lead screw. Hand-turn the ball nut until it comes into contact with the nut housing mounting surface. If necessary, turn the leadscrew to correctly position lube fitting of the ball nut. Insert, but DO NOT TIGHTEN, the 5/16-18 x 3/4" (or M10 x 25 mm) SHCS, attaching the ball nut to the nut housing. (Place a drop of blue Loctite on each of the SHCS before inserting.) Skip to Step 7.
3. Slide the lead screw up into the nut housing and gently lower it until it is resting in the support bearing.
Figure 3.9-8 Reinstalling the lead screw.
4. Place the bearing sleeve in the motor housing as shown. (It may be necessary to align the bear- ings in the sleeve to facilitate mounting on the lead screw.)
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5. Insert the six -20 x 1" SHCS attaching the bearing sleeve to the motor housing. (Place a drop of blue Loctite on each of the SHCS before inserting.) Tighten down completely.
CAUTION! Do not use more than one drop of Loctite. An excessive amount will cause a film between the sleeve and housing, which could result in backlash.
6. Hand-turn the ball nut until it comes into contact with the nut housing mounting surface. If neces- sary, turn the leadscrew to correctly position lube fitting of the ball nut. Insert, but DO NOT TIGHTEN, the five -20 x 1" (or -20 x ") SHCS attaching the ball nut to the nut housing. (Place a drop of blue Loctite on each of the SHCS before inserting.)
7. The following sequence is important to ensure proper installation of the lead screw: Tighten the clamp nut, hand tight, on the motor end. Install and tighten clamp nut on bearing support. Ensure the nut does not touch the support bearing. It will be used to hold the lead screw while the other end is tightened. Install the shaft lock onto the bearing support end of the lead screw. This will keep the lead screw from turning while torquing the clamp nut. Place a spanner wrench on the clamp nut at the motor end of the assembly. Torque the clamp nut to 15 FT-LBS.
NOTE: The 40/50 mm leadscrew clamp nut should be torqued to 50 FT-LBS.
Tighten the clamp nut screw and mark with yellow paint. Remove the shaft lock. Torque support mounting bolts to proper specifications. Loosen the clamp nut screw and clamp nut at the bearing support end and tighten to 4 IN-LBS (32 mm lead screws) against the bearing. Retighten the clamp screw.
8. Tighten down completely the five SHCS attaching the ball nut to the nut housing.
9. Reinstall the motor according to "Z-Axis Motor Removal and Installation". Reinstall the hard stop at the support bearing end of the lead screw.
10. Reconnect the oil line to the ball nut.
11. Reconnect electrical power.
12. a. Machines with counterbalances: Jog the spindle down and remove the cylinder shaft stop.
b. Machines with brake motors: Jog the spindle up slightly, just above the block of wood and push Emergency stop. Watch to see if the spindle head drops. If it does, check motor installation and electrical connections, and make proper repair.
13. For 40 and 50 mm lead screws only: Jog the spindle head towards the bearing support end. Tighten down completely the SHCS that mount the bearing support to the column. Loosen the clamp nut on the bearing support end. Adjust the nut until it seats on the bearing. Retighten the clamp nut hand-tight, then torque the clamp nut to 10 ft-lbs).
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14. Check lead screw torque at bearing support end with torque tester. Jog the spindle head to its highest position. Check the lead screw torque again. It should be the same as the previous reading.
15. Check for backlash in the lead screw ("Accuracy/Backlash" section) or noisy operation.
16. Zero return Z axis and set grid offset and parameter 64 (section 3.6).
MINI MILL LEAD SCREWS
Replacement of the mini-mill leadscrews follow the same procedures as the other mills. The leadscrews are only supported at the motor end, thereby simplifing the alignment procedure.
1. Use a standard ballscrew support bearing assembly to prevent the leadscrew for sagging, and to allow the use of the shaft lock for tightening the clamp nut at the motor end. Use only one screw to fasten the support bearing assembly (no dowel pins are necessary) to prevent it from rotating while the shaft lock is in place and tighten the clamp nut at the motor end.
2. Remove the fastener from the support bearing assembly to allow it to float on its support surface. Position the leadscrew nut toward the motor end to allow it to self align to the motor housing bearing assembly.
3. Tightening the five screws to the nut housing.
4. Install the leadscrew bumpers.
5. Install the shaft lock on the clamp nut at the motor end and allow it to wedge itself in the coupler cavity. Torque the clamp nut to 15 ft-lbs.
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June 2001
3.10 BEARING SLEEVE REMOVAL AND INSTALLATION
Please read this section in its entirety before attempting to remove or replace the bearing sleeve.
TOOLS REQUIRED Spanner wrench Pre-load fixture Wood block (16" long) Z-Axis: Cylinder shaft stop (P/N 99-7562 - VF-0 through 4, P/N 93-9962 - VF-6 through 10)
NOTE: For machines equipped with 40 or 50 mm lead screws, the lead screw must be removed in order to remove the bearing sleeve. Refer to the "Lead Screw Removal/Installation" section for instructions.
X-AXIS BEARING SLEEVE REMOVAL
1. Turn the VMC ON. ZERO RETURN all axes and put the machine in HANDLE JOG mode.
Figure 3.10-1 X-axis lead screw and components.
2. Loosen the SHCS and remove the chip tray from the mill table.
3. Jog the table to the left and remove the right way cover
4. Remove the axis motor in accordance with "X-Axis Motor Removal".
NOTE: The motor's electrical connections do not need to be removed for this operation. After removing from the motor housing, set it to one side.
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5. Loosen the 10-32 x " SHCS and remove the clamp nut on the lead screw in the motor housing.
6. Loosen the six -20 x 1" SHCS and remove the bearing sleeve from the motor housing. Push on the mill table or the opposite end of the lead screw to loosen.
CAUTION! Do not pry the bearing sleeve away from the housing. Damage to the sleeve, bearing, or lead screw will result.
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. Move mill table to the far right.
3. Place the bearing sleeve in the motor housing as shown. (It may be necessary to align the bear- ings in the sleeve to facilitate mounting.)
Figure 3.101-2 Lead screw assembly.
4. Insert the six -20 x 1" SHCS, attaching the bearing sleeve to the motor housing. (Place a drop of blue Loctite on each of the SHCS before inserting.) Tighten down completely.
CAUTION! Do not use more than one drop of Loctite. An excessive amount will cause a film between the sleeve and housing, which could result in backlash.
MECHANICAL SERVICE
16196-8100 rev C
June 2001
5. Start the clamp nuts on both ends of the lead screw. Do not tighten.
6. Hand-turn the mill table to the far left position.
7. Loosen the six -20 x 1" SHCS attaching the bearing sleeve to the motor housing and retighten completely. DO NOT SKIP THIS STEP. It ensures the lead screw is installed and runs parallel and flat to the linear guides and the saddle.
NOTE: For the angular contact design bearing, no pre-load is necessary. Do the following:
Tighten the clamp nut on the motor housing to 15 foot-pounds. Tighten the SHCS on the clamp nut. Tighten the clamp nut on the support bearing end of the lead screw until it contacts the bearing, then tighten further approximately 1/8 of a turn. Tighten the SHCS on the clamp nut.
8. Reinstall the axis motor in accordance with "X-Axis Motor Removal".
9. Reinstall the way covers and chip tray.
10. Check for backlash in the X-axis lead screw (Troubleshooting section) or noisy operation.
11. Zero X axis and set grid offset.
Y-AXIS BEARING SLEEVE REMOVAL
1. Turn the VMC ON. ZERO RETURN all axes and put the machine in HANDLE JOG mode.
2. Remove the axis motor in accordance with "Y-Axis Motor Removal".
3. Remove the hard stop from the bearing housing on the lead screw.
4. Loosen the 10-32 x " SHCS and remove the clamp nut from the bearing support end of the lead screw.
5. Loosen the six -20 x 1" SHCS and remove the bearing sleeve from the motor housing. Push on the mill table or the opposite end of the lead screw to loosen.
CAUTION! Do not pry the bearing sleeve away from the motor housing. Damage to the sleeve, bearing, or the lead screw will result.
MECHANICAL SERVICE
162 96-8100 rev C
June 2001
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. Slide the bearing sleeve into the motor housing and start all six -20 x 1" SHCS into the motor housing. (Place a drop of blue Loctite on each of the SHCS before inserting.)
CAUTION! Do not use more than one drop of Loctite. An excessive amount will cause a film between the sleeve and housing, which could result in backlash.
3. Move the table to the rear of its travel.
4. Tighten the six -20 x 1" SHCS that attach the bearing sleeve to the motor housing.
5. Loosely install the clamp nut on the lead screw at the motor housing end
NOTE: For the angular contact design bearing, no pre-load is necessary (follow the procedure in "X-axis bearing sleeve" section).
6. Reinstall the axis motor.
7. Check for backlash in the Y-axis lead screw (Troubleshooting section) or noisy operation.
8. Zero Y axis and set grid offset.
MECHANICAL SERVICE
16396-8100 rev C
June 2001
Z-AXIS BEARING SLEEVE REMOVAL
WARNING!
ALWAYS BLOCK THE HYDRAULIC CYLINDER WITH SHAFT STOP BLOCK BEFORE SERVICING ANY Z-AXIS COMPONENTS.
1. Turn the machine power ON. Zero return (ZERO RET) all axes and put the machine in HANDLE JOG mode.
2. Loosen the six SHCS that attach the rear cover to the side covers, and remove from the spindle head.
NOTE: If machine is equipped with a hydraulic counterbalance, remove entire spindle head cover for VF-0/OE/1/2, VCE 500/550/700/750, or right side spindle head cover for VF-3/4, VCE 1000/1250.
3. If the bearings are to be serviced, remove the three SHCS attaching the Z-axis way cover to the spindle head and slide the cover to the bottom position.
4. Remove the hard stop from the bearing housing on the lead screw.
5. Loosen the 10-32 x " SHCS and remove the clamp nut from the bearing support end of the lead screw.
6. Raise the spindle head until the bottom edge is approximately sixteen inches (16") above the mill table.
7. Install cylinder shaft stop. HANDLE JOG Z-axis up until shaft stop block axis.
8. Place the wood block beneath the spindle head and lower the spindle head until it is resting on the block.
MECHANICAL SERVICE
164 96-8100 rev C
June 2001
Figure 3.10-3 Z-axis bearing sleeve.
9. Perform Steps 6-10 of "Z-Axis Motor Removal".
NOTE: The motor's electrical connections do not need to be removed for this operation. After removing from motor housing, set it to one side.
10. Loosen the 10-32 x " SHCS and remove the clamp nut from the motor housing end of the lead screw.
11. Loosen the six -20 x 1" SHCS and remove the bearing sleeve from the motor housing. Hand-turn the lead screw in an upward direction to push the bearing sleeve out of the motor housing.
CAUTION! Do not pry the bearing sleeve away from the motor housing. Damage to the sleeve, bearing, or the lead screw will result.
MECHANICAL SERVICE
16596-8100 rev C
June 2001
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. Slide the bearing sleeve into the motor housing and start all six -20 x 1" SHCS into the motor housing. (Place a drop of blue Loctite on each of the SHCS before inserting.)
CAUTION! Do not use more than one drop of Loctite. An excessive amount will cause a film between the sleeve and housing, which could result in backlash.
3. Tighten the six -20 x 1" SHCS that attach the bearing sleeve to the motor housing.
4. Loosely install the clamp nut on the lead screw at the motor housing end.
5. Reinstall the hard stop on the bearing housing end of the lead screw.
NOTE: For the angular contact design bearing, no pre-load is necessary. Follow the procedures as outlined in "X-Axis Bearing Sleeve" section.
6. Reinstall the axis motor in accordance with "Z-Axis Motor-Installation".
7. Remove shaft stop.
8. Check for backlash in the Z-axis lead screw (Troubleshooting section) or noisy operation.
9. Zero return Z axis and set grid offset and parameter 64 according to section 3.6.
MECHANICAL SERVICE
166 96-8100 rev C
June 2001
3.11 AUTOMATIC TOOL CHANGER
1. Toolchanger Trap Door
2. Loc Nut Elastic
3. Washer
4. Nylon Washer
5. Vertical Axle
6. 2 Pin Geneva Star
7. Bearing Housing
8. Extractor Key
9. Extractor Spring
10. Extractor Finger
11. 20 Pocket Carousel
12. Toolchanger Door Spring
13. Sliding Panel
14. Sliding Panel Cover
15. Number Ring
16. Cap, Toolchanger
MECHANICAL SERVICE
16796-8100 rev C
June 2001
CARRIAGE CASTING REPLACEMENT
TOOLS REQUIRED Two-jaw puller Hydraulic jack 1-2-3 Block Cardboard
NOTE: If the carriage casting is damaged in a crash, it must be replaced. Look specifically for broken bosses where the roller bolts mount to the casting. If the carriage casting is broken off of the holding plate but not damaged, only the roller bolts need be replaced.
1. Turn the machine power off.
2. Remove the left side enclosure panel of the machine.
3. Disconnect all cables from the carriage casting and remove any bolts holding the ATC to the holding plate.
NOTE: If the carriage casting has been damaged, replacement is necessary; move the ATC to a bench and remove all components from the damaged carriage casting and place in the new casting. Skip to Step 6 for replacement.
4. Place a piece of cardboard over the machine's table, and carefully lower the carriage casting (with carousel) onto the machine table.
5. If the carriage casting has crashed and/or has been broken off of the holding plate, it should be inspected for damage before going any further.
6. Remove any damaged roller bolts from the carriage casting. Replace with new bolts.
7. With a lifting device, carefully lift the ATC assembly up and onto the holding plate.
NOTE: Ensure the cam follower on the slip clutch engages the slot on the carriage casting.
8. With the ATC assembly securely supported, install the lower roller bolts and adjust in accordance with "Roller Bolt Replacement".
9. Repair or replace any cables damaged and adjust the ATC. Align the ATC assembly in accordance with the following sections, and set Parameter 64 in accordance with "Spindle Motor and Transmis- sion" section.
MECHANICAL SERVICE
168 96-8100 rev C
June 2001
ROLLER BOLT REPLACEMENT
1. Remove the shuttle motor cover from the back of the machine (VF-0, VF-1, VF-2).
2. Place a support under the center of the carousel.
3. Loosen the eccentric locks on the bottom roller bolts.
CAUTION! Ensure the ATC is securely supported, otherwise it may fall when an upper roller bolt is removed.
4. Carefully remove the damaged roller bolt from the ATC shuttle and replace with a new bolt.
NOTE: REPLACE ONLY ONE ROLLER BOLT AT A TIME. Carefully inspect the V-groove rollers for roughness or damage, and replace if necessary.
5. Tighten the eccentric locks on the bottom rollers until there is no play between the rollers and the V-guide on the ATC holding plate.
6. Set the tool change offset (Parameter 64) in accordance with "Setting Parameter 64" section.
7. Verify the ATC alignment in accordance with the following section.
8. Reinstall the shuttle motor cover (VF-0, VF-1, VF-2).
MECHANICAL SERVICE
16996-8100 rev C
June 2001
AUTOMATIC TOOL CHANGER (ATC) ALIGNMENT
1. Verify that the spindle orientation is correct (Refer to appropriate section).
2. Command an automatic tool change, and press EMERGENCY STOP when the shuttle is in the full in position.
3. Verify that the spindle dog lines up to the alignment key in the ATC, in the Y plane.
NOTE: If the spindle dog and alignment key do not line up, loosen the four HHB that hold the ATC holding arm to the column.
Figure 3.11-1. Underside showing centering measurements.
4. Move the entire tool changer until the tool alignment key lines up with the spindle dog. Tighten the four HHB.
NOTE: Parameter 64 must be checked, and adjusted if necessary, when the ATC is aligned.
5. Make at least 50 tool changes after the alignment is complete. Verify that the tools are being picked up squarely.
MECHANICAL SERVICE
170 96-8100 rev C
June 2001
SHUTTLE STROKE ADJUSTMENT
6. Move the ATC away from the spindle and loosen the four HHBs in the ATC holding arm in the X-axis plane.
7. Push the cam follower to its full upward stroke, then push the entire ATC assembly in by pushing on the tool changer holding plate until ATC is fully engaged on the tool holder.
8. Ensure the extractor is making full contact on the tool flange.
Figure 3.11-2 Automatic Tool Changer - Mechanical Assembly (Side View)
MECHANICAL SERVICE
17196-8100 rev C
June 2001
EXTRACTOR FORK REPLACEMENT
NOTE: Extractor forks that do not hold the tool holders firmly, or forks that are bent, must be replaced. Damage to the ATC will result if not replaced.
1. With no tool holders in the spindle or in the ATC, command "ATC FWD" until the extractor fork needing replacement is facing the spindle.
2. Command "ATC FWD" again, but press the EMERGENCY STOP after the spindle head lifts up off the carousel
NOTE: At this point, the shuttle should be in and the spindle should be about 4" above the carousel.
3. Loosen the SHCS that attach the damaged extractor fork to the ATC carousel.
Figure 3.11-3 Automatic Tool Changer - Mechanical Assembly (Top View)
4. With the extractor fork removed, inspect the alignment key mounted under the extractor. If it is damaged due to improper spindle orientation, replace it and correct the orientation (Refer to appropriate section) after the extractor fork has been replaced.
5. Put a drop of blue Loctite on each of the SHCS and attach the new extractor fork to the ATC with the SHCS. DO NOT OVER-TORQUE! Ensure the distance from the edge of the extractor fork to the edge of the pocket in the carousel is the same on both sides in accordance with the following section.
6. Test run the ATC to ensure proper operation.
MECHANICAL SERVICE
172 96-8100 rev C
June 2001
SLIDING COVER REPLACEMENT
NOTE: If any of the sliding covers on the ATC do not slide freely or are bent in a crash, they must be replaced.
1. Loosen the four screws that attach the sliding panel cover to the carousel. Be careful to not lose the spring that holds the sliding cover closed or the number plate on the ATC carousel.
2. Inspect the cover for any galling or damage. Inspect the spring for damage.
3. Loosely install the two innermost screws that attach the number plate and the cover to the carou- sel and slide the spring into position in the slot in the ATC carousel.
4. Put the replacement sliding panel in place, making certain that the tongue on the panel pushes on the end of the spring.
5. Tighten the two rear screws completely and install the two front screws.
6. Ensure the sliding panel moves freely.
NOTE: If the sliding door is bent, determine the cause before resuming normal operation.
SHUTTLE MOTOR REMOVAL
1. Turn the VMC off.
2. Remove the cover from the tool carriage casting.
3. Remove the hex bolt that attaches the cam follower to the slip clutch (see Fig. 3.11-2).
4. Push the tool changer in as far as it will go.
5. Loosen the set screw that secures the slip clutch assembly to the shuttle motor (see Fig. 3.11-3).
6. Using a small two-jaw puller, pull the slip clutch assembly (see Fig. 3.11-3) off the shuttle motor shaft.
7. Remove the SHCS attaching the cover to the holding arm casting on the tool changer.
8. Remove the cover from the wire channel inside the holding arm casting and unplug the shuttle motor from the wiring harness.
MECHANICAL SERVICE
17396-8100 rev C
June 2001
Figure 3.11-4 Wiring harness for shuttle motor.
9. Remove the four FHCS attaching the shuttle motor to the holding plate on the tool changer. The FHCS are visible from the front of the VMC. Do not remove the HHBs holding the shuttle motor gear box together.
MECHANICAL SERVICE
174 96-8100 rev C
June 2001
SHUTTLE MOTOR INSTALLATION
1. Install the new motor on the tool changer holding plate using the four 10-32 x " FHCS. Before inserting the FHCS, place a drop of blue Loctite on each screw.
2. Reattach the shuttle motor connection to the wiring harness in the holding arm casting.
3. Replace the cover on the holding arm casting.
10 - 32 x 3/4" FHCS (4)
Figure 3.11-5 Front view of holding plate showing FHCS location.
4. Reattach the slip clutch assembly to the shuttle motor shaft. Before placing on the shaft, put two or three drops of red Loctite on the slip clutch hub.
5. Insert and tighten down the set screw holding the slip clutch assembly to the shuttle motor shaft. Before inserting the set screw, put a drop of blue Loctite on the set screw.
6. Ensure the actuating arm on the slip clutch assembly contacts the shuttle IN and OUT limit switches.
7. Ensure the hub of the slip clutch assembly does not interfere with the face plate on the shuttle motor.
8. Start the VMC and go through a performance check consisting of at least 30 tool changes, assur- ing correct operation.
MECHANICAL SERVICE
17596-8100 rev C
June 2001
TURRET MOTOR REMOVAL
1. Power on the VMC and put it in MDI mode.
2. Zero Return all axes (ZERO RET - AUTO ALL AXES).
3. Press ATC FWD then the EMERGENCY STOP after the spindle head has moved during the tool change cycle. At this time, the tool changer should be at the full in position and the spindle head should be above the tool changer.
4. Turn the VMC power OFF.
5. Remove the 10-32 SHCS from the carriage casting cover and remove the cover.
6. Tag both limit switch connections for reassembly, then unplug the limit switches and the power connections at the carriage casting.
7. Remove the four SHCS attaching the turret motor and mounting plate to the tool carriage casting.
Figure 3.11-6 Carriage casting with cover removed.
8. Carefully lift the turret motor assembly off of the tool carriage casting.
NOTE: The gear motor should never be disassembled and is not field-serviceable. All gear motors should be returned to Haas for evaluation and rebuilding.
MECHANICAL SERVICE
176 96-8100 rev C
June 2001
INSTALLATION -
1. Grease the locking element and drive pin on the Geneva driver. Also, grease the teeth on the Geneva star.
2. Rotate the Geneva driver until the cam depresses the limit switch on the turret motor assembly.
3. Place a narrow strip of paper around the locking element of the Geneva driver and install the turret motor assembly onto the casting. Be certain that the locking element of the Geneva driver is seated against the star with the paper strip acting as a shim.
MECHANICAL SERVICE
17796-8100 rev C
June 2001
Figure 3.11-7 Required spacing for Geneva driver.
4. Attach the turret motor assembly to the carriage casting with the four SHCS.
5. Reconnect the power and limit switch lines to the turret motor.
6. Power on the VMC and ZERO RETURN all axes (ZERO RET - AUTO ALL AXES).
7. Go to MDI mode and press "T - 1 - ATC FWD".
NOTE: The machine may alarm at this time (Alarm 115 or 127). If this occurs, ZERO RETURN the Z-axis (ZERO RET - SINGL AXIS) and repeat step 8. This step may need to be repeated two times to clear all possible alarms.
8. Press "T - 9 - ATC FWD". The tool changer should go to tool nine. If the tool changer travels to tool seven, the turret motor is wired backwards. Reverse motor leads and repeat steps 7-10. Also, the turret should run quietly with no strain in the motor, banging, or vibration.
9. Reinstall the tool carriage casting cover.
10. Test the tool changer for proper operation.
MECHANICAL SERVICE
178 96-8100 rev C
June 2001
GENEVA STAR REPLACEMENT
NOTE: If the ATC Geneva star is damaged or worn in its driven slots, it must be replaced.
1. Turn the machine power off.
2. Remove the cover from the front of the ATC shuttle.
3. Remove the turret motor assembly (Refer to previous section).
4. Place a support for the ATC under the center of the carousel.
5. Loosen the nut inside the carriage casting that attaches the ATC carousel assembly to the cast- ing. There is a socket head in the top of the shaft to hold it stationary while loosening the nut.
6. Place the cardboard over the mill table and carefully lower the carousel until it rests on the table.
7. Remove the six SHCS that attach the Geneva star to the bearing housing on the ATC carousel.
8. Install the Tool #1 standoff on the replacement Geneva star.
9. Install the replacement Geneva star. Check the concentricity of the star to the shaft on the carou- sel assembly; it must be within 0.005". If the star is not within tolerance, loosen the SHCS and adjust the alignment until it is acceptable.
10. Installation is reverse of removal. Be certain to grease the perimeter of the star before installation and readjust the ATC in accordance with "Alignment Preparation" and "Shuttle Stroke Adjustment", if necessary.
MECHANICAL SERVICE
17996-8100 rev C
June 2001
ATC TRAP DOOR REPLACEMENT
NOTE: If the ATC trap door is damaged in a crash, it must be replaced.
1. Turn the machine power off.
2. Remove the turret motor assembly in accordance with the previous section.
3. Place a support for the ATC under the center of the carousel.
4. Loosen the nut inside the carriage casting that attaches the ATC carousel assembly to the cast- ing. There is a socket head in the top of the shaft to hold it stationary while loosening the nut.
5. Place the cardboard over the mill table and carefully lower the carousel until it rests on the table.
6. Remove the two SHCS that attach the guide pin for the ATC trap door to the ATC holding plate and remove the guide pin.
7. Slide the trap door from between the carousel cover and the shuttle casting. Be careful to not lose the two nylon washers that sandwich the trap door between the carousel cover and the shuttle casting.
8. Installation is reverse of removal. When installing the guide pin, ensure the mounting slot is approximately central to the mounting screws and be certain the pin does not interfere with the top of the ATC carousel cover. Grease the carousel cover where the plastic standoffs ride, the slot in the ATC shutter, the guide pin, and the nylon washers where the shutter pivots. The position of the ATC may need to be readjusted after installation.
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 for the DISTANCE TO GO is .118 (This equals of a revolution of the encoder).
MECHANICAL SERVICE
180 96-8100 rev C
June 2001
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.
MECHANICAL SERVICE
18196-8100 rev C
June 2001
3.12 40 TAPER CAROUSEL SIDE MOUNT TOOL CHANGER
Special Tools Required: Lifting Device (1000lb capacity for ATC removal) Spanner Wrench
MECHANICAL SERVICE
182 96-8100 rev C
June 2001
40 TAPER CAROUSEL REMOVAL AND INSTALLATION
Removal:
Figure 3.12-1 ATC Assembly, Carousel Removal
1. Power Off machine.
2. Unscrew the BHCS from the carousel number disc and remove. Refer to Figure 3.12-1.
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. Refer to Figure 3.12-3.
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.
MECHANICAL SERVICE
18396-8100 rev C
June 2001
Figure 3.12-2 Carousel Assembly Figure 3.12-3 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 (5/16-18). Manually rotate the carousel for each tool pocket installation. Re-install the pocket stop and slider. Refer to Figure 3.12-3. The carousel can be rotated by manually rotating the carousel pulley by hand. See Figure 3.12-4
Figure 3.12-4 Pulley locations and ATC movement
4. Re-attach the carousel number disc with the BHCS. Apply blue loctite to the BHCS and tighten.
5. Re-check slider adjustment. Refer to section on tool pocket slider adjustment.
MECHANICAL SERVICE
184 96-8100 rev C
June 2001
50 TAPER CAROUSEL REMOVAL AND INSTALLATION
Removal
CAUTION! Do not attempt to remove the carousel with the pockets installed.
1. Remove sheetmetal disc covering the carousel. Press <TOOL CHANGER RESTORE>. Press <Y> 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 <E-STOP>.
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. Rotate 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.
ATC 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.
MECHANICAL SERVICE
18596-8100 rev C
June 2001
4. Insert an eye-bolt into the threaded 1/2-13 hole at the top of the carousel housing. Attach the lifting device to the eye-bolt and support the ATC assembly (Refer to Figure 3.12-5). Remove the five carousel mounting SHCS from the ATC mounting bracket and move ATC assembly away from the column (Refer to Figure 3.12-6).
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. See Figure 3.12-5.
Figure 3.12-5 ATC Assembly Lifting Position Figure 3.12-6 ATC Mounting Bracket
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 the control and re-attach 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.
MECHANICAL SERVICE
186 96-8100 rev C
June 2001
ATC ALIGNMENT
This procedure is for a newly mounted ATC assembly without the double-arm installed.
Cam Box to Tool Pocket Alignment:
1. Remove all cam box sheet metal fasteners and covers. Place protective covers on the machine table.
2. Power Up machine. Raise Z-axis to top of travel. 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). Refer to figure 3.12-7.
Figure 3.12-7 Double Arm Alignment
4. POWER OFF the machine. Disconnect the air supply line at the rear of the machine. The tool pocket will raise once the air is disconnected.
5. At the top of the ATC assembly, reverse the two air lines going from the solenoid valve to the air cylinder. See Figure 3.12.8. Reconnect the air supply line at the rear of the machine. (The tool pocket holder in the tool change position should move down)
MECHANICAL SERVICE
18796-8100 rev C
June 2001
Figure 3.12-8 Airline connection location
6. At the top of the ATC assembly, manually rotate the cam box pulley clockwise until the output shaft is lowered and just before it begins to rotate 1800.
7. Align the double-arm underneath the tool pocket and the spindle with the unlocking finger buttons facing upward. 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 an empty tool holder without a pull stud into the double arm end beneath the tool pocket. Depress the tool release button on top of the double-arm and insert a tool holder. Slightly push the double-arm in the clockwise direction to remove backlash in the drive assembly. Refer to Figure 3.12-9.
Radial alignment of Double Arm to Carousel:
9. Rotate the cam box pulley counter-clockwise to raise the double-arm into the tool pocket holder. Visually check the centerline alignment of the tool holder to the centerline of the tool pocket.
10. In order to adjust the radial alignment of the tool pocket holder to the double arm, loosen the lock ring SHCS and adjust the double-arm. Refer to Figure 3.12-9.
11. If the double arm is not aligned in the y-axis with the centerline of the tool pocket holder, loosen the four cam box SHCS and insert a pry-bar between the slots. Adjust the cam box until the centerline of tool holder is aligned with the centerline of the tool pocket.
12. Torque the cam box SHCS to 100 ft-lbs.
MECHANICAL SERVICE
188 96-8100 rev C
June 2001
Figure 3.12-9 Cam Box / Double Arm Alignment, top view.
Checking Parallelism of Double-arm to Table:
13. Rotate the cam box pulley clockwise to lower the double arm. Remove the tool holder from the double arm.
14. Rotate the cam box pulley counter-clockwise to raise 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 top of the ATC assembly. Re-attach the air supply line (the tool pocket holder should retract to its home 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 lowers and is parallel to the x-axis. Insert a short tool holder into the double arm by pressing the tool release button located near the shaft. Refer to Figure 3.12-9
Place a magnetic base and indicator on to the machine table. Measure the bottom of the tool holder to the nearest .001.
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18. Move the tool holder and indicator setup to the other end of the double-arm. Measure the bottom of the tool holder 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 tool holder from the double-arm. Return the double-arm to the home position.
Setting the Double-arm Height:
20. Press the DOWN ARROW to command the tool pocket down. Place a tool holder with a pull stud into the tool pocket. In TCR mode, rotate the double arm near the tool pocket.
21. Visually check the height alignment of the double arm to the V-groove on the tool holder. If neces- sary loosen the lock ring SHCS and adjust the height of the double arm. Torque the lock ring SHCS to 7 ft-lbs.
22. Repeat steps 9 & 10 to re-check radial alignment.
23. Return the double-arm to the home position.
Double-Arm to Spindle Alignment:
1. ZERO RETURN the Z-axis.
2. In TCR mode, lower the double arm and re-insert the short tool holder without pull stud into the double arm. Orient the spindle dogs for a tool change. (If the orientation has changed reset Param- eter 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. Raise and lower the double-arm to move the tool in and out of the spindle. Check for alignment. Refer to Figure 3.12-10.
4. Check the X-axis alignment of the tool holder to the spindle center. Refer to Figure 3.12-10.
Figure 3.12-10 Double Arm to Spindle Center Alignment, along the Y-axis.
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5. If necessary, loosen the five ATC mounting SHCS. Refer to Figure 3.12-11.
Figure 3.12-11 ATC Assembly X-axis alignment Figure 3.12-12 ATC Assembly Y-axis alignment.
6. Insert a pry-bar between the locating pins and the ATC mounting bracket. Adjust the bracket to align the tool holder in the double arm to the center of the spindle in the X-axis. Refer to Figure 3.12-11.
7. Torque the SHCS to 100 ft-lbs.
8. Check the Y-axis alignment of the tool holder to the spindle.
9. If necessary, loosen the five ATC SHCS (Refer to Figure 3.12-12). Insert a small pry bar between the locating pins and the mounting bracket. Adjust the ATC along the mounting slots and align the tool and spindles center.
10. Check the spindle tool change height. If the spindle tool change height has changed, reset Param- eter 64 (section 3.6).
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 100 ft-lbs. Replace all cam box sheet metal covers and fasten- ers. Apply blue loctite to the fasteners and tighten.
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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 (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).
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.
Figure 3.12-13 Spindle Orientation Setting
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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.
Figure 3-12-14 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. Re-attach the lock ring to the double-arm with six SHCS.
3. Re-align the double-arm to the spindle and tool pocket. Refer to section on ATC alignment.
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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 <Tool Changer Restore>. Press <Y> three times.
3. Remove the four SHCS that hold the pocket stop. See the following figure:
CAUTION: Place the machine in E-Stop before proceeding to step 4.
4. Remove the shoulder bolt from the back of the pocket slide.
NOTE: The machine must be in Tool Changer Recovery Mode to perform the next step.
5. Press <v> to retract the air cylinder shaft. Manually lower the pocket and remove the pocket retaining screw. See the following figure:
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6. 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 section.
Installation
7. 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.
8. Clear all alarms. Return to Tool Changer Recovery Mode and press <^>. 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.
9. 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 <MDI> and then <ATC FWD>. Check for any binding or interference of installed parts.
50 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 disc covering the carousel.
2. Press <Tool Changer Restore>. Press <Y> three times.
3. Remove the four SHCS that hold the pocket stop. See the Figure below:
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NOTE: Do not remove the set screws. Doing so will change the pocket slide and groove alignments.
4. Manually rotate the carousel to the affected pocket by manually rotating the carousel motor and disconnect air from the machine. Remove the pocket retaining screw. See the Figure below:
5. Remove the tool changer pocket by carefully maneuvering the pocket out of the pocket slide fingers, taking care not to drop the pocket.
NOTE: If the carousel is to be replaced, skip to the Carousel Removal and Installation section.
Installation
1. Replace the damaged pocket with a new one. Apply grease to the shaft. Install the pocket into the pocket slide fingers. Apply a drop of Blue Loctite to the pocket retaining screw and install. Torque to 23 ft./lbs. Reconnect air to the machine.
2. Press <^>. This will extend the air cylinder shaft and raise the pocket.
3. Install the pocket stop, using Blue Loctite and torquing the four SHCS to 45 ft./lbs. Activate the pocket up and down several times. Restore the machine to automatic mode and perform a tool change. Check for any binding or interference of installed parts.
4. Raise the pocket and verify that the pocket slide groove matches the casting groove. See the following figure.
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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. Refer to Figure 3.12-4.
2. Visually check for mis-alignment (tool pockets should move smoothly). Refer to Figure 3.12-15
3. If necessary, loosen the set-screw nut. Adjust the set-screw 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 set-screw lock nut.
Figure 3.12-15 Tool Pocket Orientation / Set-Screw Adjustment
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PROXIMITY SWITCH REMOVAL / INSTALLATION
Removal
1. Power Off machine. Remove the carousel number disc and the top cover plate.
2. Remove the 1/4NPT 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 Figure 3.12-16.
Figure 3.12-16 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 switch into the cam box. Connect the proximity switch connector to the plug on the switch bracket. Refer to Figure 3.12-17.
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Figure 3.12-17 Proximity Switch Connection Bracket.
3. Power On machine. Press E-Stop.
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. See Figure 3.12-16.
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
On a Vertical mill: For Z-axis; displacement from home switch to tool change position and machine zero. On machines eqipped with 40 taper or 50 taper side mount tool changers this distance is:
(Distance from Home in Inches) X (Line Encoder Constant) = Z-axis tool change position setting
Example: .625 x 1378718 = 861699
To reset Parameter 64 (Z-axis tool change position) if a ATC assembly has been installed or replaced.
1. Enter PARAMETERS page and record original Parameter 64 setting value.
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2. (Make sure there are no tools in the spindle head or tool pocket positions). Command the spindle head to its tool change height. Enter DEBUG and record Z-axis spindle height value.
3. Enter TCR mode. Press the DOWN ARROW, command a tool pocket down. Manually insert a tool into the tool pocket.
Figure 3.12-18 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.
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. Refer to Figure 3.12-18.
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: 40 Taper SMTC
(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 necessary.
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3.13 ENCLOSURE REPLACEMENT
Please read this section in its entirety before attempting to replace the doors or windows.
TOOLS REQUIRED Trim installation tool (dull-edged knife or caulking spatula)
DOOR REPLACEMENT
CAUTION! If possible, have two people performing this operation, as the weight of the doors may be a factor in removal.
REMOVAL -
1. Turn the machine power off.
2. Slide the doors to the full open position.
3. Remove the tension springs (2) connecting the two swivel roller brackets at the top and bottom of the door.
4. Slide the door to the fully closed position. Loosen the two upper roller hex nuts, and disengage the upper swivel roller brackets from the top roller guide.
5. Lift the door from the bottom roller guide and remove.
INSTALLATION -
6. Ensure that the lower roller hex fasteners are wrench tight and the upper roller fasteners are finger tight in the middle of their adjusting slots. Place the door into the enclosure, and position with the lower rollers resting on the lower roller guide.
7. Rotate the door to the upright position, and engage the top rollers onto the top roller guide.
8. Replace the tension springs onto the upper and lower roller swivel brackets. Tighten the upper roller fasteners.
9. Verify that the door travels smoothly. If it does not: Check that all roller wheels are seated and roll on their tracks. If all roller wheels are seated on their tracks, it will be necessary to adjust the door travel
by loosening the upper and lower roller hex fasteners.
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Figure 3.13-1 Roller/roller guide assembly.
DOOR ADJUSTMENTS -
10. Close both doors and check that the vertical gap between them is uniform. If it is not: Determine which door must be adjusted. Loosen the door's outer lower roller attachment and pivot the door on the inner lower roller
wheel. When the door is in the desired position (the vertical gap is uniform), tighten the lower
outer roller fastener.
Figure 3.13-2 View of vertical gap between front doors.
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11. Check the gap between the door and the front panel flange, and verify it is 5/8" throughout the travel of the door. If it is not: Loosen the door's upper roller fasteners and tilt the door forward or back, as necessary, to
adjust door position.
Figure 3.13-3 View of gap between front of door and front panel flange.
SWITCH ADJUSTMENT -
12. Move the door to the fully closed position. Go to the "Diagnostics" page on the control panel, and ensure "DOOR S" reads "0". Move the door to the open position, and ensure "DOOR S" reads "1". If either reading is incorrect: Loosen the SHCS that mounts the switch actuator bracket to the top of the door. (NOTE:
It is possible to access this bracket from the side window.) Move the bracket in its slot to the proper position and tighten the SHCS.
WINDOW REPLACEMENT
REMOVAL -
1. Turn the machine power off.
2. Move the door to the fully closed position so the window is accessible. Use a trim installation tool to pull the locking tab out of the inside of the window seal (the tab is a part of the seal).
3. Remove the window panel from the seal. The tool can be placed between the window panel and the seal to aid in removing the window panel.
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4. Remove the seal from the enclosure's cutout.
Figure 3.13-4 Cross-section of window seal.
INSTALLATION -
5. Replace the seal around the enclosure's cutout, with the locking tab facing the inside of the machine.
6. Replace the window panel into the seal. The tool can be placed between the window panel and the seal to aid in replacing the window panel into the seal.
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3.14 HYDRAULIC COUNTERBALANCE
TOOLS REQUIRED
(1) 4 x 4 x 14" head support block
Hydraulic counterbalance service kit, consists of: Pressure tank with manifold assembly, prefilled with (2) quarts DTE-25 hydraulic oil Hydraulic cylinder with hose attached (if necessary)
HYDRAULIC TANK REPLACEMENT
REMOVAL -
CAUTION! While performing this procedure, the spindle head may drop if the control loses power or alarms.
1. Raise spindle head by HANDLE JOG up to 14.5" above table. Insert wood block and lower head casting onto it. EMERGENCY STOP the machine. Head should rest securely on table block. Power OFF VMC.
NOTE: Do not lower spindle onto block.
2. Disconnect the two-pin end of the pressure sensor cable(s) to the pressure sensor(s), if tank is equipped with sensor.
Figure 3.14-1 Hydraulic counterbalance charge/discharge kit (shown in place to discharge system).
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3. Remove cap to Schrader filler valve.
4. Ensure T-handle of the gas chuck is turned completely counterclockwise. Attach charge/discharge kit by tightening gas chuck to the Schrader valve finger tight, then wrench lightly to tighten (see Figure 3.14-1).
5. Place the CGA 580 end of charge/discharge kit into a bucket to the contain the hydraulic oil while discharging the system.
6. Slowly turn the T-handle clockwise until the system begins to discharge. Complete discharge may take up to 10 minutes. Verify tank gauge reads 0 psi.
7. Turn the T-handle completely counterclockwise and remove the charge/discharge kit from the Schrader valve.
8. Disconnect the hydraulic hose from the tank assembly.
9. Remove the tank assembly from the column by removing the four SHCS from the tank mount.
INSTALLATION -
10. Connect the hose to the tank before mounting the tank in the inverted position. This prevents hydraulic oil from spilling.
NOTE: For a positive seal, ensure the hose-to-tank connection is straight, and not skewed.
11. Mount the tank assembly to the column with the tank mount and four SHCS. Ensure the hydraulic hose is not twisted.
12. Connect the two-pin end of the pressure sensor cable(s) to the pressure sensor(s).
13. Use cable ties to secure the cable to the hydraulic hose.
NOTE: For this step, use regulated dry nitrogen gas (welding grade acceptable) that accepts a right-hand thread CGA 580 fitting.
14. Attach the CGA 580 fitting end of the charge/discharge kit to the source pressure. Ensure T- handle of the gas chuck is turned completely counterclockwise. Attach charge/discharge kit by tightening gas chuck to the Schrader valve finger tight, then wrench lightly to tighten. Pressurize the system to required pressure as listed in Figure 3.14-2.
NOTE: For VF-6/8 follow installation procedure for each hydraulic tank.
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NOTE: Do not use compressed air, oxygen or flammable gas. Refer to the table below and verify pressure according to machine and spindle head position. Verify cylinder is seated in counterbore.
Figure 3.14-2 Tank pressure requirements.
15. Power on the machine and zero return (ZERO RET) Z-axis only. Check for any leaks or abnormal noises. Verify tank pressure at top of travel. Remove charging system and replace valve cap.
NOTE: If there is an E-stop alarm that will not reset, check for correct system pressure and the correct tank assembly.
HYDRAULIC CYLINDER REPLACEMENT
REMOVAL-
1. Remove the hydraulic tank as described in previous section.
2. To gain access to the cylinder rod, remove the three SHCS holding the Z-axis way cover to the spindle head.
3. Remove the cotter pin and lock nuts from the threaded end of the cylinder rod.
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Figure 3.14-3 Hydraulic Cylinder Rod Installation for VF-0 through 4 and (VF-6/8).
NOTE: For VF-6/8 loosen jam nut from clevis then remove the cotter pin, clevis pin, clevis and jam nut.
4. Remove the band clamp that holds the cylinder to the stabilizer bracket. Loosen the two SHCS that attach the bracket to the column.
5. Remove the hydraulic cylinder from the top of the column.
Figure 3.14-4 VF-Series hydraulic counterbalance - right side view.
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Fig. 3.14-5 VF-Series hydraulic counterbalance view - left side view.
NOTE: Do not disassemble unit. Keep the hose attached to the cylinder.
6. Return complete assembly to HAAS Automation.
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INSTALLATION-
7. Install cylinder with cylinder rod extended from top of column.
NOTE: Cylinder rod should pass through column bracket and spindle head bracket. Cylinder body must rest in column bracket counterbore.
8. Orient cylinder body with hydraulic hose facing away from lead screw.
NOTE: For VF-6/8 orient cylinder bodies with hydraulic hose facing the lead screw.
9. Install lock nuts, at threaded end of cylinder rod, wrench tight. Install safety cotter pin.
NOTE: For VF-6/8 install jam nut and clevis at end of cylinder rod then attach to spindle head bracket with clevis pin. Install safety cotter pin and lock the clevis by tightening jam nut.
10. Install the hydraulic tank as described in the previous section, but DO NOT power up the ma- chine.
11. Power on the machine and zero return (ZERO RET) Z-axis only. Observe cylinder body for motion or abnormal noises. Check for fluid at manifold, cylinder hose connection and cylinder rod. Verify tank pressure at top of travel. Remove charging system and replace valve cap.
12. Install the band clamp and tighten the two SHCS that attach the stabilizer bracket to the column.
13. Zero return (ZERO RET) machine. HANDLE JOG Z-axis in 0.1 increments. Verify full Z travel.
14. Cycle Z-axis, using the following program, for five minutes and check for oil leaking at top of cylinder and cylinder rod.
G28, G54, Z-14. M99 50% Rapid
15. If Z-axis overcurrents alarm during travel, verify and correct system pressure.
NOTE: If Z-axis overcurrent alarm at top or bottom of travel, call HAAS Automation Service Department immediately for assistance. If fluid leaks from hydraulic fittings, check that fittings are tight. If leaking continues, call HAAS Automation Service Department for assistance.
16. Reinstall Z-axis way cover with three SHCS that hold it to the spindle head.
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3.15 THROUGH THE SPINDLE COOLANT SYSTEM - ADJUSTMENTS
TOOLS REQUIRED Tool holder with small TSC drill or restrictor (with a small orifice #T-1461) TSC Gauge Kit (P/N 93-9011), includes:
0-15 PSI Precharge pressure gauge 0-160 PSI Purge pressure gauge (Not used on newer TSC machines) 0-600 Coolant pressure gauge Ball valve
PRECHARGE REGULATOR ADJUSTMENT
1. CAUTION! Extreme care must be taken in making this delicate adjustment. Insert a short piece of 1/4" plastic tubing into the 0-15 psi pressure gauge. Insert the short tube into the precharge pressure regulator (located on top of the transmission) and connect the plastic precharge tube (leading to the TRP) to the pressure gauge.
2. Manually turn on the precharge air by pushing the plunger on the precharge solenoid valve.
3. Hold down the precharge solenoid valve for at least 20 seconds to allow the pressure reading to stabilize, then set the precharge pressure to 4.0 psi (0.4 psi). Release the solenoid and hold it down again for 20 seconds and re-check the precharge pressure. Repeat this a few times to ensure the pressure setting remains stable. Be sure the regulator adjustment knob is securely locked in place.
4. Remove the pressure gauge and short 1/4" hose. Reattach the precharge tube to the regulator.
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. This procedure should also be performed whenever the pump has sucked in air (e.g. low coolant).
50 Taper TSC (old system)
1. With no tool in the spindle, switch to MDI mode. 2. Close the programmable coolant (P-Cool) and lock line shut-off valves. 3. Press the COOLNT key to turn on the main coolant pump; this will prime the TSC pump. 4. Wait 20-30 seconds for the TSC pump to fill. 5. Press the AUX CLNT key to turn on the TSC. Wait for coolant to flow from the spindle at full force. 6. Press the reset key to shut off the system. The TSC system will continue to hold its prime.
High pressure TSC 40 and 50 taper
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. Allow coolant to flow for at least one minute. 4. Press the AUX CLNT button again to turn off TSC.
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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). Old TSC system uses pump head (93-3280B).
1. Insert the 0-600 psi coolant pressure gauge into the coolant line between the coolant filters 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 described above.
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 any future tampering.
TESTING THE COOLANT PRESSURE SWITCH
1. Insert the ball valve and pressure gauge into the TSC pump outlet. The ball valve must be between the pump and pressure gauge. Connect the other end to the machine. For high pressure TSC, the connectors must be tightened snug with wrenches. DO NOT OVERTIGHTEN.
2. Run TSC system for one minute to purge air
3. Insert a TSC type tool holder (with a small TSC drill or restrictor) in the spindle. CAUTION! Chang- ing tools after running TSC can cause coolant to spray out. Wear safety glasses.
WARNING! Do not put your hands in the high pressure coolant stream as coolant and particles can be blown into your skin.
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 +/- 5 psi). If the switch is outside this range, replace the switch.
NOTE: Test the electrical continuity of the pressure switch cable and the control function by shorting the leads of the cable. The "LO CLNT" bit on the Diagnostics page should change from "1" to "0". Check this before replacing the pressure switch.
6. Reset Parameter 236 to 1000.
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3.16 AIR / OIL LINE DIAGRAM
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THROUGH THE SPINDLE COOLANT SYSTEM FLOW DIAGRAM - 40 TAPER SPINDLE
AT BOTTOM REAR OF SPINDLE HEAD
PARAMETER 237 (TSC CLNT LINE PURGE)
THE TSC PUMP IS A PRECISION GEAR PUMP AND WILL WEAR OUT FASTER AND LOSE
REAR OF GEAR BOX/SPINDLE MOTOR ASSEMBLY ON TOOL RELEASE PISTON ASSEMBLY SIDE OF GEAR BOX/SPINDLE MOTOR ASSEMBLY REAR OF MACHINE & COOLANT TANK ASSEMBLY
AFTER CHANGING OR CLEANING FILTER ELEMENTS, RUN TSC SYSTEM
CHECK GAGE (G2) ON 100 MICRON FILTER WITH TSC SYSTEM RUNNING AND NO TOOL IN SPINDLE. CHANGE ELEMENT WHEN THE INDICATOR REACHES THE RED ZONE. USE 100 MICRON FILTER ELEMENT (58-6045) OR COMMERCIALLY AVAILABLE EQUIVALENT.
CLEAN PUMP INTAKE FILTER WHEN INDICATOR (G1) IS IN RED ZONE. RESET WITH BUTTON.
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
TOP-OFF COOLANT TANK DAILY (EVERY 8 HOUR SHIFT) DURING HEAVY TSC USAGE.
WHEN MACHINING CASTINGS, SAND FROM THE CASTING PROCESS AND 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.
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 TANK IS RECOMMENDED.
SHORTENED PUMP LIFE, REDUCTION OF PRESSURE AND INCREASED MAINTENANCE ARE NORMAL AND TO BE EXPECTED IN ABRASIVE ENVIRONMENTS AND ARE NOT COVERED BY WARRANTY.
CAUSES: TOOL RELEASE PISTON DID NOT MOVE DOWN WHEN COMMANDED OR IT MOVED
A) CHECK FOR LOW AIR SUPPLY PRESSURE, B) CHECK FOR T.R.P. FAILURE. UP DURING TSC OPERATION, OR ANOTHER ALARM OCCURED DURING TSC OPERATION.
C) PRESS RESET AND RUN TSC AGAIN TO PURGE AIR FROM SYSTEM. A) CHECK FOR LOW COOLANT IN TANK, B) CHECK DIRT INDICATORS ON BOTH FILTERS,
TO TOOL
FAILURE TO DO SO CAN FLOOD SPINDLE HEAD WITH COOLANT.
CAUSE: COOLANT PRESSURE IN SYSTEM FELL BELOW 40 PSI. LOW THRU SPINDLE COOLANT (ALARM 151):
WEAR SAFETY GLASSES WHEN MANUALLY CHANGING TSC TOOLS. COOLANT CAN SPRAY OUT.
DO NOT RUN TSC WITH LOW COOLANT LEVEL IN TANK.
TSC REQUIRES TOOL HOLDER WITH THROUGH HOLE IN PULL STUD AND TOOL.
THROUGH SPINDLE COOLANT (TSC) WARNINGS!!
THROUGH SPINDLE COOLANT SYSTEM
PRE-CHARGE FAILURE (ALARM 198):
THROUGH SPINDLE COOLANT ALARMS
2.
3.
1.
2.
1.
EXH
AIR SUPPLY
COOLANT TIP
FLOW DIAGRAM
(5) TO DRAIN
85 PSI
TT
MINIMUM (DEFAULT) VALUE IS 2500, NO MAXIMUM LIMIT. ADJUSTABLE TSC PARAMETER:
ON TOOL RELEASE PISTON ASSEMBLY
REAR OF MACHINE & COOLANT TANK ASSEMBLY REAR SIDE OF TRANSMISSION ASSEMBLY
AT REAR INSIDE OF ENCLOSURE PAN TOP & SIDE OF TRANSMISSION ASSEMBLY
WITH NO TOOL IN SPINDLE FOR AT LEAST ONE MINUTE TO PURGE AIR. SPECIAL INSTRUCTIONS:
THROUGH SPINDLE COOLANT (TSC) MAINTENANCE SCHEDULE
3.
2.
1.
(T.R.P.) ASSEMBLY
DRAWBAR ASSEMBLY-TSC
TOOL RELEASE PISTON
HMC
LOCATION:
(3) (4) (5)
(1) (2)
AIR SUPPLY 85 PSI
PURGE AIR
T
EXH
T
LOCATION:
VMC
85 PSI AIR SUPPLY
(3) (4) (5)
(1) (2)
V1
SV3
SV2
SV1
SHUTTLE VALVE
PRESSURE IF ABRASIVE PARTICLES ARE PRESENT IN THE COOLANT.
SV2
TOOL RELEASE AIR
TRP EXH. AIR
(3)
CV
CVA
CV
PRECHARGE AIR
VENT AIR PRECHARGE
V1 (3)
PURGE AIR
PS
(4)
VENT
SV1 (4)
R1
PRA
F2 P1
COOLANT FLOW
(2) (1)
G2
FA2
(1)
EXH
SV3
PVA
TT
CV
(4)
COOLANT TANK
F1
PVA
PS
PRA
R1
(30-3276)
SET AT 40 PSI
(30-3270A)
P1
G2
G1
FA1
FA2
F2
TSC PUMP
FA1 (1)
G1 CVA
F1
CV CHECK VALVE
TSC SYSTEM WARNING!
MECHANICAL SERVICE
214 96-8100 rev C
June 2001
THROUGH THE SPINDLE COOLANT SYSTEM FLOW DIAGRAM - 50 TAPER SPINDLE
THE TSC PUMP IS A PRECISION GEAR PUMP AND WILL WEAR OUT FASTER AND LOSE
WHEN MACHINING CASTINGS, SAND FROM THE CASTING PROCESS AND 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.
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 TANK IS RECOMMENDED.
SHORTENED PUMP LIFE, REDUCTION OF PRESSURE AND INCREASED MAINTENANCE ARE NORMAL AND TO BE EXPECTED IN ABRASIVE ENVIRONMENTS AND ARE NOT COVERED BY WARRANTY.
PRESSURE IF ABRASIVE PARTICLES ARE PRESENT IN THE COOLANT.
TSC SYSTEM WARNING!
CAUSE: COOLANT PRESSURE IN SYSTEM FELL BELOW 40 PSI. LOW THRU SPINDLE COOLANT (ALARM 151):
WEAR SAFETY GLASSES WHEN MANUALLY CHANGING TSC TOOLS. COOLANT CAN SPRAY OUT!
DO NOT RUN TSC WITH LOW COOLANT LEVEL IN TANK.
FAILURE TO USE PROPER TOOLING CAN DAMAGE PUMP. TSC REQUIRES TOOL HOLDER WITH HOLE THROUGH PULL STUD AND TOOL.
THROUGH SPINDLE COOLANT (TSC) WARNINGS!!
PRE-CHARGE FAILURE (ALARM 198) DOES NOT APPLY TO THIS SYSTEM.
C) CHECK HOSES FOR KINKS OR DAMAGE AND THAT ALL CONNECTIONS ARE TIGHT.
B) CHECK GAGES ON BOTH FILTERS.
A) CHECK FOR LOW COOLANT LEVEL IN TANK.
50 TAPER SPINDLE OPTION FLOW DIAGRAM
2.
THROUGH SPINDLE COOLANT ALARMS
1.
3.
2.
1.
THROUGH SPINDLE COOLANT SYSTEM
TO DRAIN
SPINDLE ASSEMBLY
DRAWBAR
TO TOOL
EXTENSION TUBE
ROTATING UNION
RETRACT TRP
ADVANCE TRP
SV1
85 PSI AIR SUPPLY
EXH
AB
IN
TOOL RELEASE
AIR BLAST
AIR
AIR FLOW
V2
V1
(2)
S1
FLOW COOLANT
CVA
(1) REAR OF MACHINE & COOLANT TANKLOCATION:
WITH NO TOOL IN SPINDLE FOR AT LEAST ONE MINUTE TO PURGE AIR. AFTER CHANGING OR CLEANING FILTER ELEMENTS, RUN TSC SYSTEM
CLEAN INTAKE FILTER WHEN SUCTION GAGE (G1) IS IN THE RED ZONE.
ELEMENT WHEN THE INDICATOR IS IN THE YELLOW ZONE. USE 20 MICRON FILTER ELEMENT CHECK GAGE (G2) ON TSC FILTER WITH NO TOOL IN SPINDLE AND TSC RUNNING. CHANGE
TOP OFF COOLANT TANK BEFORE EACH SHIFT DURING HEAVY TSC USAGE.
(2) SIDE OF SPINDLE MOTOR (3) TOP OF SPINDLE MOTOR
PARAMETER 237 (TSC CLNT LINE PURGE) MINIMUM (DEFAULT) VALUE IS 2500, NO MAXIMUM LIMIT.
ADJUSTABLE PARAMETER:
(58-6046) OR COMMERCIALLY AVAILABLE EQUIVALENT.
THROUGH SPINDLE COOLANT (TSC) MAINTENANCE SCHEDULE
SPECIAL INSTRUCTIONS:
3.
2.
1.
TRSA
EXH IN
SV2
PURGE AIR
A
V2
V3
V1
SV2
SV1
S1
P1
(3)
V3
F2
TRSA
G2
(1) FA2
P1 (1)
COOLANT TANK
F1
FA2
G2
G1
FA1
(1)
G1
F2
F1
FA1 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
(30-0066A)
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
(30-3287A)
(30-0072)
INTAKE FILTER ASSEMBLY
CHECK VALVE ASSEMBLY (30-3275B)
100 MESH
MECHANICAL SERVICE
21596-8100 rev C
June 2001
3.17 AUTOMATIC PALLET CHANGER (APC)
PALLET REPLACEMENT
TOOLS REQUIRED: Hoist Straps or Chains Eyebolts (2)
CAUTION! Be careful when changing out pallets, each pallet weighs approx. 300lbs.
NOTE: Pallets that have been replaced must be re-aligned to the receiver. Pallets shipped with the VMC from the factory have been machined perpendicular to the spindle. It is recommended that replacement pallets be machined after aligning them to the receiver.
1. Remove the old pallet from the APC using the supplied eyebolts and a hoist.
2. Set the new pallet on the APC, aligning the roller grooves on the bottom of the pallet with the rollers on the APC.
3. Loosen the clamp rail bolts on the new pallet (the bolts should be snug and not overtighten).
4. Run new pallet into the receiver. Clamp and unclamp the pallet a few times (this will allow the pallet to center on the guide pins). Torque the clamp rail bolts to 50 FT-LB while the pallet is clamped to the receiver.
Figure 3.17-1 Pallet Replacement
IMPORTANT! New pallets should be machined on the VMC in order for them to be perpendicular to spindle.
MECHANICAL SERVICE
216 96-8100 rev C
June 2001
PALLET CLAMP RAIL REPLACEMENT
TOOLS REQUIRED: Hoist Straps or Chains Eyebolts (2)
NOTE: This procedure must be performed with the pallets on the APC.
1. Loosen the clamp rail bolts.
2. Screw the eyebolts into place and lift the pallet carefully.
3. Remove the clamp rails from the pallets.
Figure 3.17-2
4. Verify the condition of the wipers and determine if they need replacing.
5. Re-install the new rails leaving the bolts loose.
6. Carefully place the pallet back onto the APC using the hoist.
7. Position the pallet back onto the receiver and clamp/unclamp the pallet several times to allow the rails to center themselves on to the guide pins.
8. Finish torquing the clamp rail bolts.
MECHANICAL SERVICE
21796-8100 rev C
June 2001
ALIGNMENT PIN REPLACEMENT
TOOLS REQUIRED: Hoist Straps or Chains Eyebolts (2)
CAUTION! Be careful when changing out pallets, each weighs approx. 300lbs.
NOTE: The receiver must be removed in order to access the alignment pins.
1. Both pallets must be on the APC in order to access the receiver.
2. Position the receiver to the front of the machine.
3. Disconnect the air from the machine.
Figure 3.17-3 Alignment Pin Removal
3. Remove the six (6) receiver mounting bolts.
4. Use a hoist and the two eyebolts supplied with the APC, lift the receiver off the table.
5. Use a punch to remove the alignment pins.
6. Install the new pins using a brass hammer. The pins should bottom out in the holes.Pin height from the base of the receiver to the top of the pin should be within .450 to .490.
MECHANICAL SERVICE
218 96-8100 rev C
June 2001
7. Position the receiver back onto the table.
8. Install the six mounting bolts.
9. Reconnect the air to the machine.
10. Position a pallet onto the receiver and clamp/unclamp the pallet to the receiver several times. Check for the pallets sticking during this process. If the pallets are sticking, loosen the clamp rail bolts and clamp/unclamp the pallet several times to center the alignment pin to the rails.
NOTE: Because the receiver has been removed from the VMC, any tooling on the pallets must be re-aligned.
DRIVE PIN REPLACEMENT
NOTE: If the drive pin assembly is damaged due to a crash or from excessive wear, all components should be checked for damage and replaced.
NOTE: The chain must be loosened in order to remove the entire drive pin assembly.
1. Power off the machine.
2. Remove the drive pin retaining clip.
Figure 3.17-4 Drive Pin Assembly
3. Remove 5/16" washer.
4. The cam follower is lightly pressed onto the pin. The spacer should slide off easily.
MECHANICAL SERVICE
21996-8100 rev C
June 2001
LOOSENING THE CHAIN
5. Remove the two screws that mount the coverplate over the sprocket located at the far end of the APC as shown.
Figure 3.17-5 Loosening Chain Sprocket
6. Loosen the 4 bolts that mount the sprocket bracket to the casting.
7. Loosen the chain sprocket tensioner screw slightly.
8. At this point there should be enough slack in the chain to slide the drive pin out.
9. Re-assemble the drive pin assembly according to the assembly drawing.
10. Re-tension the chain in the reverse order.
MECHANICAL SERVICE
220 96-8100 rev C
June 2001
APC PALLETS
There are two different designs of pallets for use with the APC. This difference in design is for locating the pallet on to the receiver. The earlier method uses two friction blocks to slow the pallet and locate it correctly as it enters the machine (part number 20-0053, or 20-0579 for a metric pallet). The current design uses a pin and latch to locate the pallet (part number 20-0053A, or metric 20-0579A). Current method pallets can be used on earlier machines by replacing the location stub (part number 20-1082), with a friction block (part number 20- 1081). See the following figures.
8X 40-1712 SHCS 5/16-18X1/2
2X 20-1081
Pallet Part number 20-0053 (metric 20-0579) Pallet Part number 20-0053a (metric 20-0579a)
The spare pallet, P/N PAL40, will come with two filler blocks (20-1081) and one APC Location Stub (20-1082). If the machine has an existing pallet with part number 20-0053 (Metric 20-0579), then the two filler blocks (20- 1081) will be used and the Location Stub (20-1082) will not be used. See the figures.
If the machine has an existing pallet with a part number 20-0053A (Metric 20-0579A), then one filler block (20-1081) will be used, one Location Stub (20-1082) will be used, and one filler block (20-1081) will not be used. See the figures.
NOTE: The bolts used for the filler block are 40-1712 SHCS 5/16-18 X (QTY 4). Torque to 35 ft-lb. The bolts for the Location Stub are 40-16385 SHCS 5/16-18 X (QTY 4). Torque to 35 ft-lb.
221
ELECTRICAL SERVICE
96-8100 rev C
June 2001
4. ELECTRICAL SERVICE
4.1 SOLENOIDS
Please read this section in its entirety before attempting to replace any solenoid assemblies.
AIR SOLENOID ASSEMBLY
REMOVAL -
1. Turn machine power on and raise spindle head to uppermost position. Turn power off.
2. Remove spindle head covers (Mechanical Service).
3. Remove air supply from machine.
4. Disconnect all air lines going to and from the air solenoid assembly on the bottom rear of the solenoid bracket. Do not remove the fittings --- remove the lines from the fittings.
5. Disconnect the two leads to the low air pressure sensor.
6. Unplug the wiring leading to the plug marked on the solenoid bracket as "880 FROM I/O PCB TO SOLENOID VALVES" and the plug marked "SPARE".
Figure 4.1-1 Air solenoid assembly.
7. Remove the SHCS holding the assembly to the bracket and remove the assembly.
ELECTRICAL SERVICE
222 96-8100 rev C
June 2001
INSTALLATION:
8. Replace the air solenoid assembly and attach to the bracket with the SHCS previously removed. Tighten securely.
9. Reconnect all air lines at this time, ensuring that all connections are tight and do not leak.
10. Reconnect the two leads to the low air pressure sensor.
11. Reconnect the wiring to the plugs on the solenoid bracket (see Step 6).
12. Reconnect air supply to the machine.
TOOL RELEASE PISTON ASSEMBLY AIR SOLENOID
1. Turn machine power on and raise spindle head to uppermost position. Turn power off.
2. Remove spindle head covers (See the procedure in the Mechanical Service section).
3. Remove air supply from machine.
4. Remove the tool release piston assembly (See the procedure in the Mechanical Service section).
5. Unscrew the air solenoid assembly from the tool release piston assembly, taking care to not disturb the position of the clamp/unclamp switches.
6. Unscrew the air solenoid from the air solenoid assembly.
CAUTIO N
3/8" - 16 X 1 3/4" SHCS
TSC Fitting (Optional)
3/8" Air Hose Fitting
1/4" Air Hose Fitting
Unclamp switch
Clamp switch
Figure 4.2-2 Tool release piston assembly with air solenoid assembly.
223
ELECTRICAL SERVICE
96-8100 rev C
June 2001
7. Install the new air solenoid on the air solenoid assembly. Reinstall the air solenoid assembly onto the tool release piston assembly. Take care to not disturb the position of the clamp/unclamp switches.
8. Reinstall the tool release piston assembly (Mechanical Service).
9. Ensure all air lines are reconnected to their proper fittings.
SPINDLE LUBE AIR SOLENOID
1. Turn the machine power off and remove the air supply from the machine.
Figure 4.1-3 Front side of lube/air panel.
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.
ELECTRICAL SERVICE
224 96-8100 rev C
June 2001
Figure 4.1-4 Top view of spindle lube/air solenoid assembly.
4. Unscrew the assembly from the T-fitting.
Figure 4.1-5 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.
225
ELECTRICAL SERVICE
96-8100 rev C
June 2001
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.
CAUTION!Working with the electrical services required for the VMC 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 your organization or otherwise obtain the necessary help BEFORE you continue.
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.
ELECTRICAL SERVICE
226 96-8100 rev C
June 2001
Figure 4.2-1 Control cabinet general overview.
227
ELECTRICAL SERVICE
96-8100 rev C
June 2001
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.
CAUTION! Working with the electrical services required for the VMC 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 your organization or otherwise obtain the necessary help BEFORE you continue.
WARNING!
The electrical panel should be closed and the three latches 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.
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 problems, such as servo over- loads.) To check, simply pull on the wires after the screws are tightened.
ELECTRICAL SERVICE
228 96-8100 rev C
June 2001
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 (354 and 488 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 tight.
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:
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
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.
229
ELECTRICAL SERVICE
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June 2001
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.
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 voltage 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.
WARNING!
ALL POWER MUST BE TURNED OFF AT THE SOURCE PRIOR TO ADJUSTING PHASING.
ELECTRICAL SERVICE
230 96-8100 rev C
June 2001
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 emissions.
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:
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, 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.
231
ELECTRICAL SERVICE
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June 2001
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)
ELECTRICAL SERVICE
232 96-8100 rev C
June 2001
4.3 FUSE REPLACEMENT
Please read this section in its entirety before attempting to replace any fuses.
OVERVOLTAGE FUSE
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. 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. Unscrew the three screws to open the cabinet door. (Control cabinets may require a key)
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. Wait until at 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).
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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
P8P9
P10
P11
P12
P13
P14 P15
P16 P17 P18 P19 P20
P21
P22
P23
P24 P25
P26P27
P28P30
P31P32
P33P34P35
P29
TB1
TB3
TB2
NE1
NE4
FU8FU12 FU11 FU10 FU9
NE6 NE5
NE3
FU13
FU12NE12
NE11 NE10 NE9 NE8 NE7
NE13
FU1 FU2 FU3
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 voltage to the machine does not exceed 260 volts.
SERVO DRIVER & SDIST FUSES
1. Turn the main switch (upper right of electrical cabinet) to the off position.
2. 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. Wait until at least the red CHARGE light on the servo drive assembly goes out before beginning any work inside the electrical cabinet.
3. On the SERVO DRIVE ASSEMBLY, there are three fuses on the SDIST panel, and three individual fuses on each of the SERVO DRIVE boards (See Fig. 4.3-3; the F3 fuses are not shown).
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4. On the SDIST panel, use a flat tip screwdriver to turn the fuse(s) counterclockwise to remove. Replace the blown fuse(s) with ones having the same type and rating (FU1, FU2: amp, type AGC, 250V; FU3: 5 amp, type ABC, 250V).
5. On each of the SERVO DRIVER boards, the fuses (F1, F2, F3) may be replaced by simply pulling out the fuses by hand and replacing with fuses of the same type and rating (F1, F2: 20 amp, type ABC, 250V; F3: 10 amp, type ABC, 250V).
Figure 4.3-3 Servo Drive Assembly; fuse locations
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4.4 PCB REPLACEMENT
Please read this section in its entirety before attempting to replace any PCBs.
MICROPROCESSOR, MOCON (MOTIF) & VIDEO / KEYBOARD
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.
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(s) on the servo amplifiers (servo drive assembly for brush machines) goes out. The servo drive as- sembly is on the left side of the main control cabinet and about half- way 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.
MOCON (or MOTIF) 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. Loosen the three screws on the cabinet door and then open the door enough to safely work on the electrical panel. Wait until the red CHARGE light on the servo amplifiers (servo drive assembly on brush machines) goes out before beginning any work inside the electrical cabinet.
4. Disconnect all leads to the Motor Controller (MOCON), or Motor Interface (MOTIF) board (for brush machines). 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 (or MOTIF) board, attaching it to the VIDEO / KEYBOARD (beneath the MOCON / MOTIF board) with the standoffs.
7. Reconnect all leads (previously removed) to their proper connections.
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VIDEO / KEYBOARD -
NOTE: Refer to "Cable Locations" for a diagram of this board.
8. Remove the MOCON (or MOTIF) 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.
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 need 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 (or MOTIF) board as described in Steps 1-5, and the Video / Keyboard as described in Steps 8-9.
14. Disconnect all leads to the Processor (68020) board. Ensure all cables are properly labeled for reconnecting later. The following illustration shows all cable numbers and the locations on the 68030 board.
15. After all cables have been disconnected, unscrew the standoffs, taking care to hold the board in place until all standoffs have been removed.
16. Replace the Processor (68030) board, attaching it to the electrical cabinet (beneath the 68030 board) with the standoffs.
17. Reconnect all leads (previously removed) to their proper connections.
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SERVO DRIVER & SDIST
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. 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.
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. Wait until the red CHARGE light on the servo drive assembly goes out before beginning any work inside the electrical cabinet.
SDIST BOARD -
NOTE: Refer to "Cable Locations" for a diagram of this board.
4. Disconnect all leads to the Servo Distribution (SDIST) board. Ensure all cables are clearly marked for reconnecting later.
NOTE: The connection labeled "860A" on the board should be used for the cable marked "860B". Some boards, the connection for cable 920 has been incor- rectly marked as "1030". Please note its location for future reference.
NOTE: On some SDIST boards, there may be cables attached to the capacitors with a plastic strap. This will have to be cut off and the cables moved aside in order to remove the board. It will be necessary to replace this strap after the board is replaced.
5. After all cables have been disconnected, remove the eight screws attaching the board to the cabinet. Take care to hold the board in place until all screws have been removed.
6. Replace the SDIST board, attaching it with the eight screws previously removed, using one of the screws as a grounding connection.
7. Reconnect all leads (previously removed) to their proper connection.
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SERVO DRIVER BOARDS -
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 Servo Driver (DRIVER) board that you wish to replace. Ensure all cables are properly labeled for reconnecting later.
NOTE: When replacing any DRIVER board, it will be necessary to disconnect all leads on all DRIVER boards in order to remove or replace the board.
5. Remove the board by first removing the two screws that fasten it to the cabinet. Take care to hold the board in place until both screws have been removed.
6. Replace the DRIVER board, attaching it to the cabinet with the two screws previously removed.
7. Reconnect all leads to all boards at this time. Ensure the red and black leads go to the appropri- ate 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 illustration in the Cable Locations section shows all cable numbers and their 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.
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POWER & 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 (See warning at beginning of "Servo Driver & 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.
4. Disconnect all leads to the Power Distribution (POWER) 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. Don't 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 -
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 illustration in the Cable Locations section shows all cable numbers and their locations on the LVPS board.
10. After all cables have been disconnected, unscrew the two standoffs at the bottom of the 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.
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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 & 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 & KEYBOARD PCB
MICRO PROCESSOR PCB
P1 700B 850
P850
P850A
J13
J3
RS 232/ 32-4090 J1
PORT 1
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.
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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 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 still 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 ORed 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.
Also, disconnect both shield connections on the RS-232 ribbon cables. One connection is at the red-box to the chassis, the second connection is at the processor stack with the shields for the active circuitry.
These two adjustments make a very big difference in the signals and will minimize and possibly eliminate RS- 232 communications problems.
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4.5. FRONT PANEL
Please read this section in its entirety before attempting to replace any component of the control panel.
CRT ASSEMBLY REPLACEMENT
1. Turn the power off and disconnect 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. At this time, remove the end cap on the support arm and unplug the white cable at the connection inside, then unplug the black cable at the connection in the control panel. It may be necessary to cut straps off the black cable's connector to unplug.
4. Unscrew the four hex nuts on the bottom row of the CRT bracket and remove, along with the washers. Set aside in a safe place.
5. While holding up the CRT assembly, remove the four hex nuts on the top row of the CRT bracket, along with the washers.
CAUTION!Take extreme care to not drop or damage the CRT assembly when removing from the control panel.
6. CAREFULLY pull the CRT assembly out toward the rear until it is clear of the control panel and all wiring. Set CRT assembly down in a safe place so as not to damage.
7. Replace by sliding the new assembly onto the eight bolts (four each on top and bottom). Starting with the bottom right, 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 with the socket.
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+ -
771
W h
it e
B la
c k
R e
d
G re
e n
Fan
731
7 4
4
7 4
3
7 4
2
7 4
1
732
772
750
Figure 4.5-1 Interior of control panel (rear).
8. Plug the black cable and white cable into the matching cables. Feed the white cable through the opening in the top of the control panel.
9. Replace the back cover panel and attach with the four screws previously 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.
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 connector must face as shown in Fig. 4.5-2 when reconnecting; otherwise, damage may occur to the machine.
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Blank pin goes to this side of connector
Figure 4.5-2 Jog handle encoder.
4. Using a 5/64" allen wrench, loosen the two screws holding the knob to the control panel and remove.
POWER ON
CYCLE START FEED HOLD
SPINDLE LOAD
POWER OFF
EMERGENCY STOP
HANDLE
+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.
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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 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 counterclockwise 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.
7. Replace the back panel of the pendant.
SPINDLE LOAD METER REPLACEMENT
1. Turn the power off and disconnect 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 two leads at the back of the spindle load meter assembly. Ensure the two leads are properly marked for reconnecting later.
4. Unscrew the 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.
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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.
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 the board.
8. Replace the front and rear cover panels and fasten with the screws that were previously removed.
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SERIAL KEYBOARD INTERFACE (KBIF)
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 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.
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4.6 SPINDLE ENCODER REPLACEMENT
Please read this section in its entirety before attempting to remove or replace encoder.
REMOVAL
1. Turn machine power on. Raise or lower spindle head to a position that will allow you to easily work on the encoder (must be above the enclosures). Turn machine off.
2. Remove head covers (See the procedure in the Mechanical Service section).
3. Disconnect the encoder cable at the top of the encoder.
4. Unscrew and remove the four 10-32 screws holding the encoder to the four standoffs (VF-1, VF-2, VF-3,VF-4) or mounting bracket (VF-0). Remove the encoder, leaving the belt on the pulley at the orient ring.
INSTALLATION
If you wish to install an encoder on a machine start at step 5; if this is just a replacement, skip to step 13. Please note the differences in installation between the VF-0, VF-1, VF-2, and the VF-3,VF-4.
5. For the VF-1, VF-2, and VF-3, VF-4, put some blue Loctite on the threads of the four set screws and screw approximately halfway into the standoffs. Screw the hex end of the set screws into the standoffs.
6. Screw the standoffs into the four holes located at the rear of the transmissions top plate.
7. For the VF-0, place the mounting bracket in place. Fasten to the top plate with the four screws and four lock washers.
8. Place the 18-tooth pulley onto the pulley bushing and tighten down. Place the SHCS through the center axis of the pulley.
9. Screw this assembly into the spindle orientation ring.
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Figure 4.6-1 Spindle encoder installation (VF-1/VF-2).
10. Place the 36-tooth pulley onto the encoder, making the top of the pulley flush with the end of the shaft. Tighten down with the 5/64" hex wrench.
11. Unscrew the four screws and remove the cover panel on the box at the base of the flexible tube.
12. Feed the encoder cable through the flexible tube and connect at the plug in the box on top of the electrical cabinet.
Figure 4.6-2 VF-0 encoder installation.
13. Place the belt on the 36-tooth pulley, then loop over the 18-tooth pulley. Place the encoder assem- bly on the four standoffs (mounting bracket on the VF-0) and attach with the four 10-32 SHCS, placing the #10 lock washers between the socket head and the encoder base.
14. Connect the encoder cable to the encoder assembly.
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5. TECHNICAL REFERENCE
5.1 TOOL CHANGER
The tool changer is an all electric fixed shuttle type. 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 P6 on the side of the control cabinet.
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 carou- sel on a mill with a side mount tool changer and alarm 120 LOW AIR PRESSURE is generated if such a problem exists.
If the shuttle should become jammed, the control will automatically come to an alarm state. To correct this, push the EMERGENCY STOP button and remove the cause of the jam. Push the RESET key to clear any alarms. Press "Tool Changer Restore" button, to automatically reset the tool changer after a crash. Never put your hands near the tool changer when powered unless the EMERGENCY STOP button is pressed.
There is a fuse for the tool changer motors. It might be blown by an overload or jam of the tool changer. 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 CB4.
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When a tool change operation is performed, the following sequence of events occurs:
1) Z axis moves up to machine zero, 2) If the spindle is turning, it is commanded to stop; coolant stopped, 3) Spindle oriented to Tool Changer, 4) Turn TSC pump off, (optional) 5) Turn purge on and off (optional) 6) Pre-charge is on (40 taper spindle only), 7) Shuttle moves in to receive tool, 8) Tool unclamps, 9) Z axis moves up, 10) Tool Changer rotates, 11) Z axis moves down, 12) Tool clamps, 13) Pre-charge off (40 taper spindle only), 14) Shuttle moves out.
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PULL STUDS
The tool holders used are CT #40 taper, V flange, commonly called CT 40. For the 50 taper spindle option, the tool holders used are CT #50 taper, V flange, commonly called CT 50. Use A 45 Degree, P40T Type 1 (P50T Type 1 for 50 taper) inch threads pull stud built to JMTBA standard MAS 403-1982. This pull stud is charac- terized 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. If the machine is equipped with the optional BT tool changer, use BT tooling only. Pull studs are available through HAAS.
A
B
C
A
B
E
C
D
E
D
CT
BT
Tool Holders/Pull Studs
A B C D E
40T
40T
45T
50T
4 0
T 4
0 T
5 0
T 5
0 T
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
0.311.780 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
1-84.00 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 P50T-1
M24 X 3 Threads
JMTBA Standard MAS 403 P50T-1
E
D
A
B
C
DIN-69871 (MIKRON) ISO-7388
A B C D E
45T 3.25 3.23 .44 .82 2.25
40T 2.69 2.50 .44 M16X2
M24X3
1.75
4 0
T
50T 4.00 3.84 .44 2.75
5 0
T
Kit #
Kit #
Kit #
Kit #
20-7556 (TSC)
22-7171 (TSC)
20-7164A (non-TSC)
22-7170 (non-TSC)
TPS24E50
PS24E50
TPS24E
PS24E
45 o
1.780
1.780
1.386
1.386
0.31
45 o
45 o
0.990 0.172 Thru.
45 o
0.990
M24 X 3 Threads
JMTBA Standard MAS 403 P50T-1
M16 X Threads2
M16 X 2 Threads
JMTBA Standard MAS 403 P40T-1
JMTBA Standard MAS 403 P40T-1
M24 X 3 Threads
JMTBA Standard MAS 403 P50T-1
NOTE: CT 40T Pullstud = One Identification Groove BT 40T Pullstud = Two Identification Grooves MIKRON 40T Pullstud = Three Identification Grooves
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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 to the shuttle occurs. When the TOOL RELEASE button 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.
TOOL CHANGER LUBRICATION
Place lubricating grease on the outside edge of the guide rails of the tool changer and run through all tools.
SHUTTLE IN/OUT MOTOR
A DC brush motor is used to move the tool changer assembly towards and away from the spindle. This is called the shuttle. The motor is geared down to a low RPM and then connected to an arm that rotates through 180o and pushes the shuttle in and out.
NOTE: This motor should never be disassembled.
TURRET ROTATION MOTOR
A DC brush motor is used to rotate the tool turret between tool changes. This motor is geared down to a low RPM and connected to a Geneva mechanism. Each 1/2 revolution of the Geneva mechanism moves the tool turret one tool position forward or backward.
NOTE: This motor should never be disassembled.
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5.2 TOOL CLAMP/UNCLAMP
The tool holder drawbar is held clamped by spring pressure. Air pressure is used to release the 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 (but this is quite dangerous), from the keyboard, and from the button on the side of the spindle head. The two manual buttons only operate in MDI or JOG modes.
TOOL CLAMP/UNCLAMP AIR SOLENOIDS
A single solenoid controls the air pressure to release the tool clamp. When the tool clamp relay is activated, 115V AC is applied to the solenoid. This applies air pressure to release the tool. The relay is on the I/O PCB. A circuit breaker will interrupt power to this solenoid.
TOOL CLAMP/UNCLAMP SENSE SWITCHES
There are two switches used to sense the position of the tool clamping mechanism. They are both normally closed and one will activate at the end of travel during unclamping and the other during clamping. 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 Z-axis pulls up from the tool. 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 Through the Spindle Coolant system applies low air pressure and releases the clamped switch (with 40 taper spindle only).
REMOTE TOOL UNCLAMP SWITCH
The Remote Tool Unclamp switch is mounted on the side of the cover to the spindle head. It operates the same as the button on the keyboard. It must be held for second before the tool will be released and the tool will remain released for second after the button is released.
While the tool is unclamped, air is forced down the spindle to clear chips, oil, or coolant away from the tool holder.
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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 7500 RPM (5000 RPM for 50 taper spindles).
Speeds from S1 to the Parameter 142 value (usually 1200) will automatically select low gear and speeds above Parameter 142 will select high gear. Two M codes, M41 and M42 can be used to override the gear selection. M41 for low gear and M42 for high gear. Low gear operation above S1250 is not recommended. High gear operation below S100 may lack torque or speed accuracy. Spindle speed accuracy is best at the higher speeds and in low gear.
If there is no gear box in your machine (VF-0/E/0E) the gear box is disabled by parameters, it is always in high gear, and M41 and M42 commands are ignored.
The spindle is hardened and ground to the precise tool holder dimensions providing an excellent fit to the holder.
SPINDLE WARM-UP PROGRAM
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 warm-up prior to high- speed use. The program number is O02020 (Spindle Warm-Up).
O02020 (Spindle Warm-Up) S500M3; G04 P200.; S1000M3; G04 P200.; S2500M3; G04 P200.; S5000M3; G04 P200.; S7500M3; G04 P200.; S10000M3; G04 P200.; M30;
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SPINDLE RUN-IN PROGRAM
All spindles must go through a run-in cycle at the time of machine installation prior to operating the spindle at speeds above 1,000 RPM. A program has been supplied with the machine that will run-in the spindle during machine installation and should also be used after long periods of machine down-time (two weeks or more). The program number is O02021 (Spindle Run-In). Cycle Time: 2 hours. See Installation Section for copy of the program.
These programs can be used for all spindle types. Adjust spindle speed override depending on maximum spindle speed of machine: Set override at 50% for 5,000 RPM machines; Set at 100% for 7,500 and 10,000 RPM machines; Set at 150% for 15,000 machines.
SPINDLE ORIENTATION
Orientation is performed electrically and no shot pin or solenoid is required for locking the motor in place. 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 locked in position. If the spindle is orientated and locked, commanding spindle forward or reverse will release the lock.
SPINDLE ORIENTATION SEQUENCE
When spindle orientation is commanded, the following sequence of operations occurs:
1) If the spindle is turning, it is commanded to stop, 2) Pause until spindle is stopped, 3) Spindle orientation speed is commanded forward, 4) Pause until spindle is at orientation speed, 5) Spindle encoder rotates past a reference mark, 6) The spindle drive stops and holds the spindle position at a parameter distance from the reference mark, 7) Command spindle lock air solenoid active, 8) Pause until spindle locked status is active and stable, 9) If not locked after time-out time, alarm and stop.
15K HIGH SPEED SPINDLE SPINDLE
Non-Serviceable, Anti-Rotation Drawbar
The drawbar and the spindle are not serviceable as separate items on the 15K Spindle. The 15K Spindle comes with TSC and an extra high clamp drawbar and may be used in both TSC and non-TSC applications. If there is a need to replace the spindle or the drawbar the entire spindle must be replaced.
NOTE: The spindle and the drawbar are balanced at the factory as a matched assembly.
The anti-rotation drawbar does not allow the drawbar to turn in the spindle shaft. By not changing the position of the drawbar changes in vibration output of the spindle are minimized. The balance is also retained when the drawbar does not turn.
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Oil Flow
The specification for oil flow is 0.15-0.18 cc per 0.5 hour when measured from the spindle restrictor with no airflow. This oil flow is measured on each machine. The flow rate is adjusted by changing the restrictor used and by changing the total output of the pump. The pump nominally puts out 3cc per 0.5 hour. The pump has a 0.5 hour cycle time. The pump runs only when the spindle is running or one of the axes is moving. Different sized restrictors are used to control flow. A 3/0 restrictor has twice the flow of a 4/0, which has twice the flow of a 5/0 restrictor.
SPINDLE AIR PRESSURE
Verify Spindle air pressure using the gauge located behind the Air Regulator panel. VF machines should show 17 psi. Adjust if necessary (see Air Connection in the Installation section). VF machines equipped with a 15K spindle, must have the regulator set to 20 psi.
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.
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5.4 CONTROL CABINET
Control cabinet general overview.
Connectors on side of control cabinet.
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5.5 SERVOS BRUSH / BRUSHLESS
SERVO ENCODERS
Haas machines are equipped with brushless motors, which provides for better performance, and no mainte- nance. In addition to the performance differences, these machines differ from brush type machines, which have already been discussed, in the following areas:
The brushless motors have 8192 line encoders built in, which result in a resolution of 32768 parts per revolu- tion.
The motor controller board has a dedicated processor which does all the servo control algorithm.
There is no servo distribution board anymore, therefore there is no CHARGE light present. Care should still be taken however, since there are high voltages present on the amplifiers, even when power is shut off. The high voltage comes from the spindle drive, which does have a CHARGE light.
The servo drive cards are replaced by Brushless Servo Amplifiers, and are controlled differently.
A low voltage power supply card is added to the servo drive assembly to supply the low voltage requirement to the amplifiers.
The user interface and motion profiling have not changed however, and the user should not see any functional differences between a brush type machine and a brushless machine.
SERVO 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 temperature and over voltage protection.
There is a 15 amp (20A for a medium amplifier) supply fuse for failure protection. This fuse is relatively slow, therefore it can handle the 30 amp peak. 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 installed 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.
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5.6 INPUT/OUTPUT ASSEMBLY
The IOPCB contains a circuit for electronically turning the tool changer power on and off. This prevents any arcing of the tool changer relays and increases their life tremendously. This includes an adjustable current limit to the tool changer. Potentiometer R45 adjusts the current limit to the tool changer motors. R45 should be set to limit current to between four and six amps.
The IOPCB also contains a circuit for sensing a ground fault condition of the servo power supply. If more than 0.5 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.
Relay 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 tool changer.
The Input/Output Assembly consists of a single printer circuit board called the IOPCB.
TECHNICAL REFERENCE
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5.7 TWO-SPEED GEAR TRANSMISSION
The spindle head contains a two-speed gear transmission. The spindle motor is directly coupled to the transmission and the transmission is cog belt-coupled to the spindle.
GEAR BOX LUBRICATION
Gear Box: Mobil DTE 25 oil.
The gear box uses an oil sump and is cooled by gear oil. The VF-0/E/0E does not have a gearbox and is air- cooled.
GEAR BOX AIR SOLENOIDS
There is a double solenoid valve controlling air to the gear box shifter. 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 of low gear. A circuit breaker will interrupt power to these solenoids. Power is left on the solenoid which is commanded last.
On machines equipped with a 50 taper spindle, an electric motor drives the gearbox shifter into high or low gear.
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 (50 Taper machines indicate high or low gear by opening). Between gears, both switches are closed indicating a between-gear condition. The diagnostic display shows 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.
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
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5.8 CONTROL PENDANT
JOG HANDLE
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.
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 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%.
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. The EMER- GENCY STOP switch will shut down motion even if the switch opens for as little 0.005 seconds.
Be careful of the fact 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 EMERGENCY STOP as this will leave the tool changer in an abnormal position that takes special action to correct.
Note that tool changer alarms can be easily corrected by first correcting any mechanical problem, pressing RESET until the alarms are clear, selecting ZERO RETURN mode, and selecting AUTO ALL AXES.
If the shuttle should become jammed, the control will automatically come to an alarm state. To correct this, push the EMERGENCY STOP button and remove the cause of the jam. Push the RESET key to clear any alarms. Push the ZERO RETURN and the AUTO ALL AXES keys to reset the Z-axis and tool changer. Never put your hands near the tool changer when powered unless the EMERGENCY STOP button is pressed.
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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 and that the beeper volume control is not closed.
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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 PCBs are interconnected by a local buss on dual 50-pin connec- tors. At power-on of the control, 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 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 LEDs.
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 LEDs 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:
+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.
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.
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.
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.
MSG Power-on serial I/O message output complete. (Normally On) If this light does not come on, there is a problem with serial I/O or interrupts. Disconnect anything on the external RS-232 and test again.
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.
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.
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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 microproces sor or the software running in it. Check all of the buss connectors to the other two PCBs and ensure all three cards are getting power.
There is 1 two-position DIP switch on the processor PCB labeled 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 memory 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.
MOTOR INTERFACE PCB (MOTIF) OPTIONAL
The Motor Interface PCB is used to interface with linear scale encoders.
MOTOR CONTROLLER (MOCON) - BRUSHLESS
The brushless machining centers are equipped with a microprocessor based brushless motor controller board (MOCON) that replaces the motor interface in the brush type controls. It runs in parallel with the main proces- sor, 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 board for a 5 axis machine.
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5.10 SPINDLE DRIVE ASSEMBLY
The spindle drive is located in the main cabinet on the right side and halfway down. It operates from three- phase 200 to 240V AC. It has a 10 (or 20) H.P. continuous rating, and a 15 (or 30) H.P. one-minute rating. The spindle drive is protected by CB1. Never work on the spindle drive until the small red CHARGE light goes out. Until this light goes out, there are dangerous voltages inside the drive, even when power is shut off.
For all other data on the spindle drive, refer to the supplied documentation for your drive.
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 superior 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.
SERVO DRIVE REGEN RESISTOR
A 25-ohm, 300-watt resistor is used by the brush-type servo drives to dissipate excess power caused by the effects of decelerating the servo motors. If the servo motors are 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 automatic control shutdown is begun. If that resistor is removed from the circuit, an alarm may subsequently occur because of an overvoltage condition for the servo buss.
OVERHEAT SENSE SWITCH
There is an over-temperature sense switch mounted near the above-mentioned regen resistors. This sensor is a normally-closed switch that opens at about 1000 C. It will generate an alarm and all motion will stop. After the time period, specified by parameter 297, of an overheat condition, an automatic shutdown will occur in the control.
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5.12 POWER 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 (see chart for ratings) is primarily 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 ratings are listed in the following chart.
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. 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 PSUP PCB.
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SECONDARY CIRCUIT BREAKERS
The following circuit breakers are located on the Power supply assembly.
CB2 controls the 3-phase 115volt distribution. It can be tripped only if there is a short in the control cables or on the IOPCB.
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.
CB6 is a single phase 115V protected output for the user. It may be used on Horizontal mills and lathes with a barfeeder.
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.
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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.
Transformer with 354-488V range Transformer with 195-260V range
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.
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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)
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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. This will only happen if there is a failure of the amplifier card. The user should never attempt to replace these fuses.
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). FU7-12 are ultra fast 20A fuses. They will only blow in the case of a cable short for either the TSC or coolant pump. Spare fuses for the power card are located above the breakers on the spare fuse PCB.
SIZE FUSE NAME TYPE RATING VOLTAGE LOCATION (amps)
5mm FU1 Slo-Blo 250V PSUP pcb, upper right 5mm FU2 AGC 250V " " 5mm FU3 AGC 250V " " 1/4 FU1 Ultra fast 10 250V I/O PCB 1/4 F1 Ultra fast 15 250V Amplifier (X,Y,Z,A,B) 5mm FU4,5 Fast blow 5A 250V PSUP, bottom right corner 1/4 FU7-12 Ultra fast 20A 250V PSUP, bottom
FU2 on the IOPCB is a spare.
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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:
M21
M-FIN
CNC is: Running Waiting for M-fin
.05 ms delay Waiting
for end M-fin Running
The Diagnostic Data display page may be used to observe the state of these signals.
NOTE: See the 8M option section for more details.
M FUNCTION RELAYS
The M code relay 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. Inspect the relays for existing wires to determine which have been used. Contact the Haas factory for more details.
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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 #10 and is wired from input #10 on the I/O PCB. The return line for grounding the circuit should also be picked up 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.
TURNING M FUNCTIONS ON AND OFF
The M code relays can also be separately turned on and off using M codes M51-M55 and M61-M65. M51 to M55 will turn on one of the eight relays and M61 to M65 will turn the relays off. M51 and M61 correspond to M21, etc.
NOTE: Refer to the Diagnostic section in the manual for specific machine Inputs and Outputs.
WIRING THE RELAYS
The relays are marked on the IOPCB, with their respective terminals forward of them. If the optional 8M relay board is installed then the connections on the IOPCB are to be left unused as they are replaced by the relays on the optional board. Refer to the figure, and the Probe Option figure in the Electrical Diagrams section for the terminal labeling.
WARNING!
Power circuits and inductive loads must have snubber protection.
N C
C O
M
N O
M21 M22 M23 M25M24
N C
C O
M
N O
N C
C O
M
N O
N C
C O
M
N O
N C
C O
M
N O
IOPCB Relays
CAUTION! If a screw terminal is already in use DO NOT connect anything else to it. Call you dealer.
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5.16 LUBRICATION SYSTEM
The lubrication system is a resistance type system which forces oil through metering units at each of the 16 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 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 3.0 cc of oil every 30 minutes throughout the oil lines to the lube points. Every lube point receives approximately 1/16 of oil. The control monitors this system through an internal level switch in the reservoir 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 an 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 90000. 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.
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5.17 SWITCHES
LAMP ON/OFF SWITCH
An on/off switch is supplied for the operator's lamp. It is located on the side of the operators pendant.
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.
The wiring for the door switches is routed through the front panel support arm and down through the top of the enclosure.
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 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
There are a number of limit switches located on the VMC, and some are difficult to reach. Ensure the problem is the switch before beginning removal procedures. The following is a list of all switches, their general location, and a functional description:
CLAMP/UNCLAMP SWITCHES
[Tool Release Piston Assembly (2)] There are two switches used to sense the position of the tool clamping mechanism. They are both normally closed and one will activate at the end of travel during unclamping and the other during clamping. 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 Z-axis pulls up from the tool. 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.
SPINDLE ORIENT SWITCH
[Top rear of transmission]
NOTE: This switch does not exist on machines that have a Vector Drive.
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A normally-open switch that is held closed is used to sense when the pin drops in to lock the spindle. When the pin drops the switch opens, indicating orientation is complete.
The normally-closed side of the same switch that is held open, is wired to the spindle drive and commands it into a "Coast Stop" condition. This is done to ensure the spindle motor is not powered when the pin is locking the spindle.
X, Y, AND Z LIMIT SWITCHES
Prior to performing an POWER UP/RESTART or an AUTO ALL AXES operation, 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 per- formed, 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.
Auto search for zero in the Z-axis is followed by a rapid move from the limit switch position down to the tool change position. This makes the Z-axis a little different from the other axes. The position found with the limit switch is not machine zero but is the position used to pull tools out of the spindle. Machine zero for Z is below this by Parameter 64. Be careful during the Z zero search and stay clear of that rapid move.
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 completes, 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.
TOOL CHANGER POSITION SWITCHES
[Inside of Tool Carriage (2)]
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GENEVA WHEEL POSITION MARK
The turret rotation mechanism has a switch mounted so that it is activated for about 30o of travel of the Geneva mechanism. When activated, this switch indicates that the turret is centered on a tool position. This switch is normally closed. The diagnostic display will show this status of this input switch as TC MRK. A 1 indicates the Geneva wheel is in position.
TOOL #1 SENSE SWITCH
The tool rotation turret has a switch that is activated when tool one is in position or facing towards the spindle. At POWER ON this switch can indicate that tool #1 is in the spindle. If this switch is not active at power-on, the first tool change will rotate the turret until the switch engages and then move to the selected tool. The diagnostic display will show the status of this input switch as TOOL #1. A 1 indicates that tool #1 is in position.
SHUTTLE IN/OUT SWITCHES
[Tool Changer Holding Plate (2)]
Two switches are used to sense the position of the tool changer shuttle and the arm that moves it. One switch is activated when the shuttle is moved full travel inward and one is activated when it is full travel outward. These switches are normally closed so that both will be closed between in and out. The diagnostic display will show this status of the input switch. A 1 indicates the associated switch is activated or open.
TRANSMISSION HIGH/LOW GEAR POSITION SWITCHES
[Bottom of Gearbox Assembly (2)]
On machines with a two-speed transmission, 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 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. See Mechanical Service, for Spindle Motor and Transmission removal.
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5.18 Z-AXIS BRAKE MOTOR
The servo brake motor compensates for the weight of the spindle head on machines without a counterbalance. 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 parameter governs the ability of the brake motor, therefore mills without counterbalances must have param- eter 39, Z-Axis Torque Preload, set correctly. Check the parameters sections for the correct value.
5.19 HYDRAULIC COUNTERBALANCE
The spindle head weight is balanced by the upward pull of a hydraulic cylinder. The hydraulic oil forces the piston to retract into the cylinder body. The oil is then pressurized by a nitrogen reservoir. The system is self contained and passive (no pump is required to maintain the lift). Normal Z-Axis of the gas/oil counter balance has the initial pressure to balance the weight at full system volume, plus an additional 50-75 psi overcharge for longevity.
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 LEDs on the processor PCB. If the audible beeper is alternating a second beep, there is a problem with the main control program stored in EPROMs on the processor PCB. If any of the processor electronics cannot be accessed correctly, the LEDs 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 CRT will have the message:
POWER FAILURE ALARM
and all other functions of the control will be locked out.
When the machine is operating normally, a second push of the PARAM/DGNOS key will select the diagnostics display page. The PAGE UP and PAGE DOWN keys are then used to select one of two different displays. These are for diagnostic purposes only and the user will not normally need them. The diagnostic data consists of discrete input signals, discrete output relays and several internal control signals. Each can have the value of 0 or 1. In addition, there are up to three analog data displays and an optional spindle RPM display. Their number and functions are described in the following section.
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5.21 DISCRETE INPUTS / OUTPUTS
The inputs/outputs that are followed by an asterisk (*) are active when equal to zero (0).
DISCRETE INPUT
# Name # Name
1000 TC Changer In 1023 Spare 3 1001 TC Changer Out 1024 Tool Unclmp Rmt* 1002 Tool One In Pos. 1025 Low Phasing 115V 1003 Low TSC Pressure 1026 Spare 3A 1004 Tool In Position 1027 Spare 3B 1005 Spindle High Gear 1028 Ground Fault 1006 Spindle Low Gear 1029 G31 Block Skip 1007 Emergency Stop 1030 Spigot Position 1008 Door Switch 1031 Conveyr Overcrnt 1009 M Code Finish* 1032 Spare 4A 1010 Over Voltage (Mini-Mill - P.S. Fault) 1033 Spare 4B 1011 Low Air Pressure 1034 Spare 5A 1012 Low Lube Press. 1035 Spare 5B 1013 Regen Over Heat 1036 Spare 6A 1014 Draw Bar Open 1037 Spare 6B 1015 Draw Bar Closed 1038 Spare 7A 1016 Spare 1039 Spare 7B 1017 Spare 1040 Spare 8A 1018 Spare 1041 Spare 8B 1019 Spare 1042 Spare 9A (SMTC: Motor stop) 1020 Low Trans Oil Prs 1043 Spare 9B (SMTC: Origin) 1021 Spare 1 1044 Spare 10A (SMTC: Clamp / Unclamp) 1022 Spare 2 1045 Spare 10B
The inputs are numbered the same as the connections on the inputs printed circuit board.
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DISCRETE OUTPUTS
# Name # Name
1100 Powered Servos 1120 Unclamp Pre-Chrg 1101 Spare 1121 HTC Shuttle Out (Air Drive Shuttle: Move shuttle in) 1102 Spare 1122 Brake 5TH Axis 1103 Spare 1123 CE Door Lock 1104 Brake 4th Axis 1124 M21 1105 Coolant Pump On 1125 M22 1106 Auto Power Off 1126 M23 (Air Drive Shuttle: Move Shuttle Out) 1107 Spind. Motor Fan 1127 TSC Coolant 1108 Move T.C. In 1128 Green Beacon On 1109 Move T.C. Out 1129 Red Beacon On 1110 Rotate T.C. CW 1130 Enable Conveyor 1111 Rotate T.C. CCW 1131 Reverse Conveyor 1112 Spindle Hi Gear 1132 M-fin 1113 Spindle Low Gear 1133 Probe 1114 Unclamp Tool 1134 spare 1115 Spare 1135 spare 1116 Move Spigot CW 1136 spare 1117 Move Spigot CCW 1137 spare 1118 Pal Ready Light 1138 spare 1119 TSC Purge 1139 spare
NOTE: If the machine is equipped with an APC the following inputs and outputs will change:
# Name # Name
1009 Pallet Clamped SW 1121 PAL Clamp 1021 APC Door 1122 Door 1022 APC Pin CLR #1 1125 APC Motor 1023 APC Pin CLR #2 1126 Beeper 1026 APC PAL #2 Home 1027 APC PAL #1 Home
The second page of diagnostic data is displayed using the PAGE UP and PAGE DOWN keys. It contains:
INPUTS 2
Name Name Name
X Axis Z Channel X Overheat X Cable Input Y Axis Z Channel Y Overheat Y Cable Input Z Axis Z Channel Z Overheat Z Cable Input A Axis Z Channel A Overheat A Cable Input B Axis Z Channel B Overheat B Cable Input
X Home Switch X Drive Fault Spindle Z Channel Y Home Switch Y Drive Fault Z Home Switch Z Drive Fault A Home Switch A Drive Fault B Home Switch B Drive Fault
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The following inputs and outputs pertain to the Haas Vector Drive. If it is not enabled, these will display a value of *. Otherwise, it will display a 1 or 0.
Spindle Forward Spindle Reverse Spindle Lock Spindle at Speed* Spindle Stopped Spindle Fault Spindle is Locked Spindle Over heat Spindle Cable Fault
The following Discrete Inputs / Outputs 2 are available when parameter 278 SMNT BIT 1,2 or 3 (Side Mount Tool Changer) is set and parameter 209 MCD RLY BRD (M-Code relay board) is ON.
DISCRETE INPUTS 2
Name Name
Spare Input 4A Spare Input 8A Spare Input 4B Serp. Shot Pin* Spare Input 5A Motor Stop Spare Input 5B Origin Spare Input 6A Clamp / Unclamp Spare Input 6B Serp. Cam Count Spare Input 7A Spare Input 11A Spare Input 7B Spare Input 11 B
DISCRETE OUTPUTS 2
Name Name
Spare Output 40 Spare Output 48 (SMTC: Serp. ATC Enable) Spare Output 41 Spare Output 49 (SMTC: Serp. ATC Rev.) Spare Output 42 Spare Output 50 (SMTC: Serp. Carsl CW) Spare Output 43 Spare Output 51 (SMTC: Serp. Carsl CCW) Spare Output 44 Spare Output 52 (SMTC: Serp. Carsl Ena.) Spare Output 45 Spare Output 53 Spare Output 46 Spare Output 54 Spare Output 47 Spare Output 55
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ANALOG DATA
Name Description
DC BUSS Voltage from Haas Vector Drive (if equipped) uP TEMP Microprocessor enclosure temperature (dis-
played only when Parameter 278 bit "uP ENCL TEMP" is set to 1)
SP LOAD Spindle load in % SP SPEED Spindle RPM CW or CCW RUN TIME Machine total run time TOOL CHANGES Number of tool changes VER X.XXX Software version number MOCON MOCON software version YY/MM/DD Today's date MDL HS__ Machine model
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5.22 THE EQUATIONS OF MOTION
An analysis of the physics of motion of a machine tool can give some important insights into the famous 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>>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 Haas 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 inches/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.
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5.23 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 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)
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5.24 SHIPPING THE VMC
NOTE: See the illustrations in the Installation and Shipping the Machine Without a Pallet section for additional information.
IMPORTANT!
1. All of the warnings and cautions in the previous sections of this manual apply to preparation for shipping review them carefully.
2. Once the VMC is crated, the crate must be covered with waterproof tarpaulins any time there is a chance it could be exposed to rain, splashing from wet roads, or other conditions where it could get wet.
3. Parts of an unprotected VMC can be damaged by heavy tarps, indiscriminate use of tie-downs, etc. Therefore, unless a machine is being moved a short distance by professional machinery movers, it must be prepared for shipping and crated according to the following guide lines.
TOOLS REQUIRED
Staple gun Claw hammer 9/16" hex wrench 3/4" wrench 1 1/8" wrench
Forklift with the following specifications:
E/0-FV TXE/E0-FV 1-FV 2-FV 3-FV 4-FV 04/5-FV
*thgieWenihcaM 000,7 009,7 001,7 000,8 005,21 003,31 006,41
htgneLkroF '8 '8 '8 '8 '8 '8 '8
05/5-FV 6-FV 7-FV 8-FV 9-FV 01-FV 11-FV
*thgieWenihcaM 001,61 000,12 000,32 000,42 000,52 000,82 004,92
htgneLkroF '8 '8 '8 '8 '8 '8 '8
* The forklift must be capable of lifting at least this weight.
Cleaning
Clean the machine as necessary before preparing it for shipping.
MATERIALS REQUIRED
One crate (including pallet and 40 corner clips) 3/8" x 3" lag bolts (18) 3/8" washers (18) 6-mil plastic sheet 6-mil plastic cover Coolant box (cardboard) Wire ties Foam pads Fiber banding -13 x 10" bolts (4) " washers (4) -13 Nylock nuts (4) 16d nails (as required)
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LOCK UP THE MACHINE FOR SHIPPING
1. Remove any tools from the tool carousel and spindle.
2. Clean the interior of the enclosure, including the windows, as necessary. After cleaning, spray all metal parts around the way covers, table, and spindle (including up into the spindle) with rust preventive oil. (See the cautionary notes on cleaning the machine in the Maintenance section.)
3. Use the jog handle to center the table under the spindle. NEVER PUT ANY SUPPORT UNDER THE SPINDLE!! THIS WILL DESTROY THE SPINDLE BEARING!!!
4. Set the shipping bracket on the table, then use the JOG HANDLE to bring the head down until it rests on the bracket. Attach the shipping bracket to the table and head with the four SHCS.
5. Press EMERGENCY STOP and the machine is locked up for shipping.
6. Power down (press the POWER OFF button at upper left of control).
7. Remove the discharge tube. Remove the chip conveyor from the motor hub. Pack them both for shipping.
8. Place all loose items in the drain bucket. These items include the control cabinet key, washdown kit, brush, leveling feet, and the leveling screws.
DISCONNECT SERVICES
WARNING!
Working with the electrical and air services required for a VMC can be extremely hazardous. Make sure that pressure has been removed from the air line before you disconnect it from the machine. Similarly, the electrical power must be off and steps must be taken to ensure that it will not be turned back 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 your organization or otherwise obtain the necessary help BEFORE you continue.
1. Disconnect the air supply line at the pressure regulator (below the electrical panel on the back of the machine).
2. Turn off the electrical power to the machine at its source (see the warning at the beginning of this section).
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3. Set the main switch on the machine (upper right of the electrical panel on the back of the machine) to OFF.
4. Release the three latches along the edge of the panel door and open the door.
5. Using a screwdriver to release the terminals, disconnect the three electrical leads to the terminals behind the main switch and the adjacent ground-bus connection. Pull the wires out of the top of the panel box and secure them safely.
6. Remove the air-filter screen mounted toward the bottom on the outside of the panel door (lift it up and then pull the bottom edge out). Clean it with compressed air if necessary.
7. Place the air-filter screen, along with the manuals and other documentation, inside the panel at the bottom left.
8. Set the main switch to OFF (rotate the shaft that engages the handle on the panel door counter- clockwise as far as it will go and then let it snap 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 and lock the latches.
SECURE THE FRONT
CAUTION! No heavy or abrasive ties, chains, wraps, or bindings should be placed in contact with painted or plastic parts of the machine. Damage caused by ignoring this caution is NOT covered by the warranty.
1. Make sure that the machine is locked up and remove any loose material from the table area.
2. Place a pad between the doors, pull them closed, and secure them with two wire ties through the handles.
3. Wrap some padded packing material around the pendant (control box) and secure with some heavy-duty tape. Also, place a couple inches thickness of foam or other packing material on the enclosure behind the control panel.
4. For the VF-3/4, remove the support bolt from the control arm, and swing the arm back and into shipping position. Put the shipping brace into place and secure with two bolts.
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MOVE ONTO THE PALLET
NOTE: If you did not store your shipping materials, pallets and crates are available from Haas Automation. Contact the factory for information.
IMPORTANT! Keep in mind when moving the VMC that much of its weight is concentrated in the column at the back. Therefore, when lifting a VF- 0/1/2 from the side, it is important that the forks of the forklift be positioned as close to the back of the machine as possible without being on the pads.
CAUTION! Do not lift the machine any farther than necessary off the floor when moving it, and move as slowly and cautiously as possible. Dropping the machine, even from a height of a few inches, can cause injury, result in expensive repairs, and void the warranty.
WARNING!
For the VF-0/1/2: The only acceptable way to move a VF-0/1/2 is to pick it up from the side with a forklift. IMPORTANT! Follow the machine weight and fork length specifications described earlier. The forks must be set as far apart as possible without being on the pads. The forks must be positioned all the way to the back of the VMC and they must extend at least 3" past the far side of the machine base. Also, there must be about approximately 6" clearance between the forklift and the side of the machine.
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For the VF-3 through 10: The VF-3 through 10 must be lifted from the BACK of the machine with a forklift. IMPORTANT! Follow the machine weight and fork length specifications described earlier. The forks must be set as far apart as possible without being on the pads. Also, there must be approximately 6" clearance between the forklift and the back of the machine.
Attempting to move the machine any other way may void the warranty.
CAUTION! Use caution when lifting the machine with a forklift not to damage the sheet metal aprons with the forks.
1. Lift the machine a few inches off the floor.
2. Cover the pallet with a 6-mil thick, continuous plastic sheet.
NOTE: This and the other plastic that is added later provide a shield against moisture while the machine is in transit. HOWEVER, the plastic wrapping is not 100 percent waterproof and the crate must be covered with waterproof tarpaulins any time there is a chance it could be exposed to rain, splashing from wet roads, or other conditions where it could get wet.
3. Move the machine over the pallet and align the leveling screws with the holes in the pallet. Note that the pallet center support is offset to one side. When the machine is placed on the pallet, the rear of the machine must be on this side of the pallet.
4. Remove the leveling screws at the four corners of the base. Insert the 3/4-10 mounting bolts through the leveling screw holes. Tighten the bolts to the coupler mounted in the pallet.
5. Drain and clean the coolant system. Pack it in the box it came in and slip the box, heavy end down, into the space on the left side of the machine, between the panel at the back of the machine and the enclosure.
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WARNING!
The box must be positioned with the heavy end down. Then slip packing material between the box and the machine at all points where there is contact. finally, nail a 12" two-by-four cleat to the pallet with 16d nails to hold the box in place.
6. Put the leveling screws, pads, Allen wrench, and screwdriver in the tote kit and position it between the coolant box and the support strip toward the front of the machine. Then nail a 12" two-by-four cleat to the pallet with 16d nails to hold the tote kit in place.
7. Clean the drip pan as necessary and slide it under the machine. If the machine is furnished with the drain bucket, place it at the rear of the machine, under the air/lube panel, and tie into place.
CRATING THE VMC
1. Cover the machine with a sheet of 6-mil thick plastic. Then carefully roll the edges of the bottom plastic and the cover together and staple them to the pallet. This forms a moisture resistant cocoon around the machine. HOWEVER, as noted earlier, the plastic wrapping is not 100% waterproof and the crate must be covered with waterproof tarpaulins any time there is a chance it could be exposed to rain, splashing from wet roads, or other conditions where it could get wet.
2. Set the four sides of the crate around the machine. Note that the front and back of the pallet are shorter than the sides. Therefore, the side panels have more reinforcing strips than the front and back. Also, if you are reusing a crate, make sure that the fork location marks are in the correct location (see earlier comments).
3. Position one of the sides (longer panels) on the edge of the pallet and secure it with five 3/8" lag bolts.
4. Position an adjoining side and secure it in place with a corner clip (use a claw hammer to snap the clip into place). Then secure it with four lag bolts.
5. Repeat the above two steps for the remaining two sides--clip the corner and secure the side. (Remember to use four lag bolts for the short side and five lag bolts for the long side.)
6. Complete clipping the four corners. There should be a total of five clips at each corner.
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7. Place the top panel on top of the crate and clip each side. Use five clips per side.
8. If the fork locations are not painted on the sides, add these marks (refer to earlier figure).
CAUTION! The fork positions marked on the sides of the crate are the key to safely moving the crated VMC. If the fork positions are ignored, there is a good chance that the retaining bolts will be sheared off by the forks and also that the machine will tip over when it is picked up.
This completes packing the VMC for shipping. If you have questions, contact your dealer or the Haas Automa- tion factory.
5.25 SHIPPING THE MACHINE WITHOUT A PALLET
To ship a VMC a short distance, it may not be necessary to mount it on a pallet and crate if you employ professional machinery movers. Nevertheless, you must make specific preparations for moving it and certain precautions are necessary.
NOTE: We strongly recommend using an air-ride suspension truck to minimize jarring the machine. It is well worth the few extra dollars involved. And make sure to ask specifically for air-ride suspension -- not all riggers have trucks of this type.
IMPORTANT!
1. All of the warnings and cautions in the previous sections of this manual apply to shipping without a pallet review them carefully.
2. Parts of an unprotected VMC can be damaged by heavy tarps, indiscriminate use of tie-downs, etc. Therefore, it must be shipped in accordance with the following guide lines.
TOOLS REQUIRED
9/16" hex wrench " wrench (open-end or box-end) Forklift with the following specifications:
E/0-FV TXE/E0-FV 1-FV 2-FV 3-FV 4-FV 04/5-FV
*thgieWenihcaM 000,7 009,7 001,7 000,8 005,21 003,31 006,41
htgneLkroF '8 '8 '8 '8 '8 '8 '8
05/5-FV 6-FV 7-FV 8-FV 9-FV 01-FV 11-FV
*thgieWenihcaM 001,61 000,12 000,32 000,42 000,52 000,82 004,92
htgneLkroF '8 '8 '8 '8 '8 '8 '8
* The forklift must be capable of lifting at least this weight.
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MATERIALS REQUIRED Four metal tie-downs Four -11 nuts (in addition to the four nuts that come with the machine) Two 4 x 4s at least 5' long
PROCEDURE
1. Prepare the machine as described in the Preparation for Shipping the VMC section up to the point of putting it on a pallet. Make sure the spindle is on tool number one. Replace and secure the shipping bracket -- even for the shortest moves. Tie-wrap the doors together and stow the air filter from the control panel door (on the back of the machine) inside the panel.
2. To transport the machine without a pallet, you need four metal tie-downs. (Additional tie-downs can be purchased from Haas if you have lost yours.) After raising the machine with a forklift, turn the four corner levelling adjustment screws clockwise, with the 9/16" hex wrench, until they protrude at least " through the bottom of the machine. Tighten the -11 nuts until the levelling screws are secured in the casting. Place a metal tie-down on each of the four levelling screws (the small hole in the tie-down slips over the top of the screw and rests on the top of the -11 nut). Position the tie-downs so they are at 45 angles to the front, back, and sides of the machine and secure them on the screws with additional -11 nuts.
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3. Place two 4" x 4" posts that are least 5' long on the truck. Lower the VMC onto the truck and align the two pieces of lumber under the leveling screws at the corners of the machine. Remove the forklift and have the rigger secure the machine using the large holes in the four tie-downs as the attachment points for the riggers chains. When the chains are tightened, the leveling screws dig into the 4" x 4" posts to help hold the machine in place.
CAUTION! Do not cross the chains.
4. Using the four corner tie-downs, the machine can be secured without dragging chains across its top. It is a fast, easy, and secure transportation method that protects against damage. If there is limited access, wrap the perimeter of the base above the feet with chain tension as necessary. Be sure to explain to the rigger that this is how you want the machine to be moved BEFORE he does something else.
5. If you wish to tarp the machine, you should be aware of a few potential trouble spots. If a tarp is simply placed over the machine and tightened down, it can do considerable damage, such as bending the conduit carrier for the headstock, wearing paint off the machine, distorting the enclo- sure, and damaging the clear plastic parts. If you must use a tarp, make sure that it is supported off the machine by a wooden frame or other secure structural means.
6. If the fork locations are not painted on the sides, refer to the earlier figures and add them.
CAUTION! These fork positions are very important, and if they are ignored, there is a good chance that the retaining bolts will be sheared off by the forks and that the machine will tip over when it is lifted.
This completes packing the VMC for shipping. If you have questions, contact your dealer or the Haas Automa- tion factory.
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5.26 CABLE LIFT INSTRUCTIONS
PLEASE READ THIS SECTION IN ITS ENTIRETY
BEFORE ATTEMPTING TO LIFT THE VMC.
It is mandatory that preparation and lifting of the VMC be performed by PROFESSIONAL RIGGERS and that this section be used as a reference guide only.
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LIFT KITS for the HAAS VERTICAL MACHINING CENTERS
:)E0097-03TIKTFIL(2/1/0-FV
"8/5,EAS,REHSAW)1(TLOBEYE"61/11x11-8/5)1( "4/3,REHSAWTUCTALF)2(STLOBEYE61/31x01-4/3)2(
SNOITCURTSNI)1(
:)E0099-03TIKTFIL(4/3-FV
SREHSAWTUCTALF"4/3)2(STEKCARBGNITFIL)2( TLOBEYE"61/31x"01-4/3)2(SCHS"2/11x31-2/1)2(
SNOITCURTSNI)1(SREHSAWDRAH,KCALB"2/1)6(
:)1230-03TIKLOOT(5-FV
SREHSAWTUCTALF"4/3)2(STEKCARBGNITFIL)2( TLOBEYE"61/31x01-4/3)2(SCHS"2/11x31-2/1)2( TLOBEYE"61/11x1x8/5)2(REHSAWDRAH,KCALB"2/1)6(
*SRABREDAERPS)2(SNOITCURTSNI)1(
:)E0197-03TIKLOOT(01URHT6-FV
STLOBEYE4/32x7-8/11)2( SNOITCURTSNI)1(
*SRABREDAERPS)2(
NOTE: PRIOR TO JAN. 1996 , 1- 8 EYE BOLT, HEX NUT (P/N 46-1696) AND HOLE PLUG (P/N 22-9918) ARE REQUIRED FOR THOSE MACHINES WITH EYEBOLT THROUGH HOLES.
* Spreader bars and spacer blocks are not included in lift kits
EYEBOLT WORKLOAD RATING
EZISTLOBEYE GNITAR
31-2/1 11-8/5 01-4/3
8-1 7-81/1
sbl008,2 sbl001,5 sbl000,7 sbl000,9 sbl000,21
SNOITUACERPGNITFIL
stniopgnitfilniamehteranmulocehtfopotehtotdehcattasniahcehT:TNATROPMI .tfilehttuohguorhtroolfehtottcepserhtiwlacitrevniamerdluohsdna
tondluohsdnaenihcamehtezilibatsplehoteraesabehtotdehcattasniahctnorfehT .daolniamehtyrracotdesueb
ehtffoenihcamehttfilneht,tuatlitnusniahcehtnopullupylwols,enihcamehtgnitfilnehW .decnalabsniamerenihcamehtgnirusne,roolf
gnippihsrofderaperpsienihcamehterusne,enihcamehtgnitfilrotiktfilehtgnillatsnierofeB .launaMsihtfonoitcesGNIPPIHSROFNOITARAPERPehtnidetonsa
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SECTION 1: INSTALLING THE LIFT KIT VF- 0 / 1 / 2
1. Place a washer on the 5/8"-11 x 1 1/4" eyebolt and mount it to the front Y-axis way cover, as shown in Figure 12.26-1. Hand tighten and orient the bolt vertically as shown.
Fig. 12.26-1 Eyebolt mounting location for VF-0, VF-1, and VF-2.
2. Place a washer on each of the 3/4-10 x 1 3/16" eyebolts and mount to the top of the column as shown in Figure 12.26-2. Tighten securely.
Fig. 12.26-2 VF-0/1/2 eyebolt locations.
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INSTALLING THE LIFT KIT
VF- 3 / 4 3. Install the lifting brackets with (2) 1/2"-13 SHCS and (3) 1/2" hard washers, [(2) washers under
bracket and (1) above bracket] on the base as shown in Figure 12.26-3. Tighten securely.
Fig. 12.26-3 Lifting bracket mounting location for VF-3 and VF-4.
4. Install (2) -10 x 1" eyebolts and (2) 3/4" hard washers to the column casting as shown in Figure 12.26-4. Tighten securely.
Fig. 12.26-4 VF-3/VF-4 eyebolt locations.
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SINGLE POINT LIFTING VF-0 / 1 / 2 / 3 / 4
5. Attach the lifting chain and hooks to the lifting points as shown in Figures 12.26-5 and 12.26-6, ensuring that the chain does not come in contact with the top door beams or rub against any part of the machines sheet metal enclosure.
There is a minimum chain height requirement to lift the machine without damaging the enclosure and to keep the rear chains perpendicular to the floor. The chain length is measured from the top of the column casting.
IMPORTANT: The chains attached to the top of the column are the main lifting points and should remain perpendicular to the floor throughout the entire lift.
The front chains attached to the base are to help stabilize the machine and should not carry the main load.
When lifting the machine, slowly pull up on the chains until taut, then lift the machine, ensuring the machine remains balanced.
Before installing the lift kit or lifting the machine, ensure the machine is prepared for shipping as noted earlier in the PREPARATION FOR SHIPPING pages in this section of the manual.
Fig. 12.26-5 VF-0/1/2 lifting positions. Fig. 12.26-6 VF-3/4 lifting positions.
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1. Install the lifting brackets with (2) 1/2" -13 SHCS and (3) 1/2" hard washers, [(2) washers under bracket and (1) above bracket] on the base as shown in Figure 12.26-7. Tighten securely.
Fig. 12.26-7 Lifting bracket mounting location for VF-5.
2. Install (2) 5/8 x 1 x 1 1/16" eyebolts and (2) 3/4" hard washers to the column as shown in Figure 12.26-8. Tighten securely.
Fig. 12.26-8 VF-5 eyebolt locations on top of column.
SECTION 2: INSTALLING THE LIFT KIT VF-5 40 / 50 TAPER
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3. Attach the lifting chains to the rigging beam as shown. Use the spreader bars to protect against any possible contact points.
IMPORTANT! The spreader bar above the column is used to keep the chains parallel to the column and evenly distribute the load on the eyebolts.
Fig. 12.26-9 VF-5 lifting positions.
BEAM STYLE LIFTING VF-5 40 / 50 TAPER
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VF-6 thru 11 SECTION 3: INSTALLING THE LIFT KIT
* On machines with eyebolt through-holes, remove the eyebolt plugs on the base casting.
1. Install the two 1 1/8"- 7 eyebolts to the base casting as shown below and tighten. Eyebolts should be facing towards the front of the machine when tightened.
Fig. 12.26-10 Eyebolt and position access hole for VF-6 thru 10.
2. These specifications are an approximation of the weight distribution and chain length needed to lift the VF-6 through 11.
Fig. 12.26-11 VF Series weight specifications.
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3. Attach the lifting chains and hooks to the lifting points, with the rigging beam, spreader bar, and spacer block in place. Position the spreader bar so the lifting chains do not come into contact with the waycovers.
Fig. 12.26-12 VF 6 through 10 lifting positions.
4. Use the spacer block to keep the chains from damaging the rear conduit lines.
* On machines with eyebolt through-holes, reinstall the hole plugs.
5. The following weight specifications are an approximation of weight distribution and chain length required to lift the machines.
enihcaM )sdnuop(thgieW htgneLniahC )nmuloc(
0-FV E0-FV 1-FV 2-FV 3-FV 4-FV
04/5-FV 05/5-FV
6-FV 7-FV 8-FV 9-FV 01-FV 11-FV
000,7 009,7 001,7 000,8 005,21 003,31 006,41 001,61 000,12 000,32 000,42 000,52 000,82 004,92
- - - - - - - -
"021 "021 "021 "021 "021 "021
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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, lead 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
Parameter 1 X SWITCHES Parameter 1 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 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 ROT ALM LMSW Rotary alarms at the limit switch.
20 ROT TRVL LIM Rotary travel limits are used.
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22 D FILTER X8 Enables the 8 tap FIR filter. Used to eliminate high frequency vibrations, depending on the axis motor.
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 For HAAS diagnostic use only.
26 2 EREV/MREV For HAAS diagnostic use only.
27 NON MUX PHAS For HAAS diagnostic use only.
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
Parameter 2 X P GAIN Proportional gain in servo loop.
Parameter 3 X D GAIN Derivative gain in servo loop.
Parameter 4 X I GAIN Integral gain in servo loop.
Parameter 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)
Parameter 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
Parameter 7 X ACCELERATION Maximum acceleration of axis in steps per second per second.
Parameter 8 X MAX SPEED Max speed for this axis in steps per second.
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Parameter 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 parameter is to prevent "motor runaway" in case of phasing reversal, or bad parameters. If this parameter is set to 0, it defaults to 1/4 of parameter 183 Max Frequency.
Parameter 10 X FUSE LEVEL Used to limit average power to motor. If not set correctly, this parameter can cause an overload alarm.
Parameter 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 compensate, 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. However, when an axis with the brake has been disabled, the brake must not be released at all. This feature takes care of that situation. Normally, this parameter should be set to zero on all axes. Exceptions are: Mini-mills with the axis brake instead of a counterbalance, parameter 39 Z axis TORQUE PRELOAD must be set to 300. The TORQUE PRELOAD parameter for the remaining axes must be set to zero. Vertical mills with the axis brake instead of a counterbalance, parameter 39 Z axis TORQUE PRELOAD must be set to 600. The TORQUE PRELOAD parameter for the remaining axes must be set to zero. Horizontal mills with the axis brake instead of a counterbalance, parameter 25 Y axis TORQUE PRELOAD must be set to 500. The TORQUE PRELOAD parameter for the remaining axes must be set to zero.
Parameter 12 X STEPS/REVOLUTION Encoder steps per revolution of motor. Thus, an 8192 line encoder gives:
8192 x 4 = 32768
Parameter 13 X BACKLASH Backlash correction in encoder steps.
Parameter 14 X DEAD ZONE Dead zone correction for driver electronics. Units are 0.0000001 seconds.
Parameter 15 Y SWITCHES See Parameter 1 for description.
Parameter 16 Y P GAIN See Parameter 2 for description.
Parameter 17 Y D GAIN See Parameter 3 for description.
Parameter 18 Y I GAIN See Parameter 4 for description.
Parameter 19 Y RATIO (STEPS/UNIT) See Parameter 5 for description.
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Parameter 20 Y MAX TRAVEL (STEPS) See Parameter 6 for description.
Parameter 21 Y ACCELERATION See Parameter 7 for description.
Parameter 22 Y MAX SPEED See Parameter 8 for description.
Parameter 23 Y MAX ERROR See Parameter 9 for description.
Parameter 24 Y FUSE LEVEL See Parameter 10 for description.
Parameter 25 Y TORQUE PRELOAD See Parameter 11 for description.
Parameter 26 Y STEPS/REVOLUTION See Parameter 12 for description.
Parameter 27 Y BACKLASH See Parameter 13 for description.
Parameter 28 Y DEAD ZONE See Parameter 14 for description.
Parameter 29 Z SWITCHES See Parameter 1 for description.
Parameter 30 Z P GAIN See Parameter 2 for description.
Parameter 31 Z D GAIN See Parameter 3 for description.
Parameter 32 Z I GAIN See Parameter 4 for description.
Parameter 33 Z RATIO (STEPS/UNIT) See Parameter 5 for description.
Parameter 34 Z MAX TRAVEL (STEPS) See Parameter 6 for description.
Parameter 35 Z ACCELERATION See Parameter 7 for description.
Parameter 36 Z MAX SPEED See Parameter 8 for description.
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Parameter 37 Z MAX ERROR See Parameter 9 for description.
Parameter 38 Z FUSE LEVEL See Parameter 10 for description.
Parameter 39 Z TORQUE PRELOAD See Parameter 11 for description.
Parameter 40 Z STEPS/REVOLUTION See Parameter 12 for description.
Parameter 41 Z BACKLASH See Parameter 13 for description.
Parameter 42 Z DEAD ZONE See Parameter 14 for description.
Parameter 43 A SWITCHES See Parameter 1 for description AND make sure that this parameter is se to enable the fourth axis before you try to enable the fourth axis from settings.
Parameter 44 A P GAIN See Parameter 2 for description.
Parameter 45 A D GAIN See Parameter 3 for description.
Parameter 46 A I GAIN See Parameter 4 for description.
Parameter 47 A RATIO (STEPS/UNIT) This parameter defines the number of encoder steps required 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 = 2000 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
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Parameter 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 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.
Parameter 49 A ACCELERATION See Parameter 7 for description.
Parameter 50 A MAX SPEED See Parameter 8 for description.
Parameter 51 A MAX ERROR See Parameter 9 for description.
Parameter 52 A FUSE LEVEL See Parameter 10 for description.
Parameter 53 A BACK EMF See Parameter 11 for description.
Parameter 54 A STEPS/REVOLUTION See Parameter 12 for description
Parameter 55 A BACKLASH See Parameter 13 for description.
Parameter 56 A DEAD ZONE See Parameter 14 for description.
Parameters 57 through 128 are used to control other machine dependent functions. They are:
Parameter 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:
0 REV CRANK Reverses direction of jog handle.
1 DISABLE T.C. Disables tool changer operations.
2 DISABLE G.B. Disables gear box functions.
3 POF AT E-STP Stops spindle then turns the power off at EMERGENCY STOP
4 RIGID TAP Indicates hardware option for rigid tap.
5 REV SPIN ENC Reverses sense direction of spindle encoder.
6 REPT RIG TAP Selects repeatable rigid tapping.
7 EX ST MD CHG Selects exact stop in moves when mode changes.
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8 SAFETY CIRC. This enables safety hardware, if machine is so equipped.
9 SP DR LIN AC Selects linear deceleration for rigid tapping. 0 is quadratic.
10 PH LOSS DET When enabled, will detect a phase loss.
11 COOLANT SPGT Enables coolant spigot control and display.
12 OVER T IS NC Selects Regen over temp sensor as N.C.
13 SKIP OVERSHT Causes Skip (G31) to act like Fanuc and overshoot sense point.
14 NONINV SP ST Non-inverted spindle stopped status.
15 SP LOAD MONI Spindle load monitor option is enabled.
16 SP TEMP MONI Spindle temperature monitor option is enabled.
17 ENA ROT & SC Enables rotation and scaling.
18 ENABLE DNC Enables DNC selection from MDI.
19 ENABLE BGEDT Enables BACKGROUND EDIT mode.
20 ENA GRND FLT Enables ground fault detector.
21 M19 SPND ORT 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 of all new machines. 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, 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 CURSR Enable use of jog handle to move cursor.
25 NEG WORK OFS Selects use of work offsets in negative direction.
26 TRANS OIL Enables transmission low oil pressure detection.
27 ENA QUIKCODE Enables conversational programming.
28 OILER ON/OFF Enables oiler power when servos or spindle is in motion.
29 NC OVER VOLT Inverts sense of over voltage signal.
31 DOOR STOP SP Enables functions to stop spindle and manual operations at door switch.
Parameter 58 LEAD COMPENS SHIFT Shift factor when applying lead screw compensation. Lead screw compensation is based on a table of 256 offsets; each +\-127 encoder steps. A single entry in the table applies over a distance equal to two raised to this parameter power encoder steps.
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Parameter 59 MAXIMUM FEED Maximum feed rate in inches per minute.
Parameter 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.
Parameter 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.
Parameter 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.
Parameter 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 motor to stop. If the arm has not stopped after the allowed time alarm 627 ATC ARM POSITION TIMEOUT is generated.
Parameter 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 On Horizontal mills, this parameter is not used. It should be set to zero.
Parameter 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.
Parameter 66 SPINDLE ORI DELAY Maximum delay allowed when orienting spindle. Units are milliseconds. After this time, an alarm is generated.
Parameter 67 GEAR CHANGE DELAY Maximum delay allowed when changing gears. Units are milliseconds. After this time, an alarm is generated.
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Parameter 68 DRAW BAR MAX DELAY Maximum delay allowed when clamping and unclamping tool. Units are milliseconds. After this, time an alarm is generated.
Parameter 69 A AIR BRAKE DELAY Delay provided for air to release from brake on A-axis prior to moving. Units are milliseconds.
Parameter 70 MIN SPIN DELAY TIME Minimum delay time in program after commanding new spindle speed and before proceeding. Units are milliseconds.
Parameter 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.
Parameter 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.
Parameter 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.
Parameter 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.
Parameter 75 GEAR CHANGE SPEED Command speed used to rotate spindle motor when changing gears. Units are maximum spindle RPM divided by 4096.
Parameter 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.
Parameter 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.
Parameter 78 GEAR CH REV TIME Time in milliseconds before motor direction is reversed while in a gear change.
Parameter 79 SPINDLE STEPS/REV Sets the number of encoder steps per revolution of the spindle. Applies only to rigid tapping option.
Parameter 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.
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Parameter 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.
Parameter 82 M MACRO CALL O9001 See parameter 81 for description
Parameter 83 M MACRO CALL O9002 See parameter 81 for description
Parameter 84 M MACRO CALL O9003 See parameter 81 for description
Parameter 85 M MACRO CALL O9004 See parameter 81 for description
Parameter 86 M MACRO CALL O9005 See parameter 81 for description
Parameter 87 M MACRO CALL O9006 See parameter 81 for description
Parameter 88 M MACRO CALL O9007 See parameter 81 for description
Parameter 89 M MACRO CALL O9008 See parameter 81 for description
Parameter 90 M MACRO CALL O9009 See parameter 81 for description
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Parameter 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.
Parameter 92 G MACRO CALL O9011 See parameter 91 for description
Parameter 93 G MACRO CALL O9012 See parameter 91 for description
Parameter 94 G MACRO CALL O9013 See parameter 91 for description
Parameter 95 G MACRO CALL O9014 See parameter 91 for description
Parameter 96 G MACRO CALL O9015 See parameter 91 for description
Parameter 97 G MACRO CALL O9016 See parameter 91 for description
Parameter 98 G MACRO CALL O9017 See parameter 91 for description
Parameter 99 G MACRO CALL O9018 See parameter 91 for description
Parameter 100 G MACRO CALL O9019 See parameter 91 for description
Parameter 101 IN POSITION LIMIT X How close motor must be to endpoint before any move is considered complete when not in exact stop (G09 or G61). Units are encoder steps. This parameter does not apply to feeds.
Parameter 102 IN POSITION LIMIT Y See Parameter 101 for description
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Parameter 103 IN POSITION LIMIT Z See Parameter 101 for description
Parameter 104 IN POSITION LIMIT A See Parameter 101 for description
Parameter 105 X MAX CURRENT Fuse level in % of max power to motor. Applies only when motor is stopped.
Parameter 106 Y MAX CURRENT See Parameter 105 for description
Parameter 107 Z MAX CURRENT See Parameter 105 for description
Parameter 108 A MAX CURRENT See Parameter 105 for description
Parameter 109 D*D GAIN FOR X Second derivative gain in servo loop.
Parameter 110 D*D GAIN FOR Y Second derivative gain in servo loop.
Parameter 111 D*D GAIN FOR Z Second derivative gain in servo loop.
Parameter 112 D*D GAIN FOR A Second derivative gain in servo loop.
Parameter 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.
Parameter 114 Y ACC/DEC T CONST See Parameter 113 for description
Parameter 115 Z ACC/DEC T CONST See Parameter 113 for description
Parameter 116 A ACC/DEC T CONST See Parameter 113 for description
Parameter 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.
Parameter 118 SPINDLE REV TIME Time in milliseconds to reverse spindle motor.
Parameter 119 SPINDLE DECEL DELAY Time in milliseconds to decelerate spindle motor.
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Parameter 120 SPINDLE ACC/DECEL Accel/decel time constant in 200ths of a step/ms/ms for spindle motor.
Parameter 121 X PHASE OFFSET The motor phase offset for X motor. This is arbitrary units.
Parameter 122 Y PHASE OFFSET See Parameter 121 for description.
Parameter 123 Z PHASE OFFSET See Parameter 121 for description.
Parameter 124 A PHASE OFFSET See Parameter 121 for description.
Parameter 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.
Parameter 126 Y GRID OFFSET See Parameter 125 for description.
Parameter 127 Z GRID OFFSET See Parameter 125 for description.
Parameter 128 A GRID OFFSET See Parameter 125 for description.
Parameter 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.
Parameter 130 GEAR STROKE DELAY This parameter controls the delay time to the gear change solenoids when performing a gear change.
Parameter 131 MAX SPINDLE RPM This is the maximum 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.
Parameter 132 Y SCREW COMP. COEF. This is the coefficient of heating of the lead screw and is used to decrease or shorten the screw length.
Parameter 133 Z SCREW COMP. COEF. This is the coefficient of heating of the lead screw and is used to decrease or shorten the screw length.
Parameter 134 X EXACT STOP DIST.
Parameter 135 Y EXACT STOP DIST.
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Parameter 136 Z EXACT STOP DIST.
Parameter 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.
Parameter 138 X FRICTION COMPENSATION
Parameter 139 Y FRICTION COMPENSATION
Parameter 140 Z FRICTION COMPENSATION
Parameter 141 A FRICTION COMPENSATION These parameters compensate for friction on each of the four axes. The units are in 0.004V.
Parameter 142 HIGH/LOW GEAR CHANG This parameter sets the spindle speed at which an automatic gear change is performed. Below this parameter, low gear is the default; above this, high gear is the default.
Parameter 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.
Parameter 144 RIG TAP FINISH DIST This parameter sets the finish tolerance for determining the end point of a rigid tapping operation. Units are encoder counts.
Parameter 145 X ACCEL FEED FORWARD
Parameter 146 Y ACCEL FEED FORWARD
Parameter 147 Z ACCEL FEED FORWARD
Parameter 148 A ACCEL FEED FORWARD These parameters set the feed forward gain for the axis servo. They have no units.
Parameter 149 Precharge DELAY This parameter sets the delay time from precharge to tool release. Units are milliseconds.
Parameter 150 MAX SP RPM LOW GEAR Max spindle RPM in low gear.
Parameter 151 B SWITCHES See Parameter 1 for description.
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Parameter 152 B P GAIN See Parameter 2 for description.
Parameter 153 B D GAIN See Parameter 3 for description.
Parameter 154 B I GAIN See Parameter 4 for description.
Parameter 155 B RATIO (STEPS/UNIT) See Parameter 47 for description.
Parameter 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.
Parameter 157 B ACCELERATION See Parameter 7 for description.
Parameter 158 B MAX SPEED See Parameter 8 for description.
Parameter 159 B MAX ERROR See Parameter 9 for description.
Parameter 160 B FUSE LEVEL See Parameter 10 for description.
Parameter 161 B BACK EMF See Parameter 11 for description.
Parameter 162 B STEPS/REVOLUTION See Parameter 12 for description.
Parameter 163 B BACKLASH See Parameter 13 for description.
Parameter 164 B DEAD ZONE See Parameter 14 for description.
Parameter 165 IN POSITION LIMIT B Same definition as Parameter 101.
Parameter 166 B MAX CURRENT Same definition as Parameter 105.
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Parameter 167 D*D GAIN FOR B Second derivative gain in servo loop.
Parameter 168 B ACC/DEC T CONST Same definition as Parameter 113.
Parameter 169 B PHASE OFFSET See Parameter 121 for description.
Parameter 170 B GRID OFFSET See Parameter 125 for description.
Parameter 171 B EXACT STOP DIST. See Parameters 134 for description.
Parameter 172 B FRICTION COMPENSATION See Parameter 138 for description.
Parameter 173 B ACCEL FEED FORWARD Same description as Parameter 145.
Parameter 174 B SCREW COMP. COEF. This is the coefficient of heating of the lead screw and is used to decrease or shorten the screw length.
Parameter 175 B AIR BRAKE DELAY Delay provided for air to release from brake on B-axis prior to moving. Units are milliseconds.
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.
Parameter 176 C SWITCHES See Parameter 1 for description.
Parameter 177 C P GAIN See Parameter 2 for description.
Parameter 178 C D GAIN See Parameter 3 for description.
Parameter 179 C I GAIN See Parameter 4 for description.
Parameter 180 C SLIP GAIN The slip 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).
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Parameter 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).
Parameter 182 C ACCELERATION Maximum acceleration of axis. The value is the units of encoder steps / second / second at the motor.
Parameter 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).
Parameter 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.
Parameter 185 C FUSE LEVEL See Parameter 10 for description.
Parameter 186 C DECELERATION Maximum deceleration of axis in encoder steps per second per second.
Parameter 187 C HIGH GEAR STEPS/REV The value is the number of encoder steps per revolution of the motor when the transmission is in high gear. If the machine does not have a transmission, this is simply the number of encoder steps per revolution of the motor.
Parameter 188 C ORIENT GAIN The value is the proportional gain used in the position control loop when performing a spindle orientation.
Parameter 189 C BASE FREQ This is the rated frequency of the motor.
Parameter 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.
Parameter 191 C MAX CURRENT See Parameter 105 for description
Parameter 192 C MAG CURRENT This is the magnetization component of the current in the motor, also called the flux or field current.
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Parameter 193 C SPIN ORIENT MARGIN When a spindle orientation is done, if the actual position of the spindle is within this value (plus or minus), the spindle will be considered locked. Otherwise, the spindle will not be locked.
Parameter 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.
Parameter 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.
Parameter 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.
Parameter 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.
Parameter 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 speeding up, and at 80 Hz when the spindle is slowing down.
Parameter 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.
Parameter 200 POST- SWITCH DELAY. UNIT: ms This is the amount of time allowed for the contactors to stabilize after a switch is commanded, before current is applied to the motor.
Parameter 201 X SCREW COMP. COEF. This is the coefficient of heating of the lead screw and is used to shorten the screw length.
Parameter 205 A SCREW COMP. COEF. This parameter should be set to 0.
Parameter 206 SPIGOT POSITIONS Vertical mills only. Maximum number of spigot positions.
Parameter 207 SPIGOT TIMEOUT (MS) Vertical mills only. Maximum timeout allowed for spigot to traverse one spigot location.
Parameter 208 SPIN. FAN OFF DELAY Delay for turning the spindle fan off after the spindle has been turned off.
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Parameter 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 HORIZONTAL When set to (1), the control identifies the machine as a horizontal mill. The control will then make the necessary adjustments, such as enabling the horizontal tool changer.
1 RST STOPS T.C. Tool changer can be stopped with RESET button.
2 CHAIN TC 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 ENA CONVEYOR Enables chip conveyor, if machine is so equipped.
4 50% RPD KBD When (1) the control will support the new style keyboards with 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 look for an additional door switch and will generate an operator message.
6 TC Z NO HOME In Horizontal mills only. This bit prevents Z-axis motion to machine zero prior to a tool change.
7 M36 AUTO MOT In Horizontal only. When set to (1), an M36 rotates the A-axis after the PART READY button is pressed.
8 AUX AXIS TC In Horizontal mills only. When enabled, means the tool changer carousel is driven by an aux. axis.
9 SPIGOT KEY INV 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 REV CONVEYOR Reverses the direction of the chip conveyor.
13 M27-M28 CONVYR Usually the chip conveyor motor and direction relays are attached to the user relays M21 and M22. When this bit is set, the control expects to see the conveyor hooked up to M27 and M28.
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 CONVY DR OVRD When (1) the conveyor 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 DSBL CLNT IN If set to 1 low coolant input will not be used.
19 DSC INP PR Discrete pallet rotate/part ready; inputs enabled if set to 1.
20 RMT TOOLS RLS If set to 1, allows use of remote tool release button on spindle head.
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21 DISK ENABL If set to 1, enables the optional disk drive.
22 TCR KEYPAD If set to 1, enables tool changer restore button on keypad.
23 MCD RLY BRD If set to 1, adds 8 additional relays, for a total of 40. These additional relays (M21-M28) become available on a secondary board, and are shown on the discrete outputs page.
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.
25 AUX JOG NACC If the jog handle is moved rapidly the auxiliary axis will not develope extremely large lags.
26 ALISM PRGRST Alias M codes during program restart.
27 DSBL JOG TST Disables the encoder test for the jog handle.
28 AIR DR @ M24 Used on horizontal mills only.
29 PAL ENABLE This parameter accommodates both the APC on the vertical mill the Rotary Pallet Changer on the Horizontal mill. This parameter bit should be set to 1 if an APC is present. Otherwise, it should be 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 P RDY @ Y160 Used on horizontal mills only.
31 SPNDL 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.
Parameter 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.
Parameter 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.
Parameter 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 this parameter and the negative MAX TRAVEL.
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Parameter 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.
Parameter 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.
Parameter 215 CAROUSEL OFFSET Used on horizontal mills only. Parameter used to align tool 1 of tool changing carousel precisely. Units are encoder steps.
Parameter 216 CNVYR RELAY DELAY Delay time in 1/50 seconds required on conveyor relays before another action can be commanded. Default is 50.
Parameter 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.
Parameter 218 CONVYR RETRY REV TIM Amount of time that the conveyor is reversed in 1/50 seconds after overcurrent is sensed. Default is 2000.
Parameter 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.
Parameter 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.
Parameter 221 MAX TIME NO DISPLAY The maximum time (in 1/50 sec.) between screen updates.
Parameter 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.
Parameter 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.
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Parameter 224 ROT AXIS ZERO OFSET This parameter shifts the zero point of A for a wheel fixture or tombstone.
Parameter 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.
Parameter 226 EDITOR CLIPBOARD This parameter assigns a program number (nnnnn) to the contents of the clipboard (for the advanced editor).
Parameter 227 DISK DIR NAME 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.
Parameter 228 QUICKCODE FILE This parameter set the program numbers to store in the Quick Code definition program. Usually, this is 9999.
Parameter 229 X LEAD COMP 10E9 This parameter sets the X-axis lead screw compensation signed parts per billion.
Parameter 230 Y LEAD COMP 10E9 This parameter sets the Y-axis lead screw compensation signed parts per billion.
Parameter 231 Z LEAD COMP 10E9 This parameter sets the Z-axis lead screw compensation signed parts per billion.
Parameter 232 A LEAD COMP 10E9 This parameter sets the A-axis lead screw compensation signed parts per billion.
Parameter 233 B LEAD COMP 10E9 This parameter sets the B-axis lead screw compensation signed parts per billion.
Parameter 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.
Parameter 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.
Parameter 237 TSC CLNT LINE PURGE The amount of time given for the coolant 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.
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Parameter 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
Parameter 239 SPNDL ENC STEPS/REV This parameter sets the number of encoder steps per revolution of the spindle encoder.
Parameter 240 1ST AUX MAX TRAVEL This parameter sets the maximum travel of the first auxiliary (C) axis in the positive direction.
Parameter 241 2ND AUX MAX TRAVEL This parameter sets the maximum travel of the second auxiliary (U) axis in the positive direction.
Parameter 242 3RD AUX MAX TRAVEL This parameter sets the maximum travel of the third auxiliary (V) axis in the positive direction.
Parameter 243 4TH AUX MAX TRAVEL This parameter sets the maximum travel of the fourth auxiliary (W) axis in the positive direction.
Parameter 244 1ST AUX MIN TRAVEL This parameter sets the maximum travel of the first auxiliary (C) axis in the negative direction.
Parameter 245 2ND AUX MIN TRAVEL This parameter sets the maximum travel of the second auxiliary (U) axis in the negative direction.
Parameter 246 3RD AUX MIN TRAVEL This parameter sets the maximum travel of the third auxiliary (V) axis in the negative direction.
Parameter 247 4TH AUX MIN TRAVEL This parameter sets the maximum travel of the fourth auxiliary (W) axis in the negative direction.
Parameter 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.
Parameter 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 milliseconds.
Parameter 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.
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Parameter 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.
Parameter 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 begin 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.
Parameter 254 VB AIR DOOR CLEARANCE This is a new parameter to support 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 moved 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.
Parameter 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.
Parameter 256 PALLET LOCK INPUT This parameter selects the discrete input (0 to 31) that is to be used to monitor the pallet locked status. Used in horizontal mills only.
Parameter 257 SPINDL ORIENT OFSET If 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.
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Parameter 258 COLD SPINDLE TEMP The 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 parameter. If the microprocessor 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.
Parameter 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, change it to 999999.
Parameter 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 zero prior to tool change (5-axes mills) .
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.
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9 X TEMP SENSOR This performs Lead 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.
Parameter 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 zero prior to tool change (5-axes mills).
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 unwrap the cables.
9 Y TEMP SENSOR This performs Lead 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.
Parameter 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 zero prior to tool change (5-axes mills) .
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
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7 Z 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 Z TEMP SENSOR This performs Lead 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.
Parameter 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 zero prior to tool change (5-axes mills).
4 A 2ND HOME BTN Used to move 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 Lead 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.
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Parameter 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 zero prior to tool change (5-axes mills). On HS mills with the 60 or 120 pocket chain-style tool changer, this bit must be set to 1. It will cause the TOOL CHANGE 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 Lead 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.
Parameter 271 C SWITCHES Parameter 271 is a collection of single-bit flags used to turn servo related functions on and off. This parameter is not used when 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 zero prior to tool change (5-axes mills).
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.
Parameter 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.
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Parameter 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.
Parameter 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.
Parameter 275 A SCREW COMP T. CONST. This parameter should be set to 0.
Parameter 276 B SCREW COMP T. CONST. This parameter should be set to 0.
Parameter 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 G.B. 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 IN This bit is used on horizontal mills only.
3 CHECK HIDN VAR This bit is used on horizontal mills only.
4 DISPLAY ACTUAL When set to 1, displays the actual spindle speed on the Current Commands display page.
5 TSC PRG ENBL Enables purge output on TSC option.
6 SNGL SW CLMP 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 SPND DRV LCK 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.
9 CNCR SPINDLE (Concurrent 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 HYD TC 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.
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11 HAAS VECT DR (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 displayed in the diagnostics display as DC BUSS.
12 UP ENCL TEMP (Microprocessor Enclosure Temperature) When set to 1, the enclosure temperature will be displayed on INPUTS2 screen of the diagnostics display.
13 HAAS RJH (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 TEMP 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 DRV SHTL 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 SPNDL 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 CKPU 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 new Haas Automatic Pallet Changer attached, and 0 for all other machines.
18 D:Y SW 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 installed, 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 D:Y SW 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.
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23 TC DR 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 old configuration where the door is driven open by a timed operation. If it is set to 1, this indicates the new 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 SDMTCRSL This parameter bit is for the HS-2 sidemount tool changer. It must be set to 1 on all HS-2 mills, and 0 on all other mills.
25 HS3 SDMTCRSL This parameter bit is for the HS-3 sidemount tool changer. It must be set to 1 on all HS-3 mills, and 0 on all other mills.
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 SAFETY INVERT 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 1.
30 SWAP A & C 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 SPD DCEL Inverse Spindle Speed Deceleration. When this parameter is set to 1, the spindle decelerates faster at lower speeds, resulting in a shorter deceleration time.
Parameter 279 X SCALE GAIN MULT This parameter 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.
Parameter 280 Y SCALE GAIN MULT See parameter 279 for description
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Parameter 281 Z SCALE GAIN MULT See parameter 279 for description
Parameter 282 A SCALE GAIN MULT See parameter 279 for description
Parameter 283 B SCALE GAIN MULT See parameter 279 for description
Parameter 284 RESERVED
Parameter 285 X LINEAR SCREW OFFS This parameter is used on machines with linear scales. This parameters account for the unused portion of the lead 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.)
Parameter 286 Y LINEAR SCREW OFFS See parameter 285 for description.
Parameter 287 Z LINEAR SCREW OFFS See parameter 285 for description.
Parameter 288 A LINEAR SCREW OFFS See parameter 285 for description.
Parameter 289 B LINEAR SCREW OFFS See parameter 285 for description.
Parameter 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 seconds) nominally. It works in conjunction with parameter 293.
Parameter 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.
Parameter 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.
Parameter 295 SHTL SETTLE 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 unaffected by it.
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Parameter 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.
Parameter 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.
Parameter 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.
Parameter 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.
Parameter 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.
Parameter 301 AUTOFEED-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.
Parameter 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 mill, 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.
Parameter 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.
Parameter 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.
Parameter 306 POCKET UP / DN DELAY This parameter supports the side mount tool changers. It specifies the time allowed (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 generated. For mills without a side mount tool changer, this parameter should be set to 0.
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Parameter 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.
Parameter 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.
Parameter 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.
Parameter 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 its commanded position within the allowed time, alarm 625 INVALID TC START CONDITION is generated.
Parameter 311 ARM BUMP TIME 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.
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.
Parameter 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.
Parameter 313 POCKET INCREMENT This is a parameter for the bridge mill. Under normal circumstances it 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 responsibility 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.
337
PARAMETERSJune 2001
96-8100 rev C
Parameter 314 FEED DELTA V This parameter supports the motion control feature. It is the maximum change in velocity in encoder steps per millisecond.
Model Basic Value Model Basic Value HS-1 8 VF-0 32 HS-1R 8 VF-0E 32 HS-1RP 8 VF-EC 32 HS-15AXT 8 VF-1 32 HS-2RP 8 VF-2 32 HS-3 8 VF-3 24 HS-3R 8 VF-3D 24 MM-1 32 VF-4 24 VR-11 16 VF-4D 24 VB-1 8 VF-5 24 VB-3 8 VF-6 16 VS-3 8 VF-7 16 G-1 8 VF-8 16
VF-9 16 VF-10 8 VF-11 8
Parameter 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 MV NXTL 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 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 XL 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. Note that when this parameter bit is set to 1, the following tool pocket configuration is not allowed (see alarm 422). An example of a tool pocket table with extra large tools:
1 - 2 L 3 - 4 - 5 L 6 -
338
PARAMETERS June 2001
96-8100 rev C
4 HIGH SPEED 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 SPIN 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.
7 RST STOP PAL 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 MILL 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.
9 DOOR OPEN SW 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 control behaves as before.
10 PAL 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.
Parameter 316 APC PAL. CLAMP TIME This is the time required to clamp the APC pallet to the receiver. It should be set to 4000. Units are milliseconds.
Parameter 317 APC UNCLAMP TIME This is the time required to unclamp the APC pallet from the receiver. It should be set to 4000. Units are milliseconds.
Parameter 318 APC PAL. CHAIN TIME This is the time required to cycle the chain. It should be set to 8000. Units are milliseconds.
Parameter 319 APC DOOR CLOSE TIME This is the time required to close the door. It should be set to 6000. Units are milliseconds.
339
PARAMETERSJune 2001
96-8100 rev C
Parameter 320 RP DRAWBAR DOWN This is the time required for the drawbar to move down. The correct value for this will be determined later. Units are milliseconds.
Parameter 321 RP DRAWBAR UP TIME This is the time required for the drawbar to move up. The correct value for this will be determined later. Units are milliseconds.
Parameter 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.
Parameter 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.
Parameter 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.
Parameter 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.
Parameter 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.
Parameter 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.
Parameter 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.
Parameter 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.
Parameter 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.
Parameter 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.
Parameter 339 X SPINDLE THERM COEF. This parameter supports the Spindle Head Thermal Compensation feature, and should be set to 0.
340
PARAMETERS June 2001
96-8100 rev C
Parameter 340 Y SPINDLE THERM COEF. See parameter 339 for description.
Parameter 341 Z SPINDLE THERM COEF. See parameter 339 for description.
Parameter 342 A SPINDLE THERM COEF. See parameter 339 for description.
Parameter 343 B SPINDLE THERM COEF. See parameter 339 for description.
Parameter 345 X SPINDLE THERM TIME.CONST. This parameter supports the Spindle Head Thermal Compensation feature, and should be set to 0.
Parameter 346 Y SPINDLE THERM TIME.CONST. See parameter 345 for description.
Parameter 347 Z SPINDLE THERM TIME.CONST. See parameter 345 for description.
Parameter 348 A SPINDLE THERM TIME.CONST. See parameter 345 for description.
Parameter 349 B SPINDLE THERM TIME.CONST. See parameter 345 for description.
Parameter 351 THRML SENSOR OFFSET This is a parameter used for Lead Screw Thermal Compensation via a temperature sensor attached to the ball nut.
Parameter 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 (inclusive). 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.
341
PARAMETERSJune 2001
96-8100 rev C
Parameter 588 X ENC. SCALE FACTOR These are new axis parameters that 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
If, 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).
Parameter 589 Y ENC. SCALE FACTOR See parameter 588 for description
Parameter 590 Z ENC. SCALE FACTOR See parameter 588 for description
Parameter 591 A ENC. SCALE FACTOR See parameter 588 for description
Parameter 592 B ENC. SCALE FACTOR See parameter 588 for description
Parameter 593 Sp ENC. SCALE FACTOR See parameter 588 for description
Parameter 594 U ENC. SCALE FACTOR See parameter 588 for description
Parameter 595 V ENC. SCALE FACTOR See parameter 588 for description
Parameter 596 W ENC. SCALE FACTOR See parameter 588 for description
Parameter 600 PEAK SPIN. PWR - KW This is a new parameter that has been added to support 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.
342
PARAMETERS June 2001
96-8100 rev C
LEAD SCREW COMPENSATION
Separate lead 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 entries 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 lead screw compensation tables.
ELECTRONIC THERMAL COMPENSATION
When ballscrews rotate they generate heat. Heat causes the ballscrews to expand. In constant duty cycles as in mold making 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 compensation 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.
343
MAINTENANCEJune 2001
96-8100 rev C
7. MAINTENANCE SCHEDULE
The following is a list of required regular maintenance for the HAAS VF Series Vertical Machining Centers. Listed are the frequency of service, capacities, and type of fluids required. These required specifications must be followed in order to keep your machine in good working order and protect your warranty.
INTERVAL MAINTENANCE PERFORMED
DAILY Check coolant level each eight-hour shift (especially during 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. Be careful to disconnect the coolant pump from the controller and POWER OFF the control before working on the coolant tank. Do this MONTHLY for machines without the TSC option. Check air gauge/regulator for 85 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 machines specifications.
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. See section 7.4. For 50 taper spindles: Check oil level in sightglass. Add from side of gearbox if necessary. See section 7.5. Inspect way covers for proper operation and lubricate with light oil, if neces-
sary. Place a dab of grease on the outside edge of the guide rails of the tool
changer and run through all tools.
SIX MONTHS Replace coolant and thoroughly clean the coolant tank.
Check all hoses and lubrication lines for cracking.
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.
Replace air filter on control box every 2 years.
MAINTENANCE
344
June 2001
96-8100 rev C
7.1 TSC MAINTENANCE
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 red zone.
On newer machines, 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 or cleaning filter elements, run TSC system with no tool in spindle for at least one minute to prime system.
TSC coolant pump assembly. Cleaning the intake filter.
To clean the filter: Turn off the coolant pump. Remove the filter. Clean and reinstall filter.
345
MAINTENANCEJune 2001
96-8100 rev C
7.2 LUBRICATION CHART
* Mineral cutting oils will damage rubber components throughout the machine.
WARNING!
The TSC pump is a precision gear pump and will wear out faster and lose pressure if abrasive particles are present in the coolant.
Use of coolants with extremely low lubricity can damage the TSC Coolant tip and pump
When machining castings, sand from the casting process and the abrasive properties of cast aluminum and cast iron will shorten pump life unless a special filter is used in addition to the 100-micron mesh suction filter. Contact Haas Automation for recommendations.
Machining of ceramics and the like voids all warranty claims for wear and is done entirely at the customers 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. A larger coolant tank is recommended.
Shortened pump life, reduction of pressure and increased mainte- nance are normal and to be expected in abrasive environments and are not covered by warranty.
MAINTENANCE
346
June 2001
96-8100 rev C
7.3 LUBRICATION SYSTEM
All machine lubrication is supplied by the external lubrication system. The reservoir is located on the lower rear of the machine (see figure below). Current lube level is visible in the reservoir. If additional lube needs to be added, remove the cap from the fill port and add lube to the proper level.
External Lubrication System
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.
To lubricate the system, pull up on the primer pull-tab located next to the fill port. The primer will automati- cally send 3 cc of lube through the system.
347
MAINTENANCEJune 2001
96-8100 rev C
7.4 VF-1 THROUGH 6 / 40T - TRANSMISSION OIL
There is no visible indicator for the level of transmission oil in the VF 1-6/40T models.
To add transmission oil, remove the access panel located directly behind the spindle head. This will expose the Transmission Oil Overflow Pipe. Place a container on the table, beneath this outlet. Manually jog the Z axis to its full -Z travel. Power down the machine. Locate the Transmission Oil Fill Cup, ac- cessed from the top of the motor housing (see figure below). There is a cut-out provided in the top of the motor housing sheetmetal for filling. Slowly pour in Mobil DTE 25 oil until oil starts to come out of the overflow pipe. This overflow indicates your transmission oil reservoir is full. Close the Transmission Oil Fill Cup. Wipe off the overflow pipe and replace the access cover. Consider any overflow oil to be used and dispose of properly.
VF 1-6/40T Transmission Oil Fill Cup
MAINTENANCE
348
June 2001
96-8100 rev C
7.5 VF-6 THROUGH 11 50T - TRANSMISSION OIL
CAUTION! Power down the machine before performing any maintenance tasks.
The VF 6 through 11 50T machines provide a means to check the transmission oil level. The transmission oil level eye is located behind an access panel secured to the right side of the spindle housing (as viewed from the front; see figure below). To visually check the oil level, remove the 6 BHCS securing the access panel to the spindle housing sheetmetal. Remove the access panel. The transmission oil level eye will be visible. The oil level should reach the middle of the eye.
VF 6 through 11 50T Oil Level
If additional oil is necessary, remove the fill port plug located just to the left of the eye. Add Mobil DTE 25 oil until the proper level is reached. Replace the fill port bolt and tighten. Securely reattach the access panel.
7.6 CHIP AUGER
MAINTENANCE
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 trap regularly. Should the drain become clogged and cause coolant to collect in the machines pan, stop the machine, loosen the chips blocking the drain, and allow the coolant to drain. Empty the coolant tank strainer, then resume operation.
CABLE LOCATIONS
34996-8100 rev C
June 2001
8. PCB'S, CABLE LOCATIONS AND BOARD DIAGRAMS
CABLE LOCATIONS
350 96-8100 rev C
June 2001
93-1010B
J1 J2
J3
J5 J4
S2 12
U15
D1
D2
D3
D4
D5
D6
D8
D7
U16
U42 U41
U43
RP2
ADDRESS BUS DATA BUS
RP3 RP4 RP5
U50 U51 U52 U54U53
U44 U45 U46 U47 U48 U49
U17 U18 U19 U20 U21 U22 U23
U34
U39
U38U37
U7
U1
U9 U10 U11 U12 U13 U14
U2 U3 U4 U5 U6
U24
U33 850A 850
U8
J6
MICRO PROCESSOR PCB - P/N 93-1010B
CABLE LOCATIONS
35196-8100 rev C
June 2001
MICRO PROCESSOR PCB - P/N 93-1010B CABLE CONNECTIONS
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 -
CABLE LOCATIONS
352 96-8100 rev C
June 2001
BRUSHLESS SERVO AMPLIFIER - P/N 93-5550C
TO SERVO MOTOR
325VDC (FROM HAAS VECTOR DRIVE)
LOW VOLTAGE (INPUT)
SERVO DRIVE SIGNAL ( FROM MOCON)
CABLE LOCATIONS
35396-8100 rev C
June 2001
BRUSHLESS SERVO AMPLIFIER - P/N 93-5550C 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 - 320VDC SPINDLE DRIVE -
Y AXIS AMP P 580 LOW VOLTAGE L. V. POWER SUPPLY - TB A, B, C - MOTOR DRIVE Y SERVO MOTOR - P 620 Y DRIVE SIGNAL MOCON PCB P3 TB -HV +HV - 320VDC 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 - 320VDC 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 - 320VDC SPINDLE DRIVE -
CABLE LOCATIONS
354 96-8100 rev C
June 2001
POWER PCB 93-0227
32-5200H
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
P8P9
P10
P11
P12
P13
P14 P15
P16 P17 P18 P19 P20
P21
P22
P23
P24 P25
P26P27
P28P30
P31P32
P33P34P35
P29
TB1
TB3
TB2
NE1
NE4
FU8FU12 FU11 FU10 FU9
NE6 NE5
NE3
FU13
FU12NE12
NE11 NE10 NE9 NE8 NE7
NE13
FU14
FU1 FU2 FU3
CABLE LOCATIONS
35596-8100 rev C
June 2001
POWER PCB - P/N 93-0227 CABLE CONNECTIONS
I/O 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 Voltage 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 P19 90 3PH 115VAC IO PCB P56 P18 90C 115VAC spare 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
CABLE LOCATIONS
356 96-8100 rev C
June 2001
93-0228S
Q1
U30
U54
P60
LE33
LE40
LE34
LE35
LE17
TB1
P63
P64 P54
P57
P58P59
K11
K12
K10
K9
K7Q17
Q30
Q13
Q31
Q14
Q28
Q15
Q29
Q16
Q27
Q10
Q18
Q22 Q21 Q20 Q19 Q23
P31 P33P32 P34 P35 P36 P37 Q5 Q4Q3
LE31LE25
T1
FU1
K35
M21 M22 M23 M25M24
U8
U1
U2
U3
U4
U5
U6
U7
U38
U56
U58
U45 U51
U50
U53
U44
R87
P22
P23
P24
P25
P26
P27
P28
P29
P30
P21
P20
P19
P18
P17
P16
P15
P14
P13
P12
P11
P10
P8
P7 P61 P62
P6
P4
P3
P2
P1
U8
U6
U7
R119
R122
Q39 Q40
LE38
LE39
LE36
LE37
LE19 LE21
LE22
LE41
Q35
Q6
Q12
Q24
Q9
FU2
Q13
Q14
Q15
Q16
Q10
K33 K34 K35 K36 K37
P5
P9
P38 P39
P40
P41
P42
P43
P44
P45
P46
P47
P49
P51
P52
P53
P55
P56
D10
D1 R3
R52
D22 D21 D20
D19 D18 D17
DISP1
DISP2
DISP3
D12
D11
U8
R126
RI27
K17
K18
P66
P67
P68
P68
U68
U32
U47
U48
U55
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
P50
P48
Q37
P70
U21
U20
U14
U64
U67 U22
U62U63
U19
U49
U23
U24
LE18
K38
CR5
J10
Q38
U65
U66
Q34
Q26
LE20
LE32
Q25Q32
Q33 J9
TB2
I/O PCB S - P/N 93-0228
I/O PCB S - P/N 93-0228 CABLE CONNECTIONS I/O PLUG # CABLE # TO LOCATION PLUG #
P1 140B Chip Conveyor VB1/Gantry P2 820B Not Used P3 820 TC STAT P4 900 Low TSC P5 770 E-Stop Front Panel P6 770A E-Stop Sw B P7 770B E-Stop SW C P8 1050 Door Open A P9 1050A Door Open B P10 100 M-Fin P11 970 VD Over Volt VD J1 P12 950 Low Air/Low Oil P13 960 Low Lube P14 830 Regen Overheat
CABLE LOCATIONS
35796-8100 rev C
June 2001
I/O PCB S - P/N 93-0228 CABLE CONNECTIONS I/O PLUG # CABLE # TO LOCATION PLUG #
P15 890 Spindle Status P16 780 Spare P17 410 APC Door Open , VB Clamshell P18 790 APC Pin Clear P19 190 Remote Unclamp SW P20 190A Not Used P21 240 Spare APC Pallet Home P22 1070 Skip M22 P23 420 Spare P24 440 Auto Door Open P25 450 Spare P26 460 Spare P27 470 SMTC Cambox Status P28 480 Spare P29 1040A Door Lock A P30 1040 Door Lock B P31 230 5th Axis Brake P32 250 APC Door, VR Shut In P33 270 TSC Purge P34 260 Pal Ready Lt P35 200 Spigot P36 280 Beacon P37 140A Chip Conv En/Rev HS Option Card P38 140 Chip Conv Power Output P39 160 Chip Conv Power Input PSUP P21 P40 300 250V Oil Pump/Luber P41 300A SP Fan/Oil Pump P42 170 Auto Off PSUP P23 P43 940 Coolant Output P44 930 250V TSC/Cool Input Power PSUP P20 P45 940A TSC Coolant TSC Cool. Out. P46 390 4th Axis Brake P47 350 Axis Brake Trans P6 P48 120 Coolant Over Temp P49 350A Hyd En Trans P4 P50 130 TSC Over Temp P51 430 APC Pallet Clamp P52 710 Spare A/B P53 880C Wye-Delta Switch P54 880B High/Low Gear P55 880A Spindle Head Solenoids P56 90 115V IOPCB Input Pwr(AC) PSUP P19 P57 TC Jumper or SMTC Resistor P58 810A APC MTR P59 810 TC MTRS P60 860A +5/+12V Logic Pwr (IOPCB) PSUP P27 P61 540 Outputs Cable 24-55 MOCON P14 P62 540A Outputs Cbl For 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 APC Beeper P68 310 Auto Door Clutch P69 220 Pocket Up/Down,VR Shuttle Out, VB Clamshell P70 530 Outputs Cable 16-23 MOCON P13 TB1 M21-24 Probe, M-Fin, User Spare TB2 M25 User Spare
CABLE LOCATIONS
358 96-8100 rev C
June 2001
32-4031E
JOG HANDLE
J1
J2 J3
J5
Y1U9
J12
P1
P6 P5 P4 P2P3
DISCRETE INPUTS
SERIAL KEYBOARD INTERFACE PCB WITH HANDLE JOG P/N 93-1072B
CABLE LOCATIONS
35996-8100 rev C
June 2001
SERIAL KEYBOARD INTERFACE PCB WITH HANDLE JOG P/N 93-1072B CABLE CONNECTIONS
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.
CABLE LOCATIONS
360 96-8100 rev C
June 2001
VIDEO & KEYBOARD PCB W/ FLOPPY DRIVE P/N 93-1001A
CABLE LOCATIONS
36196-8100 rev C
June 2001
VIDEO & KEYBOARD PCB W/ FLOPPY DRIVE P/N 93-1001A CABLE CONNECTIONS
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
CABLE LOCATIONS
362 96-8100 rev C
June 2001
MOCON PCB - P/N 93-1067E
P34P24
P18
P20
P10 P26 P27 P28
P17 P21 P22 P12
P11 P13
P14
P16
P33
P32
P5
P4
P3
P2
P15
P19
U43
P31
P30
P9
P8
P7
P6
P1
32-4023M
CABLE LOCATIONS
36396-8100 rev C
June 2001
MOCON PCB - P/N 93-1067E 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 - P9 690 A ENCODER INPUT A ENCODER - P30 690B B ENCODER INPUT B ENCODER - 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 & 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
CABLE LOCATIONS
364 96-8100 rev C
June 2001
MOTIF PCB - P/N 93-1066
CABLE LOCATIONS
36596-8100 rev C
June 2001
MOTIF PCB - P/N 93-1066 CABLE CONNECTIONS
MOTIF
PLUG # CABLE # SIGNAL NAME TO LOCATION PLUG # ADDRESS - ADDRESS BUSS VIDEO PCB - & DATA - DATA BUSS MICRO PROC. PCB - P2 610 X DRIVE SIGNAL X SERVO DRIVE P3 P3 620 Y DRIVE SIGNAL Y SERVO DRIVE P3 P4 630 Z DRIVE SIGNAL Z SERVO DRIVE P3 P5 640 A DRIVE SIGNAL A SERVO DRIVE P3 P6 660 X ENCODER OUTPUT X ENCODER - P7 670 Y ENCODER OUTPUT Y ENCODER - P8 680 Z ENCODER OUTPUT Z ENCODER - P9 690 A ENCODER OUTPUT A ENCODER - P10 550 MOTIF INPUTS / I/O OUTPUTS I/O PCB P4 P11 510 I/O RELAYS 1-8 I/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. SPEED COMMAND SPINDLE DRIVE - P17 980 VOLTAGE MONITOR SDIST PCB P9 P18 750 JOG INFO. JOG HANDLE - P20 1000 SP. ENCODER OUTPUT SPINDLE ENCODER - P21 1020 SP. TEMP SPINDLE - P22 730B SP. DRIVE LOAD SPINDLE DRIVE - P24 990 HOME SENSORS X, Y & Z LIMIT SW. -
CABLE LOCATIONS
366 96-8100 rev C
June 2001
RS-232 PORT #1 PCB - P/N 32-4090 CABLE CONNECTIONS
PLUG # CABLE # TO LOCATION PLUG # P1 850 VIDEO & J13 INTERNAL KEYBOARD J1 - - - EXTERNAL
CABLE LOCATIONS
36796-8100 rev C
June 2001
50T TRANSMISSION P.S. / HYDRAULIC C.B. PCB P/N 93-4095C
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
CABLE LOCATIONS
368 96-8100 rev C
June 2001
M CODE RELAY BOARD P/N 93-1057B 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
36996-8100 rev C
June 2001
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-DELTA SWITCH ASSEMBLY P/N 32-5850A
CABLE LOCATIONS
370 96-8100 rev C
June 2001
CABLE LOCATION DIAGRAM
371
CABLE LIST
96-8100 rev C
June 2001
9. CABLE LIST
WIRE/ TERMINAL FUNCTION NAME: NUMBER
INCOMING POWER 195-260 VAC (353-488 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, TO CB1-3
71 PROTECTED 195-260 VAC FROM MAIN CB1-4 TO K1-1 72 PROTECTED 195-260 VAC FROM MAIN CB1-5 TO K1-2 73 PROTECTED 195-260 VAC FROM MAIN CB1-6 TO K1-3
74 195-260 VAC FROM K1-4 TO XFORMER T1 75 195-260 VAC FROM K1-5 TO XFORMER T1 76 195-260 VAC FROM K1-6 TO XFORMER T1
77 230VAC PHASE 1 , FROM XFORMER T1 TO VECTOR / CHIP CONV 78 230VAC PHASE 2 , FROM XFORMER T1 TO VECTOR / CHIP CONV 79 230VAC PHASE 3 , FROM XFORMER T1 TO VECTOR / CHIP CONV
90 115 VAC FROM TB2 (CB2 OUTPUT) TO IOPCB P33 - (3 + SHIELD) 91 STEPPED-DOWN 115 VAC (FROM XFRMER T1) #18 92 STEPPED-DOWN 115 VAC (FROM XFRMER T1) #18 93 STEPPED-DOWN 115 VAC (FROM XFRMER T1) #18 94 SHIELD DRAIN
- 115 VAC FROM XFORMER T1 TO TB1 (CB2 INPUT) 94 STEPPED-DOWN 115 VAC (FROM XFORMER T1) 95 STEPPED-DOWN 115 VAC (FROM XFORMER T1) 96 STEPPED-DOWN 115 VAC (FROM XFORMER T1)
90A 115 VAC TO CRT - (2 + SHIELD) 91A LEG 1 #16 92A LEG 2 #16 93A SHIELD DRAIN
90B 115 VAC TO HEAT EXCHANGER - (2 + SHIELD) 91B LEG 1 #16 92B LEG 2 #16 93B SHIELD DRAIN
372
CABLE LIST
96-8100 rev C
June 2001
90C 115 VAC TO CB4 - (2 + SHIELD) 91C LEG 1 #16 92C LEG 2 #16 93C SHIELD DRAIN
100 M-FIN (IOASM TO SIDE OF BOX) - (2 + SHIELD) 101 SIGNAL #20 102 COMMON #20 101 SIGNAL #20 102 COMMON #20 103 SHIELD DRAIN
140 230VAC 3PH POWER TO CHIP CONVEYOR MOTOR (5 + SHIELD) 141 PHASE A 230VAC 142 PHASE B 230VAC 143 PHASE C 230VAC 144 STARTING WINDING 230VAC 145 STARTING WINDING 230VAC 146 SHIELD DRAIN
160 3PH 230VAC TO CHIP CONVEYOR CONTROLLER (3 + SHIELD) 161 PHASE A 230VAC 162 PHASE B 230VAC 163 PHASE C 230VAC 164 SHIELD DRAIN
170 AUTO OFF FUNCTION - (2 + SHIELD) 171 UNSWITCHED LEG 1 #20 172 SWITCHED LEG 2 #20 173 SHIELD DRAIN
180 COOLANT SPIGOT DETENT SWITCH (2 + SHIELD) 181 SIGNAL 182 COMMON 183 SHIELD DRAIN
190 UNCLAMP FROM SPINDLE HEAD TO IOASM 191 INPUT 25 192 DIGITAL RETURN
200 COOLANT SPIGOT MOTOR (12VDC) 201 MOTOR + 202 MOTOR -
210 DATA CABLE TO 3" FLOPPY DISK DRIVE (40 PINS)
220 SERVO BRAKE 115VAC - (2 + SHIELD) 221 115VAC COMMON 222 115VAC SWITCHED 223 SHIELD DRAIN
373
CABLE LIST
96-8100 rev C
June 2001
230 5th AXIS BRAKE
240 SPARE INPUTS FROM IOPCB P25
250 SPARE OUTPUTS FROM IOPCB P45
260 K210 CABLING FOR EC
270 K111 CABLING FOR EC
280 RED/GREEN STATUS LIGHT WIRING (3+ SHIELD) 281 RED LAMP 115VAC 282 GREEN LAMP 115VAC 283 COMMON 115VAC 284 SHIELD DRAIN
300 115VAC TO SPINDLE MOTOR FAN/OIL PUMP/OILER (2 + SHIELD) 301 LEG 1 115VAC PROTECTED #18 302 LEG 2 115VAC PROTECTED #18 303 SHIELD DRAIN
350 SERVO BRAKE RELEASE 115VAC - (2 + SHIELD) 351 LEG 1 COMMON 352 LEG 2 SWITCHED 353 SHIELD DRAIN
360-389 RESERVED
390 115VAC TO 4TH AXIS BRAKE (LATHE PART DOOR) - (2 + SHIELD) 391 LEG 1 COMMON 392 LEG 2 SWITCHED 393 SHIELD DRAIN
410-483 RESERVED
490 ALL BRUSHLESS AXIS SERVO MOTOR DRIVE POWER CABLE 491 A PHASE 492 B PHASE 493 C PHASE 494 GROUND
490A A AXIS MOTOR POWER 490B B AXIS MOTOR POWER 490X X AXIS MOTOR POWER 490Y Y AXIS MOTOR POWER 490Z Z AXIS MOTOR POWER
374
CABLE LIST
96-8100 rev C
June 2001
500 OVERTEMP SENSOR FROM SPINDLE MOTOR - (2 + SHIELD) 501 OVERTEMP WIRE 1 #20 (N.C.) 502 OVERTEMP WIRE 2 #20 503 SHIELD DRAIN
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 (MOTIF-P10) 34 WIRE RIBBON #24
610 X AXIS HAAS AMPLIFIER CABLE TO MOTOR CONTROLLER BOARD (MOTOR CONTROLLER BOARD SIDE 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 C AXIS HAAS VECTOR CURRENT COMMAND CABLE TO MOTOR CONTROLLER BD. (SAME AS 610-1 THRU 610-10)
650 THREE PHASE POWER TO SPINDLE MOTOR - (3 + SHIELD) 651 LEG 1 OF 230VAC 652 LEG 2 653 LEG 3 654 SHIELD DRAIN
375
CABLE LIST
96-8100 rev C
June 2001
650A THREE PHASE POWER TO SPINDLE MOTOR - (3 + SHIELD) 651A LEG 1 OF 230VAC 652A LEG 2 653A LEG 3 654A SHIELD DRAIN
650B THREE PHASE POWER TO SPINDLE MOTOR - (3 + SHIELD) 651B LEG 1 OF 230VAC 652B LEG 2 653B LEG 3 654B SHIELD DRAIN
660 X-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 SW 660-7 OVERHEAT SWITCH 660-8 ENCODER A* 660-9 ENCODER 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)
690 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)
376
CABLE LIST
96-8100 rev C
June 2001
710 FORWARD/REVERSE/RESET TO SPINDLE - (4 + SHIELD) (BRUSH SYSTEMS) 711 FORWARD COMMAND (CN1-19 TO IO P9-3) 712 REVERSE COMMAND (CN1-19 TO IO P9-3) 713 RESET COMMAND (CN1-21 TO IO P9-2) 714 COMMON (CN1-14 TO IO P9-1) 715 SHIELD DRAIN
720 ANALOG SPEED COMMAND TO SPINDLE - (2 + SHIELD) (BRUSH SYSTEMS) 721 0 TO +10 VOLTS SPEED COMMAND (SPINDLE DRIVE CN1-1) #24 722 SPEED COMMAND REFERENCE (A GROUND) (CN1-17) #24 723 SHIELD DRAIN
730 POWER METER FROM SPINDLE DRIVE TO KBIF - (2 + SHIELD) (BRUSH SYSTEMS) 731 METER + (SPINDLE DRIVE CN1-5 TO KBIF) #24 732 METER - (CN1-6 TO KBIF) #24 723 SHILD DRAIN
730A POWER METER FROM KBIF TO METER - (2 + SHIELD) (BRUSH SYSTEMS) 733 METER + AFTER TRIM POT (KBIF TO METER) #24 734 METER - AFTER TRIM POT (KBIF TO METER) #24 734 METER - AFTER TRIM POT (KBIF TO METER) #24
730B ANALOG SIGNAL FROM SPINDLE DRIVE LOAD MONITOR (BRUSH SYSTEMS) 731 SIGNAL 0..5V 732 GROUND
740 POWER ON/OFF CABLE TO FRONT PANEL - (4 + SHIELD) 741 POWER ON SWITCH LEG 1 (24 VAC) #24 742 POWER ON SWITCH LEG 2 #24 N.O. 743 POWER OFF SWITCH LEG 1 (24 VAC) #24 744 POWER OFF SWITCH LEG 2 #24 N.C. 745 SHIELD DRAIN
750 JOG-CRANK DATA CABLE (REM JOG SIDE CONNECTION) - (4 + SHIELD) (ALL #28) (CABLE NUMBER 33-5750)
750-1 LOGIC RETURN (D GROUND) 0VDC 750-2 ENCODER A CHANNEL 750-3 ENCODER B CHANNEL 750-4 +5 VDC 750-5 N/C 750-6 X-AXIS 750-7 Y-AXIS 750-8 N/C 750-9 N/C 750-10 N/C 750-11 Z-AXIS 750-12 A-AXIS 750-13 X 10 750-14 X 1 750-15 SHIELD DRAIN 750-16 N/C
377
CABLE LIST
96-8100 rev C
June 2001
750-2 CYCLE START 750-4 D GROUND 750-6 FEED HOLD
760 MONITOR VIDEO DATA CABLE - (9 + SHIELD) (ALL #24) (FROM VIDEO P3 TO CRT)
770 EMERGENCY STOP INPUT CABLE - SHIELD +2 771 SIGNAL (INPUT 8) #20 772 RETURN (D GROUND) (65) #20 772 RETURN (D GROUND) (65) #20
770A SECOND E-STOP INPUT FOR HORIZONTAL
770B THIRD E-STOP INPUT FOR APC (REMOTE CONTROL PANEL)
780 STATUS CABLE FROM SPINDLE DRIVE - (4 + SHIELD) (BRUSH SYSTEMS) 781 +12 VDC (SPINDLE DRIVE CN1-25) #24 782 FAULT (INPUT 18 TO CN1-24) #24 783 AT SPEED (INPUT 20 TO CN1-23) #24 784 STOPPED (INPUT 19 TO CN1-22) #24 785 SHIELD DRAIN
790 SPARE INPUTS FROM IOPCB P24 791 SPARE 1 792 SPARE 2 793 COMMON
810 TOOL CHANGER MOTORS - (2 + SHIELD) #20 811 TURRET MOTOR + (IO P30-2 TO P6-J) #14 812 TURRET MOTOR - (IO P30-1 TO P6-I) #14 812 SHIELD DRAIN
810A TOOL CHANGER MOTORS - (2 + SHIELD) #20 813 SHUTTLE MOTOR - (IO P30-4 TO P6-A) #14 814 SHUTTLE MOTOR + (IO P30-3 TO P6-B) #14 812 SHIELD DRAIN
820 TOOL CHANGER STATUS - (7 + SHIELD)7 821 LOGIC RETURN (D GROUND) (P6-F/H/L/M) #24 822 GENEVA MARK (INPUT 5 TO P6-G) #24 (LATHE PART DOOR) 823 TOOL #1 (INPUT 3 TO P6-E) #24 824 SHUTTLE IN (INPUT 1 TO P6-C) #24 (LATHE TURRET CLAMPED) 825 SHUTTLE OUT (INPUT 2 TO P6-D) #24 (LATHE TURRET UNCLAMPED) 826 SHUTTLE IN (INPUT 1 TO P6-C) #24 (LATHE TURRET CLAMPED) 827 SHIELD DRAIN
378
CABLE LIST
96-8100 rev C
June 2001
830 OVERHEAT THERMOSTAT - (2 + SHIELD) 831 OVERHEAT SIGNAL (INPUT 14) #20 832 OVERHEAT RETURN (D GROUND) (65) #20 833 SHIELD DRAIN
840 CIRCUIT BREAKER FOR 160 VDC - SHIELD +2 841 LEG 1 (TO 81) #14 842 LEG 2 #14 843 SHIELD DRAIN
850 SERIAL PORT #1 TO SERIAL KEYBOARD INTERFACE CABLE (16 WIRE RIBBON #24)
850A SERIAL PORT #2 INTERFACE CABLE (16 WIRE RIBBON #24)
860 +12V/+5V/Gnd POWER CABLES - 6 WIRE (all #18) 861 +12 VOLTS 862 -12 VOLTS FROM LOW V SUPPLY TO 68020 PCB 863 +5 VOLTS 864 -5 VOLTS 865 LOGIC POWER RETURN (D GROUND) 866 POWER GOOD SIGNAL FROM SUPPLY
860A 12 VOLT POWER TO IOPCB - SHIELD +2 861 +12 VOLTS 862 LOGIC POWER RETURN (D GROUND)
860B +5 POWER TO 3" FLOPPY DRIVE
860C +5,+12,-12 POWER TO 68030
870 115VAC TO OILER - (2 + SHIELD) 871 115VAC LEG 1 #18 872 115VAC LEG 2 #18 873 SHIELD DRAIN
880A HIGH/LOW GEAR UNCLAMP/LOCK SOLENOID POWER - SHIELD +6 881 115 VAC SOLENOID COMMON (IO P12-5) #18 882 HIGH GEAR SOLENOID (IO P12-4) #18 883 LOW GEAR SOLENOID (IO P12-3) #18 884 TOOL UNCLAMP SOLENOID (IO P12-2) #18 885 SPINDLE LOCK SOLENOID (IO P12-1) #18 886 PRE-CHARGE SOLENOID #18 (IO P12-7) 887 SHIELD DRAIN
880B TRANSMISSION HIGH/LOW GEAR SOLENOIDS FOR LATHE 881 115 VAC SOLENOID COMMON (IO P12-5) #18 882 HIGH GEAR SOLENOID (IO P12-4) #18 883 LOW GEAR SOLENOID (IO P12-3) #18 884 SHIELD DRAIN
379
CABLE LIST
96-8100 rev C
June 2001
890 SPINDLE STATUS SWITCHES (6 + SHIELD) 891 SIGNAL RETURN (D GROUND) (65) #24 892 HIGH GEAR (INPUT 6) #24 893 LOW GEAR (INPUT 7) #24 894 TOOL UNCLAMPED (INPUT 15) #24 895 TOOL CLAMPED (INPUT 16) #24 896 SPINDLE LOCKED (INPUT 17) #24 897 SHIELD DRAIN
900 LOW COOLANT STATUS - (2 + SHIELD) 901 LOW COOLANT SIGNAL (INPUT 4 TO P7-C) #20 902 LOW COOLANT RETURN (D GROUND) (65 TO P7-D) #20 903 SHIELD DRAIN
910 115 VAC CIRCUIT BREAKER TO SOLENOIDS - (2 + SHIELD) 911 LEG 1 #18 912 LEG 2 #18 913 SHIELD DRAIN
910A 115VAC FROM CB4 ON MAIN POWER DIST. 910B 115VAC TO SERVO FAN 910C 115VAC TO DELTA/WYE COIL 910D 115VAC TO WORK LIGHT
920 REGENERATIVE LOAD RESISTOR FOR SERVO - (2 + SHIELD) (BRUSH SYSTEMS) 921 LEG 1 #18 922 LEG 2 #18 923 SHIELD DRAIN
930 FUSED 230 VAC FOR COOLANT PUMP - (2 + SHIELD) 931 LEG 1 #14 932 LEG 2 #14 933 SHIELD DRAIN
940 230 VAC TO COOLANT PUMP - (2 + SHIELD) 941 LEG 1 (P7-A) #14 942 LEG 2 (P7-F) #14 943 SHIELD DRAIN
950 LOW AIR PRESSURE SENSOR - (3 + SHIELD) 951 LOW AIR SIGNAL (INPUT 12) #20 952 LOW AIR/OIL RETURN (D GROUND) (65) #20 953 LOW OIL PRESSURE SWITCH FOR VERTICAL TRANSMISSION #20 954 SHIELD DRAIN
950A LOW HYDRAULIC PRESSURE SWITCH FOR LATHE - (2 + SHIELD) 952 LOW HYDRAULIC RETURN (D GROUND) (65) #20 953 LOW HYD PRESSURE SWITCH FOR VERTICAL TRANSMISSION #20 954 SHIELD DRAIN
380
CABLE LIST
96-8100 rev C
June 2001
960 LOW LUB/DOOR OPEN SENSORS - (4 + SHIELD) 961 LOW LUB SIGNAL (INPUT 13) #24 962 LOW LUB RETURN (D GROUND) (65) #24 963 DOOR OPEN SIGNAL (INPUT 9) #24 (OBSOLETE OPTION) 964 DOOR OPEN RETURN (D GROUND) (65) #24 (OBSOLETE OPTION) 965 SHIELD DRAIN
970 LOW VOLTAGE SENSOR - (2 + SHIELD) 971 LOW VOL SIGNAL (INPUT 11 FROM PMON P9-3) #24 972 LOW VOL RETURN (D GROUND) (PMON P9-4) #24 973 SHIELD DRAIN
980 VOLTAGE MONITOR - (2 + SHIELD) 981 VOLTAGE MONITOR 0 TO +5 (PMON P9-1 / MOTIF P17-1) #24 982 VOLTAGE MON RET (A GND) (PMON P9-2 / MOTIF P17-2) #24 983 VOLTAGE MON RET (A GND) (PMON P9-2 / MOTIF P17-2) #24
990 HOME SENSORS - (4 + SHIELD) 991 X HOME SWITCH (MOTIF P24-2 TO P5-B) #24 992 Y HOME SWITCH (MOTIF P24-3 TO P5-D) #24 (LATHE TAIL STOCK) 993 Z HOME SWITCH (MOTIF P24-4 TO P5-L) #24 994 HOME SWITCH RETURN (MOTIF P24-1 TO P5-C) #24 995 SHIELD DRAIN
1000 SPINDLE ENCODER CABLE - (5 + SHIELD) (LATHE TAIL STOCK)(BRUSH SYSTEMS) 1001 LOGIC RETURN (D GROUND) (TO MOTIF P20-1) #24 1002 ENCODER A CHANNEL (TO MOTIF P20-2) #24 1003 ENCODER B CHANNEL (TO MOTIF P20-3) #24 1004 +5 VDC (TO MOTIF P20-4) #24 1005 ENCODER Z CHANNEL (TO MOTIF P20-5) #24 1006 SHIELD DRAIN
1020 SPINDLE TEMPERATURE SENSOR CABLE - (3 + SHIELD) 1021 SIGNAL 1022 ANALOG RETURN 1023 +5 VOLTS TO SENSOR 1024 SHIELD GROUND
1030 SPINDLE LOAD RESISTOR - (2 + SHIELD) 1031 REGEN LOAD RESISTOR FOR SPINDLE DRIVE (B1) #18 1032 REGEN LOAD RESISTOR FOR SPINDLE DRIVE (B2) #18 1033 SHIELD DRAIN
1040 Y160 (MIKRON DOOR LOCK OR HORIZONTAL PART READY LAMP) 1041 SWITCHED RELAY CONTACT 1042 SWITCHED RELAY CONTACT
1050 DOOR SWITCH WIRING THRU SUPPORT ARM - (2 + SHIELD) 1051 DOOR OPEN SIGNAL (INPUT 9) #24 1052 DOOR OPEN RETURN (D GROUND) (65) #24 1053 SHIELD DRAIN
381
CABLE LIST
96-8100 rev C
June 2001
1060 GROUND FAULT DETECTION SENSE INPUT 1061 + INPUT FROM SENSE RESISTOR 1062 - INPUT FROM SENSE RESISTOR
1070 SKIP INPUT FROM SENSOR - (2 + SHIELD) 1071 LOGIC COMMON 1072 SKIP SIGNAL 1073 SHIELD DRAIN
382
ELECTRICAL DIAGRAMS June 2001
96-8100 rev C
ELECTRICAL WIRING DIAGRAMS
383
ELECTRICAL DIAGRAMSJune 2001
96-8100 rev C
384
ELECTRICAL DIAGRAMS June 2001
96-8100 rev C
385
ELECTRICAL DIAGRAMSJune 2001
96-8100 rev C
386
ELECTRICAL DIAGRAMS June 2001
96-8100 rev C
SERVO SYSTEM
1/2001 HAAS AUTOMATION VF SERIES PAGE 1
DRIVE
SPINDLESERVO
AMPLIFIER
POWER SUPPLY
M O
C O
N B
O A
R D
(C N
C )
BRUSHLESS
SERVO AMP
ENCODER
MOTOR/
X SERVO 610
LV HVHV
J2
LV
HV
A,B,C
660
620
670
J2
LV
HV BRUSHLESS
SERVO AMP A,B,C Y SERVO
MOTOR/
ENCODER
630
680
J2
LV
HV BRUSHLESS
SERVO AMP A,B,C Z SERVO
MOTOR/
ENCODER
640
690
HV
LV
J2
BRUSHLESS
SERVO AMP C BRUSH
MOTOR/
ENCODER
640B
690B
HV
LV
J2
BRUSHLESS
SERVO AMP C BRUSH
MOTOR/
ENCODER
CABLE X AXIS
CABLE Y AXIS
CABLE Z AXIS
CABLE A AXIS
CABLE B AXIS
(OPTIONAL)
+ /-
1 2
V D
C 320 VDC
MTR CMD, X
ENCODER
MTR PWR
MTR PWR
MTR PWR
MTR PWR
MTR CMD, Y
ENCODER
MTR CMD, Z
ENCODER
MTR CMD, A
ENCODER
ENCODER
MTR CMD, B
(OPTIONAL) (OPTIONAL)
(OPTIONAL)
MTR PWR
3.6 MH
3.6 MH
B SERVO
A SERVO
BRUSHLESS
3.6 MH
MTR PWR A
3.6 MH
MTR PWR A
490
660
670
490
680
490
490A
690
490B
690B
690C
640C
387
ELECTRICAL DIAGRAMSJune 2001
96-8100 rev C
388
ELECTRICAL DIAGRAMS June 2001
96-8100 rev C
389
ELECTRICAL DIAGRAMSJune 2001
96-8100 rev C
390
ELECTRICAL DIAGRAMS June 2001
96-8100 rev C
391
ELECTRICAL DIAGRAMSJune 2001
96-8100 rev C
392
ELECTRICAL DIAGRAMS June 2001
96-8100 rev C
393
ELECTRICAL DIAGRAMSJune 2001
96-8100 rev C
394
ELECTRICAL DIAGRAMS June 2001
96-8100 rev C
395
ELECTRICAL DIAGRAMSJune 2001
96-8100 rev C
1/2001 HAAS AUTOMATION VF SERIES PAGE 10
0VDC +12VDC
+12VDC
P13
PIN 16
PIN 12+12VDC
0VDC
+12VDC
0VDC
PIN 15
PIN 14
PIN 13
0VDC
0VDC
+12VDC
PIN 11
PIN 10
PIN 9
(EUROPE)
LE 24
P51
PIN 16
LE 22PIN 12
LE 23
PIN 15
PIN 14
PIN 13
PIN 11
LE 21PIN 10
PIN 9
DOOR LOCK
5TH AXIS BRAKE
K24
K23
SPARE C
PRECHARGE
K22
K21
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 20PIN 8
PIN 7
LE 19PIN 6
PIN 5
LE 18PIN 4
PIN 3
LE 17PIN 2
PIN 1
SPARE B
SPARE A
K20
K19
SPIGOT REVERSE
SPIGOT FORWARD
K18
(OPTION)
K17
(OPTION)
RELAY COIL DRIVERS, K17 THROUGH K24
I/O PCB530 CABLE
MOCON PCB
(HTC SHUTTLE)
WITH A SOLID STATE EQUIVALENT NOTE: ANY RELAY K1 ..........K35 CAN BE REPLACED
396
ELECTRICAL DIAGRAMS June 2001
96-8100 rev C
1/2001 HAAS AUTOMATION VF SERIES PAGE 11
RELAY COIL DRIVERS, K25 THROUGH K32
0VDC MOCON PCB+12VDC
+12VDC
P14
PIN 16
+12VDC PIN 12
0VDC
+12VDC
0VDC
PIN 15
PIN 14
PIN 13
0VDC
+12VDC
0VDC
PIN 11
PIN 10
PIN 9
I/O PCB CABLE
540
LE 32
P3
PIN 16
PIN 12 LE 30
LE 31
PIN 15
PIN 14
PIN 13
PIN 11
LE 29PIN 10
PIN 9
CHIP CONVEYOR ON
CHIP CONVEYOR REVERSE
K32
K31
GREEN STROBE
RED STROBEK30
K29
+12VDC
0VDC
0VDC
+12VDC
PIN 8
PIN 7
PIN 6
PIN 5
+12VDC
0VDC
+12VDC
0VDC
PIN 4
PIN 3
PIN 2
PIN 1
LE 28PIN 8
PIN 7
LE 27PIN 6
PIN 5
LE 26PIN 4
PIN 3
LE 25PIN 2
PIN 1
K28 M24 OR TSC
K27 M23
K26 M22
K25 M21
K36
WITH A SOLID STATE EQUIVALENT NOTE: ANY RELAY K1 ..........K35 CAN BE REPLACED
397
ELECTRICAL DIAGRAMSJune 2001
96-8100 rev C
NOTE:
MITSUBISHI (MAGNETEK) FOR MFG. AS SHOWN: PINOUTS ARE LISTED
ASSEMBLY BOARD
MODULE
TO PROCESSOR
TO IOPCB
POWER SUPPLY PCB
+5/+12/GND
860
860
860
860
(IN)
8 6
2
8 6
5
8 6
1
8 6
4
8 6
3
G N
D
-1 2
V
-5 V
+ 1
2 V
+ 5
V
E
POWER SUPPLY 115 VAC
LOW VOLTAGE
E 115 VAC9 6
9 5
9 4
830
SWITCH
N/C OVERHEAT
M
SPINDLE MOTOR
THERMAL
OVERLOAD
*K3
*K2 BOARD P16 TO MOCON
U V W
721
711 722
E
OH (13)
SD (17)
PR (1)
1K (13)
STF (1) 5 (17)
P (2) SPINDLE REGEN RESISTOR
*K4
TO OPERATOR PANEL
TO SPINDLE LOCK
TO INPUTS BOARD 18/19/20
713
732 731
783
781 782
402 401
RES (4)
/FM (21) SD (11)
SU (26) RUN (25)
B (20) C (19)
/SD (22)LM2 LM0
MRS (8) SD (27)
784
714
712STR (2)
E
S T
R
FORWARD
FORWARD
REVERSE
SPEED REF SPEED COMMAND
SPEED COMMAND SPEED REF
RESET COMMON
SP FAULT COMMON
TS
230 VAC
COMMON
LOAD METER+
SP STOPPED SP AT SPEED
LOAD METER-
COAST STOP
R
REVERSE
SPINDLE DRIVE UNIT
SPINDLE DRIVE UNIT
1/2001 HAAS AUTOMATION VF SERIES PAGE 12
*SOLID STATE
BRAKE UNIT (FOR 15HP AND MORE)
N PR P
N
398
ELECTRICAL DIAGRAMS June 2001
96-8100 rev C
ASSEMBLY
BOARD
MODULE
TO PROCESSOR
TO IOPCB
POWER SUPPLY PCB
+5/+12/GND
860
860
860
860
(IN)
8 6
2 8
6 5
8 6
1 8
6 4
8 6
3
G N
D -1
2 V
-5 V
+ 1
2 V
+ 5
V
E
POWER SUPPLY 115 VAC
LOW VOLTAGE
E 115 VAC9 6
9 5
9 4
830
SWITCH N/C OVERHEAT
M SPINDLE MOTOR
BOARD P33 FROM MOCON
SPINDLE REGEN RESISTOR
TS
230 VAC
R
VECTOR SPINDLE DRIVE UNIT
1/2001 HAAS AUTOMATION VF SERIES PAGE 13
HAAS VECTOR DRIVE
TO IOPCB BOARD P9
399
ELECTRICAL DIAGRAMSJune 2001
96-8100 rev C
WHITE/ORANGE
GREEN/YELLOW
1/2001 HAAS AUTOMATION VF SERIES PAGE 14
X/Y/Z AXIS MOTOR & ENCODER
WHITE/BLACK (Z CHANNEL NOT USED)
*B AXIS OPTIONAL
*B=497B/498B
CHASSIS
C
32-1425A TO 32-1430A
X=491/492
Y=493/494
Z=495/496
A=497/498
B
A
D
C BLACK
B
A
WHITE
RED
4 PIN CONNECTOR SERVO AMPLIFIERS
THROUGH CABLES:
TO BRUSHLESS
L
F
MOTOR C
MOTOR C
MOTOR B
MOTOR A
C CHANNEL
MOTOR SERVO BRUSHLESS
M
RED/WHITE
WHITE/BROWN
WHITE/YELLOW
BLACK (Z CHANNEL NOT USED)
A AXIS 690 *B AXIS 690B
D
B
BROWN
YELLOW
K
E ORANGE
17 PIN CONNECTOR
TO MOCON PCB
Z AXIS 680 Y AXIS 670 X AXIS 660
THROUGH CABLES:
32-1425A TO 32-1430A
C
A
H
G
RED
C CHANNEL
B CHANNEL
A CHANNEL
LOGIC GND
B CHANNEL
A CHANNEL
+5VDC
PULSE ENCODERM
400
ELECTRICAL DIAGRAMS June 2001
96-8100 rev C
BROWN
YELLOW
ORANGE
BROWN/WHITE
RED/WHITE
YELLOW/WHITE
ORANGE/WHITE
WHITE
HAAS AUTOMATION VF SERIES PAGE 151/2001
BLACK
GREEN/YELLOW
BLACK
BLACK
BLACK/WHITE
BLACK
4TH AXIS SOLENOID IS ON ROTARY TABLES ONLY (NO COLLET OR MULTI-COLLET INDEXERS)
TO MOCON THROUGH CABLE: 690 A AXIS ENCODER
( THIS GROUP IS ALL 24 AWG WIRES. )
TWISTED PAIR TO INDUCTORS &
DHOME
(20 AWG)
K5/K23
R
S
J
H
G
T
F
B
C
M
N
E
P
L
K
A
RED
RED
LOGIC GROUND
A/B AXIS
MOTOR+
MOTOR-
EARTH GROUND
+5 VDC
SIGNAL
Z CHANNEL
B CHANNEL
A CHANNEL
Z CHANNEL
B CHANNEL
A CHANNEL
LOGIC GND
+5 VDC
NORMALLY OPEN
4TH/5TH AIR SOLENOID
ENCODER
OVERHEAT SWITCH NORMALLY CLOSED
MAGNETIC HALL EFFECT SWITCH
M
690B B AXIS ENCODER.
CABINET CONNECTOR
BRUSH SERVO MOTOR
AMPLIFIERS
OVER/HEAT
TO MOCON
AXIS BRAKE
TO RELAY
401
ELECTRICAL DIAGRAMSJune 2001
96-8100 rev C
B
NOTE: CONNECTORS ARE LOCATED ON SIDE OF CONTROL CABINET.
CABINET CONNECTORS
1/2001 HAAS AUTOMATION VF SERIES PAGE 16
BL1
G
COOLANT PUMPP7
C
E
F
TO RELAT K10
TO INPUT #01
TO INPUT #02
TO INPUT #03
TO INPUT #05
TO RELAY K11
TO RELAY K12
TO LOGIC GND
A
L
M
N TOOL CHANGERP6
G
H
I
J
K
C
D
E
F
230 VAC SINGLE PHASE
COOLANT MOTOR
TURRET MOTOR
M
M
SHUTTLE OUT
GENEVA MARK
TOOL #1 MARKER
SHUTTLE IN
115 VAC
TO INPUT #13
LOGIC GND
TO RELAY K9
L
LOGIC GROUND
HOME SENSORS/DOOR/LUBE
A
K
A
M
P5
LOGIC GROUND
LOGIC GROUND
D
E
F
H Z HOME
Y HOME
B
C
X HOME
P24 HOMES TO MOCON
WAY LUBE PUMP MOTOR
SPINDLE COOLING SOLENOID
(VF-0 ONLY)
M
LOW LUBE LEVEL
MOTOR SHUTTLEM
LOW LUBE PRESSURE SWITCH
Z HOME SWITCH
Y HOME SWITCH
X HOME SWITCH
M TSC MOTOR
230 VAC THREE PHASE
LOW TSC
TO LOGIC GND
TO IOPCB P14 #900
D
A
B
C
3 4
2 1
L2
L3
T'STAT
T'STAT
402
ELECTRICAL DIAGRAMS June 2001
96-8100 rev C
TOOL CHANGE MOTORS
6.8 OHM
6 OHM
BLACK
1/2001 HAAS AUTOMATION VF SERIES PAGE 17
0V
K11
25W
25W
WHITE
MOTOR
TURRET
K12
BLACK
K9
CURRENT LIMIT CIRCUIT IOPCB
0V
82
+160VDC
MOTOR
SHUTTLE WHITE
K10
5A ABC FUSE
FU 1 NE 5
IOPCB
81
160VDC
0V
160VDC
403
ELECTRICAL DIAGRAMSJune 2001
96-8100 rev C
404
ELECTRICAL DIAGRAMS June 2001
96-8100 rev C
405
ELECTRICAL DIAGRAMSJune 2001
96-8100 rev C
406
ELECTRICAL DIAGRAMS June 2001
96-8100 rev C
SENSOR
SENSOR
SENSOR
SWITCH
SWITCH
SWITCH
SWITCH
SOLENOID
ARM STOW
ARM MOTOR STOP
ARM CL/UNCL
TC MARK
POCKET UP
POCKET DOWN
POCKET U/D
TOOL ONE
TO I/O P66
TO I/O P13
TO I/O P13
TO I/O P13
TO I/O P13
TO I/O P74
TO I/O P73
TO I/O P73 CABLE MOUNTING BRACKET
ARM (ATC) MOTOR UNIT ARM (ATC) MOTOR
TO I/O P30
TO I/O P39
CAROUSEL MOTOR
M
M
CAROUSEL UNITCONTROL CABINET
I/O PCB
P66 (220)
P30 (810A)
P39 (810)
P73 (470)
P74 (480)
P13 (820)
AIR DOOR
ATC MTR
CAR MTR
SPARE 9
SPARE 10
TC STAT
40/50 TAPER SIDE MOUNT TOOL CHANGER
HAAS AUTOMATION VF SERIES1/2001
407
ELECTRICAL DIAGRAMSJune 2001
96-8100 rev C
ASSEMBLY DRAWINGS
408 96-8100 rev C
June 2001
ASSEMBLY DRAWINGS
ASSEMBLY DRAWINGS
40996-8100 rev C
June 2001
VF-O/1 Base
4
2
3
1
1.50-3300 Linear guide 2. 30-0171 Oil line assembly 3. 62-0014 Yaskawa sigma 09 motor* 4. 32-2030 Telemechanique switch assembly
*Except XRT
ASSEMBLY DRAWINGS
410 96-8100 rev C
June 2001
VF-O/1 Column
OUT OF POSITION
WITHOUT 20-7005
1
VIEW B
3
4
2
1. 30-0170 Oil line assembly 2. 62-0009 Yaskawa Sigma 09 motor* 3. 32-2040 telemechanique switch assembly 4. 50-3300 Linear guide
*Except XRT
ASSEMBLY DRAWINGS
41196-8100 rev C
June 2001
VF-O/1 Saddle
4
2
1
3
1. 30-0173 Oil line assembly 2. 32-2050 Telemechanique switch 3. 50-3300 Linear guide 4. 62-0014 Yaskawa sigma 09 motor*
*Except XRT
ASSEMBLY DRAWINGS
412 96-8100 rev C
June 2001
1
3
4
2
VF-3 Base
1. 30-0221 Oil line assembly 2. 32-2031 Telemechanique switch assembly 3. 50-9011 Linear guide 4. 62-0014 Motor assembly*
*Except XRT
ASSEMBLY DRAWINGS
41396-8100 rev C
June 2001
2
1
3
4
VF-3 Column
1.30-0687 Oil line assembly 2. 32-2041 Telemechanique switch assembly 3. 50-9011 Linear guide 4. 62-0014 Yaskawa Sigma 09 motor*
*Except XRT
ASSEMBLY DRAWINGS
414 96-8100 rev C
June 2001
3
4
2
1
VF-3 Saddle
1. 30-0223 Oil line assembly 2. 32-2050 Telemechanique switch assembly 3. 50-9010 Linear guide 4. 62-0014 Yaskawa sigma 09 motor*
*Except XRT
ASSEMBLY DRAWINGS
41596-8100 rev C
June 2001
VF-6 Base
3
4
1
2
1. 32-5056 Telemechanique limit switch assembly 2. 30-0221 OIl line assembly 3. 50-9010 Linear guide 4. 62-0014 Yaskawa sigma 09 motor*
*Except XRT
ASSEMBLY DRAWINGS
416 96-8100 rev C
June 2001
3
4
2
1
VF-6 Column
1. 32-2050 Telemechanique limit switch assembly 2. 62-0014 Yaskawa sigma 09 motor* 3. 30-0464 Oil line assembly 4. 50-9010 Linear guide
*Except XRT
ASSEMBLY DRAWINGS
41796-8100 rev C
June 2001
VF-6 Saddle
2
4
3
1
1. 62-0014 Yaskawa sigma 09 motor* 2. 50-9806 Linear guide 3. 30-0463 Oil line assembly 4. 32-2051 Telemechanique limit switch assembly
*Except XRT
ASSEMBLY DRAWINGS
418 96-8100 rev C
June 2001
VF-8 Base
4
3
1
2
1. 62-0014 Yaskawa sigma 09 motor* 2. 50-9010 Linear guide 3. 30-0461 Oil line assembly 4. 32-5056 Telemechanique limit switch assembly
*Except XRT
ASSEMBLY DRAWINGS
41996-8100 rev C
June 2001
VF-8 Column
4
3
2
1
1. 32-2050 Telemechanique limit switch assembly 2. 62-0014 Yaskawa sigma 09 motor* 3. 30-0464 Oil line assembly 4. 50-9010 Linear guide
*Except XRT
ASSEMBLY DRAWINGS
420 96-8100 rev C
June 2001
2
4
3
1
VF-8 Saddle
1. 62-0014 Yaskawa sigma 09 motor* 2. 50-9806 Linear guide 3. 30-0463 Oil line assembly 4. 32-2051 Telemechanique limit switch assembly
*Except XRT
ASSEMBLY DRAWINGS
42196-8100 rev C
June 2001
8741
14 13
5
11 10
6
9
3
12
2
16 15
VF-10 Base
1. 59-6655 Rubber plug guide rail 2. 22-7458 Cam, linear guide 3. 20-9218 Y-axis bumper, motor end 4. 20-0150 Nut housing 5. 58-3031 Banjo elbow 5/16 female x M6 male 6. 58-1560 Adaptor 1/8m (NSK and THK Linear guides) 59-0001 (Star linear guides) 7. 30-0461 Oil line assembly 8. 20-0156 Bumper for 40 and 50 mm ballscrews 9. 32-5056 Limit switch assembly 10. 25-7268 Bracket mounting Y-axis 11. 50-9010 Linear guide 12. 24-9960 40mm ballscrew* 13. 25-9203 Cover plate motor mount 14. 62-0014 servo motor (40 taper) 62-0016 servo motor (50 taper)* 15. N/A 16. N/A
*Except XRT
ASSEMBLY DRAWINGS
422 96-8100 rev C
June 2001
VF-10 Column
2522 23 24
28
29
31
30
2726
19
9
6
20
21
32
14
15
16
18
7
541
8
12
10
17
11
13
1. 25-7267 Bracket mounting Y-axis 2. 25-9929 Stabilizer bracket hyd. cyl. 3. 32-2050 Limit switch Z-axis 4. N/A 5. 59-4002 Hose clamp 13/16 x 1 3/4 6. 50-9010 Linear guide 7. 22-9826A Counterweight head bracket 8. 20-9217 Z-axis bumper, support end 9. 48-0045 Dowel pin 3/8 x 1 1/2 pull 10. 25-9813 Z-axis waycover 11. 40-2021 FHCS 1/4-20 x 3 12. 25-7560B tank cover 13. 30-1420 (40 taper) 30-1421 (50 taper) Counterbalance tank assembly 14. 58-3031 Banjo elbow 5/16 F x M6 M 15. 30-0464 Oil line assembly 16. 58-1560 Linear guide adaptor 1/8m (NSK and THK) 59-0001 (Star)
17. 48-1699 Dowel pin 5/8 x 2 1/4 18. 20-9216 Z-axis bumper, motor end 19. 48-10045 Dowel pin 3/8 x 1 1/2 20. 59-6655 Rubber plug 21. 22-7458 Cam 22. N/A 23. N/A 24. N/A 25. 25-9929 Stabilizer bracket 26. 20-0365 Clevis counter balance 27. 48-0017 Clevis pin 3/8 dia. x 1 1/4 and 49-0026 Cotter pin 1/8 x 1 1/4 28. 20-0150 Nut housing 29. 22-9927 Bracket cylinder counter 30. 24-9960 40mm ballscrew* 31. 62-0014 Yaskawa sigma 09 motor*
*Except XRT
ASSEMBLY DRAWINGS
42396-8100 rev C
June 2001
BOTTOM 19 20
TOP18 17 15 16 14 13
1 2
3 8654 7
12
10 11
9
VF-10 Saddle
1. 20-0152 Bearing housing 40mm and 50mm ballscrew 2. 20-0156 Bumper 3. 59-6655 rubber plug 4. 22-7458 Cam, linear guide 5. 30-0534 Oil line assembly 6. 58-1560 Linear guide adaptor 1/8m (NSK and THK) 59-0001 (Star) 7. 58-3031 Banjo elbow 5/16 F x M6 M 8. 20-0156 Bumper 40 and 50mm ballscrews 9. N/A 10. N/A 11. N/A 12. 62-0016 Yaskawa sigma 13 motor* 13. 48-0045 Dowel pin 3/8 x 1 1/2 pull 14. 32-2055 X-axis limit switch 15. 25-9219 Bracket, limit switch 16. 20-0150 Nut housing 17. 24-0002C Ballscrew 50mm* 18. 50-0001 Linear guide 19. 25-7459 Bracket trip table 20. 25-9220 Bracket, trip X-axis
*Except XRT
ASSEMBLY DRAWINGS
424 96-8100 rev C
June 2001
32 Tool Changer Assembly VF-3/4
49
45
44
46
48
47
52
51
50
53
43 42 41 40
39
31 30
35
33
34
32
37
36
38
1 2
3
4 5
2229 28 27 26 25 24 23
76 8 9 10 11 12 13
21 20 19 18
14 15 16
17
1. 30-0005 Turret motor assembly 2. 25-7162 Connector bracket 3. 57-9335 Shuttle cover gasket 4. 25-9334 Shuttle cover plate 5. 30-0006 Carousel assembly 6. 54-0010 Cam follower, T/C 7. 22-7034 Spacer, cam follower 8. 54-0040 Standard bushing guide wheel 9. 22-7106 V track, T/C 10. N/A 11. 20-7475 Arm, slip clutch 12. 54-0030 Guide wheel 13. 32-1800 Motor assembly shuttle 14. 70-0050 PLT4S-M cable ties 15. 25-9085 Conduit mounting plate 16. 20-9008 Holding arm 17. 57-9139 Tool holding arm gasket 18. 32-7011A Molded T/C cable assembly 19. 79-1000 Wire channel 1 in x 2in 20. 79-1001 Cover wire channel 1" 21. 25-7168 Bracket, door opener 22. 22-2065 Locating pin 23. 32-7620 TL carriage cable 40T 24. 25-9329 Door, T/C cover 25. 22-7163 Rider trap door 26. 22-7263 Block switch MTG
27. 32-2010 Limit switch shuttle in/out 28. 54-0020 Bushing guide wheel 29. 25-9331 Tool changer cover TC32 30. 55-0010 Spring washer B2500-80 31. N/A 32. 22-7477 Pressure plate 33. 51-6000 Bearing locknut NT-05 34. 20-7476 Hub, slip clutch 35. 44-1710 SSS 1/4-20 x 3/8 cup with nylock 36. 75-15721 MLX 2 pin M 7.11LSW/earmolex 37.78-1996 Split flex tubing 1/2 ID 38. 46-1705 Nut 3/4-10 nylon lock 39. 63-1031 Cable clamp 1/4 40. 22-7106 V-track tool changer 41. 48-1750 Dowel pin 42. 20-9330 32 T/C holding plate 43. 25-9331 TC cover 44. 22-7255A Tool #1 standoff 45. 26-7239 Spacer ring, tool changer 46. 48-0020 Dowel pin 1/4 x 1 47. 20-7038A Bearing housing 48. 20-7035G Vertical axle 49. 48-0019 Dowel pin 1/4 x 5/8 50. 51-0012 Bearing locknut BH-06 51. 25-7036 Cap, tool changer 52. 51-0010 Bearing deep groove 53. 20-9325 Geneva star
ASSEMBLY DRAWINGS
42596-8100 rev C
June 2001
32 Tool Changer Assembly VF-6..10
6
16
5 1514
17
10921
274243 40 26 22 20
53
47
45
52
50 38
128 11
33
31
28
24
3435
1925
48
2341
30 29
32
51
3 4
21
36
44
49
46
39
37
7
18
13
1. 30-1967 Turret motor assembly 2. 25-7162 Connector bracket 3. 25-9334 Shuttle cover plate 4. 57-9335 Shuttle cover gasket 5. 30-0006 Carousel assembly 6. 54-10010 Cam follower T/C 7. 22-7034 Spacer, cam follower 8. 54-0040 Standard bushing guide wheel 9. 32-2013 Limit switch shuttle assembly 10. 54-0030 Guide wheel 11. 20-9834 Tool changer clutch arm 12. 30-1875 Motor assembly carousel/shuttle 13. 25-0014 Brace 14. 25-9912 Conduit mounting plate 15. 22-9805 Holding arm 16. 32-7012B Molded T/C cable assembly 17. 25-0014Brace VF-6/8 32 tools 18. 59-7222 Grommet 1 1/2 19. 25-7168 Bracket, door opener 20. 22-2065 Locating pin 21. 32-7611 Tool carriage conduit 22. 25-9329 Door T/C cover 23. 25-9334 Shuttle cover plate 24. 32-2013 Limit switch shuttle assembly 25. 54-0020 Bushing guide wheel 26. 22-7163 Rider trap door 27. 25-9331 Tool changer cover
28. 45-2020 Washer 1 1/4 nylon 29. 55-0010 Spring washer B2500-080 30. 45-0050 Washer steel 31. 22-7477 Pressure plate 32. 51-6000 Bearing locknut NT-05 33. 20-7476 Hub slip clutch 34. 44-1710 SSS 1/4-20 x 3/8 with nylock 35. 48-0005 Dowel pin 3/16 x 3/8 36. 75-15721 MLX 2 pin M 7.11LSW/earmolex 37. 78-1996 Split flex tubing 1/2ID 38. 46-1705 Nut 3/4-10 nylon lock 39. 75-15721 MLX 2 pin M 7.11LSW/earmolex 40. 22-7106 V-track, tool changer 41. 48-1750 Dowel pin 1/2 x 1 1/2 42. 20-9330 32 T/C holding plate 43. 40-1697 SHCS 1/4-20 x 3/4 44. 22-7255A Tool #1 standoff 45. 26-7239 Spacer ring, tool changer 46. 48-0020 dowel pin 1/4 x 1 47. 20-7038A Bearing housing 48. 20-7035G Vertical axle 49. 48-0019 Dowel pin 1/4 x 5/8 50. 51-0012 Bearing locknut BH-06 51. 25-7036 Cap, tool changer 52. 51-0010 Bearing deep groove 53. 20-9325 Geneva star 32 tool 2 pin
ASSEMBLY DRAWINGS
426 96-8100 rev C
June 2001
50 Taper Tool Changer Assembly
36
35
37
38
40
44
41
42
43
45
46
1 2 3
31
25
23 22 21 20 19
26
30
29
28
27
4 5 6 7 8 9 10 11 12
17
18
13 14 15 16
34 33 32 24
39
1. 30-0016 Geneva driver assembly 2. N/A 3. 54-0010 Cam follower T/C 4. 20-9289 Shuttle stop block 5. 78-1996 Split flex tuning 1/2 I.D. 6. 20-9291 Shuttle vertical plate 7. 25-9342 Shuttle cover 8. 30-0017A carousel assembly 9. 20-9290 Shuttle base plate 10. 20-9293 Shuttle gusset 11. 32-2030 Limit switch Y-axis 12. 22-7263 Block switch mounting 13. 51-0002 V-roller W-4 14. 59-9340 Spring, tool door 15. 22-9344 Tool door trip bracket 16. 25-9343 Tool door 17. 22-2065 Locating pin 18. 70-0050 PLT4S-M cable ties 19. 32-7012B molded T/C cable assembly 20. 22-9287 Tool changer mounting arm 21. 32-0011 Motor shuttle assembly 22. 22-7163 Rider trap door 23. 25-9345 Holding arm cover plate 24. 22-7263 Switch mounting block 25. 20-9292 Shuttle hub block
26. 25-9341 Tool changer cover 27. 46-1720 Nut 1/2-13 hex plt 28. 25-7162 Connector bracket 29. 75-15721 MLX 2 pin M 7.11 LSW/earmolex 30. 51-0003 Adj ecentric model BX-4 31. 48-0020 Dowel pin 1/4 x 1 32. 20-9295 V-track 33. 20-9289 Shuttle stop block 34. 32-2010 Limit switch shuttle in/out 24" 35. 20-9288 Shuttle plate 36. 30-0019B Slip clutch assembly 37. 20-9393 Shuttle gusset 38. 20-9336 20 pocket geneva star 39. 22-7255A Tool #1 standoff 40. 48-0020 Dowel pin 1/4 x 1 41. 51-0010 Bearing, deep groove 42. 48-0019 Dowel pin 1/4 x 5/8 43. 25-7036 Cap, tool changer 44. 51-0012 Bearing locknut BH-06 45. 20-7035G Vertical axle 46. 20-9283 Bearing housing T/C hub
ASSEMBLY DRAWINGS
42796-8100 rev C
June 2001
20 Pocket Tool Changer VF- O/1/2
59
57
58
56 55
61
60
62
63
5254 53 51 50 49 48
46
47
42 43
45
44
41
40
11
65
64
66
28 29 30 31
17
15
16
12
13
14
34 32
33 35
39
3736 38
10
9
8
7
26
22
24
18
21
19 20
23
25
27
5
6
43
1 2
ASSEMBLY DRAWINGS
428 96-8100 rev C
June 2001
20 Pocket Tool Changer VF- O/1/2
1. 20-7029B Holding arm 2. 57-7379 Tool holding arm gasket 3. 79-1000 Wire channel 1in. x 2in. 4. 79-1001 Cover wire channel 1" 5. 54-0030 Guide wheel 6. 22-7263 Block switch mounting 7. 54-0020 Bushing guide wheel 8. 48-0019 Dowel pin 1/4 x 5/8 9. 24-9257 Spring, extractor 10. 22-7067F Key extractor spring 11. 48-0002 Roll pin 7/32 x 7/8 12. 22-9574A CT extractor spring load 13. 22-9256 Bushing extractor 14. 20-7476 Hub slip clutch 15. 48-0005 Dowel pin 3/16 x 3/8 16. 22-7034 Spacer, cam follower 17. 20-7475 Arm slip clutch 18. 54-0040 Standard bushing guide wheel 19. 22-9256 Bushing extractor 20. 45-2020 Washer 1 1/4 nylon 21. 51-6000 Bearing locknut NT-05 22. 55-0010 Spring washer B2500-080 23. 22-2065 Locating pin 24. 25-7168 Bracket, door opener 25. 70-0050 PLT4S-M cable ties 26. 25-9253 Conduit mounting plate 27. 32-1800 Shuttle motor assembly 28. 51-0010 Cam follower T/C 29. 20-7030E Tool carriage 30. 32-1900A Turret motor assembly 31. 32-7610A Tool cariage conduit 32. 75-15721 MLX 2 pin M 7.11 LSW/Earmolex 33. 25-7162 Connector bracket
34. 46-1705 Nut 3/4-10 nylon lock 35. 32-2010 Limit switch shuttle In/Out 24" 36. 63-1031 Cable clamp 1/4 37. 48-1750 Dowel pin 1/2 x 1 1/2 38. 22-7106 V track 39. 20-7033 F hold plate 40. 51-0010 Bearing deep groove 41. 22-7163 Rider trap door 42. 20-9336 20 pocket geneva star 43. 48-0020 Dowel pin 1/4 x 1 44. 25-7238C Tool trap door 45. 25-7249 Sliding panel 46. 25-7250B Sliding panel cover 47. 24-2040A Compression Spring 48. 22-7255A Tool #1 standoff 49. 20-7038A bearing housing 50. 20-7035G Vertical axle 51. 54-0040 Standard bushing guide wheel 52. 25-7036Cap, tool changer 53. 51-0012 Bearing locknut BH-06 54. 26-7239 Spacer ring 55. 32-2000 Limit switch 4 wire 12" 56. 25-7570 Number ring 57. N/A 58. 20-7352B 20 tool carousel 59. 51-0001 Bearing 3/4 cam follower 60. 20-9332 Driver geneva 2 pin 61. N/A 62. 25-7237C 20 pocket T/C cover 63. 20-7236A Motor mounting plate 64. 32-7011A Molded T/C cable assembly 65. 57-7378 Tool cariage gasket 66. 78-1996 Split flex tubing 1/2 I.D.
ASSEMBLY DRAWINGS
42996-8100 rev C
June 2001
4
3
1
2
5 6
11
10
9
8
7
32 Tool Carousel Assembly (BT) VF 3-10
1. 25-9333 Number ring 2. 20-9324 Carousel 32 tool 3. 20-9193 Carousel support plate 4. 24-2010 Compressin spring 5. 25-9328 Sliding panel cover 6. 24-9257 Spring extractor 7. 25-7249 Sliding panel 8. 22-9256 Bushing extractor 9. 22-7166A Extractor BT-40 T/C 10. 22-7067F KEy extractor spring 11. 48-0004 Roll pin 3/8 x 1
ASSEMBLY DRAWINGS
430 96-8100 rev C
June 2001
4
2
1
3
5 6
11
10
9
8
7
32 Tool Carousel Assembly Assembly (CT) VF 3-10
1. 25-9333 Number ring 2. 20-9193 Carousel support plate 3. 20-9324 Carousel 32 tool 4. 24-2040A Compression spring 5. 25-9328 Tool sliding panel cover 6. 24-9257 Spring extractor 7. 25-7249 Slider panel 8. 22-9574A CT extraxctor spring 9. 22-9256 Bushing extractor 10. 22-7067F Key extractor spring 11. 48-0004 Roll pin 3/8 x 1
ASSEMBLY DRAWINGS
43196-8100 rev C
June 2001
4
3
1 2
5
6
50 Taper Carousel Assembly (CT) VF 6-10
1. 20-9296 50 Taper carousel 2. 22-9256 Bushing extractor 3. 25-9349 Number ring 4. 24-9257 Spring extractor 5. 22-9297 Extraction finger 6. 20-9298 Alignment key
ASSEMBLY DRAWINGS
432 96-8100 rev C
June 2001
VF 1-11 Gearbox Assembly 15 HP
29
26
25
24
28
27
30
23
VIEW A
16
17
13
18
15
14
19
20
11
12 21
22
7
8
1 2
10
9
3
5
VIEW A
6
4
31
32
33
58
57
54
55
56
59
37
34
35
36
38
39
40
52
53
49
51
50
47
48
41
42
46
44
45
43
ASSEMBLY DRAWINGS
43396-8100 rev C
June 2001
VF 1-11 Gearbox Assembly 15 HP
1. 25-0108 Fan bracket motor shroud 2. 36-3035 Spindle fan assembly 3. 59-7130 Protective strip 4. 32-2011Telmech. 30" cable assembly 5. 32-2010 24" limit switch 6. 25-7264 Switch mounting bracket 7. 29-0022 Shroud caution decal 8. 59-1482 Nylon finish plug, 13/16 9. 25-01074 Motor shroud 10. 20-0064 Adaptor encoder pulley 11. 62-3010 Spindle motor, 10HP 12. 59-0046 Soundcoat shroud RT/LT 13. N/A 14. N/A 15. 25-7433 Sump bracket 16. 22-7445A drain tube dry sump 17. 22-7446 Pick up tube dry sump 18. 58-2745 Magnetic oil plug 19. 57-0001 Oil seal 20. 58-3657 1/4 female 1/8 male adaptor 21. 54-2125 Drive belt HTD 300-3M-09 22. 54-1013 Drive sprocket .250 RTAP 23. 59-2040 Cable clamp 7/16 24. 58-2001 Polyu hose 1/2OD x 3/8ID 25. 32-1455D RTAP encoder cable 26. 60-1810 Shaft encoder 2000 line 27. 54-7127 Drive sprocket .375 RTAP 28. 22-7260 Encoder standoff 29. 57-0002 Oil seal 30. 25-7434 Sump tank 31. 63-1031 Cable clamp 1/4 32. 59-4006 Hose crimp, 35/64 33. 59-2040 Cable clamp, 7/16 34. 58-3616 3/8 90 deg. elbow 1/4 NPT 35. N/A 36. 58-7377 Air reg/solenoid tube 37. 76-2420 Crimp ring, 12-10 10 stud 38. 77-8011 Wire nut, ideal #30-076 39. 30-3270A Precharge regulator assy 40. N/A 41. 59-0027 Hose clamp 1/2 hose 42. 58-2020 3/8OD natural tubing 43. 22-7487 Oil fill cap modified 44. 58-2065 Coupling, 1/4NPT 45. 58-2070 1/4NPT male to 3/8 comp 46. 58-9114B Trans fill tube 47. 25-7336 Solenoid mounting bracket 48. 33-3200 Solenoid bracket cable assembly 49. 33-5088 Ground strap spindle motor shroud
50. 30-3146 Air solenoid assy mac TP 51. N/A 52. 58-2100 Sleeve lube assembly 53. 58-2110 Sleeve nuts lube assembly 54. 22-7520A Isolater trans 55. 22-7521A Spacer trans 56. N/A 57. 58-7636 High gear tube VF-3 58. 58-7635 Low gear tube VF-3 59. 63-0001 Nylon cable clamp 1/2
ASSEMBLY DRAWINGS
434 96-8100 rev C
June 2001
VF 1-11 Gearbox Assembly HT10K
36
30
29
33
34
35
31
28
32
VIEW A
9
10
8
15
14
11
16
12
13
27
25
24
23
26
19
18
17
22
7
6
1 2
21
20
4
VIEW A
5
3
53
36
48
47
52
49
51
50
44
46
45
43
42
41
54
55
58
59
56
57
40
39
38
37
64
62
60
61
63
ASSEMBLY DRAWINGS
43596-8100 rev C
June 2001
VF 1-11 Gearbox Assembly HT10K
1. 25-0108 Fan bracket motor shroud 2. 36-3035 Spindle fan assembly 3. 32-2011 Telmech 30" cable assembly 4. 32-2010 24" limit switch 5. 25-7264 Switch mounting bracket 6. 59-1482 Nylon finish plug, 13/16 7. 29-0022 Shroud caution decal 8. 55-0035 Spring washer, BS-204 9. 56-2087 Snap ring, N5000-206 10. 29-7399 Transmission motor label 11. 58-2745 Magnetic oil plug 12. 22-7446 Pick up tube dry sump 13. 22-7445A Drain tube dry sump 14. 25-7433 Sump bracket 15. 22-7376 Sprocket flange 16. 20-7374 1 1/8 sprocket 17. 20-0125 Drive sprocket encoder 18. 57-7573A Trans motor gasket 19. 36-3078 10K 10HP motor kit 20. 59-0046 Sound coat shroud RT/LT 21. 25-0107 Motor shroud 22. 54-2125 Drive belt HTD 300-3M-09 23. 58-3657 1/4 female 1/8 male adaptor 24. 55-0036 Spring washer, BS-205 25. 56-0070 Snap ring, N5000-187 26. 58-7357 Top plate tube-A 27. 57-0001 Oil seal 28. 25-7434 Sump tank 29. 57-0002 oil seal 30. 58-7358A Top plate tube-B 31. 22-7260 Encoder standoff 32. 54-7127 Drive sprocket .375 RTAP 33. 60-1810 Shaft encoder 2000 line 34. 32-1455D RTAP encoder cable 35. 58-2001 Polyu hose 1/2OD x 3/8ID 36. 59-2040 Cablt clamp, 7/16 37. 59-0027 Hose clamp 1/2 hose 38. 57-0049 Rubber stud bumper 39. 46-1625 Nut hex blk ox 1/4-20 40. 45-1800 Washer split lock 1/4 med 41. 30-3260B oil gear pump assembly 42. 30-3270A Precharge regulator assembly 43. 77-8011 Wire nut, ideal #30-076 44. 76-2420 Crimp ring, 12-10 10 stud 45. 58-7377 Air reg/solenoid tube 46. 58-3616 3/8 90 deg elbow 1/4 NPT 47. 59-4006 Hose crimp, 35/64 48. 63-1031 Cable clamp 1/4
ASSEMBLY DRAWINGS
436 96-8100 rev C
June 2001
VF 1-11 Gearbox Assembly HT10K TSC
44
37
38
41
42
43
39
36
40
VIEW A
11
12
10
9
17
16
13
18
14
15
35
22
20
19
21 33
32
31
34
26
25
23
24 30
29
8
7
1 2
28
27
3
5
VIEW A
6
4
56
55
54
61
59
62
60
58
50
53
52
51
49
47
46
63
64
67
68
65
66
45
73
71
69
70
72
48
57
ASSEMBLY DRAWINGS
43796-8100 rev C
June 2001
VF 1-11 Gearbox Assembly HT10K TSC
1. 25-0108 Fan bracket motor shroud 2. 36-3035 Spindle fan assembly 3. 59-7130 Protective strip 4. 32-2011 Telmech 30" cable assembly 5. 32-2010 24" limit switch 6. 25-7264 Switch mounting bracket 7. 59-1482 Nylon finish plug 13/16 8. 29-0022 Shroud caution decal 9. 57-0006 O-ring 2-328 buna 10. 29-7399 Transmission motor label 11. 29-9128 Label, transmission 12. 48-0020 Pin, dowel 1/4 x 1 13. 58-2745 Magnetic oil plug 14. 22-7446 Pick up tube dry sump 15. 22-7445A Drain tube dry sump 16. 25-7433 Sump bracket 17. 22-7376 Sprocket flange 18. 20-7374 1 1/8 Sprocket 19. N/A 20. N/A 21. N/A 22. N/A 23. 20-7435 Oil plate 24. 20-0064 Adaptor encoder pulley 25. 57-7573A Trans motor gasket 26. 36-3078 10K 10HP motor kit 27. 59-0046 Soundcoat shroud RT/LT 28. 25-0107 Motor shroud 29. 54-1013 Drive sprocket .250 RTAP 30. 54-2125 Drive belt HTD 300-3M-09 31. 58-3657 1/4 female 1/8 male adaptor 32. 55-0036 Spring washer, BS-205 33. 56-0070 Snap ring N5000-187 34. 58-7357 Top plate tube-A 35. 57-0001 Oil seal 36. 25-7434 Sump tank 37. 57-0002 Oil seal 38. N/A 39. 22-7260 Encoder standoff 40. 54-7127 Drive sprocket .375 RTAP 41. 60-1810 Shaft encoder 2000 line 42. 32-1455D RTAP encoder cable 43. 58-2001 Polyu hose 1/2OD x 3/8 ID 44. 59-2040 Cable clamp 7/16 45. 59-0027 Hose clamp 1/2 hose 46. 30-3260B Oil gear pump asssembly 47. 30-3270A Precharge regulator assembly 48. 30-3276 Purge solenoid valve assembly 49. 77-8001 Wire nut, ideal #30-076
50. 76-2420 Crimp ring, 12-10 10 stud 51. 58-7377 Air reg solenoid tube 52. N/A 53. 58-3616 3/8 90 deg. elbow 1/4NPT 54. 59-4006 Hose crimp, 35/64 55. 59-2040 Cable clamp 7/16 56. 63-1031 Cable clamp 1/4 57. 63-0001 Nylon cable clamp 1/2 58. 58-7635 Low gear tube VF-3 59. N/A 60. 58-7636 High gear tube vf-3 61. 22-7521A Spacer trans 62. 22-7520A Isolater trans 63. 58-2110 Sleeve nuts lube assembly 64. 58-2100 Sleeve lube assembly 65. 30-3146 Air solenoid assy mac tp 66. 33-5008 Ground strap spindle motor shroud 67. 33-3200 Solenoid bracket cable assembly 68. 25-7336 Solenoid mounting bracket 69. 58-9114B Trans fill tube 70. 58-2070 1/4NPT male to 3/8 comp 71. 58-2065 Coupling, 1/4NPT 72. 22-7487 Oil fill cap modified 73. 58-2020 3/8OD natural tubing
ASSEMBLY DRAWINGS
438 96-8100 rev C
June 2001
Spindle Assemblies
SPINDLES 30-0319A 7.5 Spindle Assembly 30-2132 10K Spindle Assembly 30-1360 15K Spindle Assembly 30-1468 15K spindle assembly VF5-11
30-0449 50 Taper Spindle Assembly
DRAWBAR 30-3410E 7.5k spindle with or without TSC 30-0067 50 Taper
ASSEMBLY DRAWINGS
43996-8100 rev C
June 2001
Tool Release Piston Assembly
VIEW B OUT OF POSITION
2 3 4 5 76 8 9
A
B
A 1
SECTION A-A
OUT OF POSITION
18 17 16 15
10 11 12 13 14
40 Taper Complete Assembly Non -TSC 30-3201A Mini Mill TRP Assembly 30-1668
TRP base XHC 30-3207 TRP base 30-3205
1. 58-3613 1/4 Street elbow 2. 58-3050 Elbow 1/4 bylon tubing 3. 58-3670 1/4NPT M 1/8F reducer 4. 58-3727A 1/4NPT x 4 nipple brass 5. 59-2832B Quick exhaust 1/4 6. 58-2165 Fitting close nipple 1/4 7. 32-5620 TRP solenoid valve assembly 8. 58-2265 Air muffler 3/8 flat 9. 58-3685 1/4NPT M 3/8 tube swivel elbow 10. N/A 11. 22-4045 Spring retainer TRP 30 degree 12. N/A 13. 32-2010 Limit sw shuttle in/out 24" 14. 25-4050C Switch mounting bracket 15. 59-2760 Comp spring/large wire 16. 57-0040 O-ring 2-111 Buna 17. 56-0040 Retaining ring N5100-62 18. 57-0018 O-ring 2-446 buna
ASSEMBLY DRAWINGS
440 96-8100 rev C
June 2001
50 Taper Tool Release Piston
13
18
19
20
21
17 16 15 14
22
23
24
25
1 2 3 4 5 6
12
11
10
9
8
7
1. 59-0049 Spring compression 2. 52-0003 Shaft clamp 3. 58-3050 Elbow 1/4 nylon tubing 4. 58-3631 Reducer bushing 1/2M-1.8F 5. 20-0016B Switch plate 6. 20-0021 Spacer upper TRP 50T 7. 32-2013 Limit switch shuttle assembly 8. 20-0019A Piston TRP 50T 9. 57-0092 O-ring 2-448 Viton 10. 57-0027 O-ring 2-121 Buna 11. 57-0095 O-ring 2-327 Viton 12. 58-1695 Elbow 1/4MPT 13. 58-1627 1/8-27 pipe plug 14. 20-0013 Spacer fork spindle 15. 20-0015 Fork lift Spindle 16. 20-0018A Shaft TRP 50T 17. N/A
18. 22-0014 Spacer .62ID x 1.25OD.857 19. 48-1662 Dowel pin 1/2 x 1 20. 20-0017A Sub plate TRP 50T 21. 59-0016 Spring compression 22. 49-0003 Shoulder bolt 5/8 x 3 1/2 23. 20-0020A Spacer lower TRP 50T 24. 20-0022A Housing air cylinder 25. 25-0009 Switch mounting bracket
50 Taper complete assembly 30-3202A
ASSEMBLY DRAWINGS
44196-8100 rev C
June 2001
TSCHP Tool Release Piston Assembly
OUT OF POSITION VIEW B
2 3 4
A
5 6 7 8 9
B
A
1
27 26 25
OUT OF POSITION
SECTION A-A
2324 22 21 20 1819
10 11 12 13 14 15
16 17
1. 58-3618 1/4 Street elbow 90 deg. 2. 58-3727A 1/4NPT x 4 nipple brass 3. 58-3050 Elbow 1/4 nylon tubing 4. 58-3670 1/4NPT M 1/8 F reducer 5. 59-2760 Compr spring/large wire 6. 58-2165 Fitting close nipple 1/4 7. 32-5620 TRP solenoid valve assembly 8. 58-2265 Air muffler 3/8 flat 9. 58-3685 1/4NPT M 3/8 tube swivel elbow 10. 22-7045A Spring retainer TRP 30 degree 11. 20-7626A Shaft TRP hex 12. 58-3614 1/4F 1/8M street elbow 13. 58-0028 Hose barb 3/8 PL-1/4 MP 14. 32-2010 Limit switch shuttle in/out 24"
15. 25-7050C Switch mount tool release 16. 58-2046 Hose 3/8ID pushlock 300psi. 17. 58-0032 Hose barb 3/8 PL 3/8 SAE F 18. N/A 19. N/A 20. N/A 21. 20-7627B Coolant tip carbide 22. N/A 23. 30-3298 24. 56-0040 Retaining ring N5100-62 25. 20-7630A TRP rectangle TSC 26. 57-2156 Quad-ring Q4-440 buna 27. 20-7007A Cylinder housing 93-30-3206 Complete assembly
ASSEMBLY DRAWINGS
442 96-8100 rev C
June 2001
Ball Screw Assembly
BALL SCREW ROTATED 90
COUPLING ASS'Y
BALL SCREW
MOTOR MOUNT
SNAP LOCK RING BMPR
Mini-mill VF 0-1 VF 2 VF 3 VF 4-5 VF-5XT Base 24-3006 30-0157 30-0157 30-0196 30-0196 30-0196 Saddle 24-3006 30-0157 30-0194 30-0195 30-0197 30-2152 Column 24-3006 30-0157 30-0157 30-0196 30-0196 30-0196
VF-6/8 VF-7/9 VF-10/11 Base 30-0474 30-0474 30-0474 Saddle 30-0470 30-0473 30-0516 Column 30-0474 30-0474 30-0474
50 Taper VF5 VF-5XT VF-6/8 VF-7/9 VF-10/11
Base 30-0202 30-0202 30-0895 30-0895 30-0895 Saddle 30-0198 30-2152 30-0896 30-0897 30-0516 Column 30-0202 30-0202 30-0895 30-0895 30-0895
*Except XRT
ASSEMBLY DRAWINGS
44396-8100 rev C
June 2001
Coupling Assembly
VF 0-5 & Mini-Mill VF-5XT VF 6/8 VF 7/9 VF10/11 Base 30-0211 30-1215 30-1219 30-1219 30-1219
(30-1220A) Saddle 30-0211 30-1219 30-1225A 30-0516
(30-1220A) Column 30-0211 30-1219 30-1219 30-1219
(30-1220A)
50 Taper VF5 VF-5XT VF-6/8 VF-7/9 VF-10/11
Base 30-1215 30-1215 30-1215 30-1215 30-1215 Saddle 30-1215 30-1215 30-1215 30-1225A 30-1225D Column 30-1215 30-1215 30-1215 30-1215 30-1215
ASSEMBLY DRAWINGS
444 96-8100 rev C
June 2001
1. Y-axisGutter 2. Y-axis Waycover 3. Y-axis Guide Rails 4. Way Cover Bracket 5. Saddle Cover 6. X-axis Gutter 7. X-axis Gutter 8. Saddle Cover 9. X-axis Waycover 10. X-axis Guide Rails 11. X-axis Guide Rails 12. Way Cover Bracket 13. Y-axis Wiper 14. Y-axis Rear Waycover 15. Z-axis Waycover Support 16. Z-axis Chip Guard 17. Z-axis Waycover 18. X-axis Waycover 19. Table Gutter 20. Table Cover
VF Interior Replaceable Parts
1
3
4
5
7
8
10
11
13
14
16
18
6
2 3
15
12
6
9
12
11
10
17
19
20
ASSEMBLY DRAWINGS
44596-8100 rev C
June 2001
1
9
10
11
6
8
7
3
4
5
2
12
13
15
14
18 17
19
20
21
22
16
VF Exterior Sheet Metal
ASSEMBLY DRAWINGS
446 96-8100 rev C
June 2001
1. Back Panel, Left 2. Side Window (handle not included) 3. Roof 4. Bridge 5. Roof 6. Back Panel, Right 7. Spindle Head Cover 8. Bottom Head Cover 9. Bottom Head Cover Inspection Panel 10. Left Door 11. Right Door 12. Right Side Panel 13. Front Right Panel 14. Apron Extension 15. Middle Front Panel 16. Front Apron 17. Access Panel 18. Pan 19. Front Left 20. Chip Chute 21. Left Side Apron 22. Left Side Panel
VF Exterior Sheet Metal
ASSEMBLY DRAWINGS
44796-8100 rev C
June 2001
11
7
9 12
3
6
8
6
5 4
1
2
8
13
14
10
20
13
14
16
15
18
19
17
VR11
VF(10&11)
VF Exterior Sheet Metal
ASSEMBLY DRAWINGS
448 96-8100 rev C
June 2001
VF Exterior Sheet Metal 1. Front Left Panel 2. Front Right Panel 3. Floor Pan Left 4. Floor Pan Right 5. Pan Right, Outrigger 6. Pan Support 7. Pan Support 8. Pan Left, Outrigger 9. Back Right Panel Extension 10. Inner Back Panel, Right 11. Inner Back Panel, Left 12. Back Left Panel Extension 13. Apron Extension Right 14. Apron Extension Left 15. Support Beam 16. Support Beam 17. Tool Changer Bracket 18. Tool Changer Cover 19. Tool Changer Pan 20. Back Panel Left
ASSEMBLY DRAWINGS
44996-8100 rev C
June 2001
1. Enclosure Side 25-0754 2. Door Assembly 25-0386 (Window 28-0011) 3. Guide Block 20-0712 4. Panel Front Enclosure 25-0753 5. Keybracket 25-0958 6. Switch Mounting Bracket 25-7050C 7. Door Keeper 25-0757 8. Lower Door Rail 22-7616 9. Lube Panel Mounting 25-7195K 10. Enclosure Side Mirror 25-0754 11. Main Electric Control Box 25-0025D 12. Junction Box 25-7198B 13. Regen Cover 25-0461 (front) 25-0462 (back) 14. Box Bar 20-3009 15. Back Panel Left 25-0384A 16. Back Panel Right 25-0385A
Mini Mini
Mill
Mill
1
4
3 56
7
8
9
10
11
12
13
14
15
17 18
16
2
ASSEMBLY DRAWINGS
450 96-8100 rev C
June 2001
1. Fan guard 59-0144 2. Fan bracket top 25-0389 3. Head Cover 25-0382 4. Back Head Cover 25-0388 5. Z lower cover 25-0381 6. Z upper cover 25-0380 7. Y-axis way cover, rear 25-0373 8. Support Cover 25-0377 9. Saddle cover (2) 25-0375 10. Tab side cover (2) 25-0378 11. Front Y-axis motor cover 25-0374 12. Y-axis Waycover, Front 25-0372 13. M
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