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HAAS SERVICE AND OPERATOR MANUAL ARCHIVE VF

1. CONTROL CABINE SPINDLE SIDE REGEN RESISTORS REAR OF MACHINE GROUNDING BARIOOOOOOOOOO0O00OQO0JO d 5 T PROCESSOR ASSEMBLY el 5 LABEL 5 CNC UNIT E E MOCON BOARD 2 3
2. INPUT VOLTAGE 353 480 VAC 115 VAC POWER Sau CI TRANSFORMER PENDANT DISTRIBUTION 115 115 230 230 1 ol o 5 VIDEO KEYBOARD AND JOG 5 5 E BRUSHLESS SPINDLE DRIVE SERV MICR AMPLIFIERS PROCESSOR CONC _ 320 voc FAULTS 1 x SPINDLE COMMANDS 046 amp SPINDLE ENCODER M SERV REGE SPINDLE I MOTORS ASSY DISCRETE INPUTS UTPUTS HEAT SENSOR SENSORS CMDS SWITCHES GEAR CHANGER DVERHEAT SENSLIRS Z PUMP W LUBE LUW CUOULANT SULENUIDS AND CHIP NOTE FOR w VOLTAGE IN SEE PAGE SYSTEM BLOCK DIAGRAM HIGH VOLTAGE 6 98 HAAS AUTOMATION SERIES C 266 401415
3. 195 260 115 VAC MAIN 192 260 AC TRANSFORMER DISTRIBUTION g 115 115 VAC 230 230 vac 9 VIDEO KEYBOARD AND JOG 3 u 7 BRUSHLESS SPINDLE DRIVE SERV MICR AMPLIFIERS PROCESSOR _ 520 voc FAULTS SPINDLE COMMANDS amp SPINDLE ENCODER M 2 a ERV REGEN SPINDLE 7 I URS ASSY DISCRETE INPUTS UTPUTS HEAT SENSOR SENSORS 3 CMDS HUME LIMIT SWITCHES GEAR BUX 1 CHANGER UVERHEAT SENSURS W CHULANIZSULENUIDS CHIP CUNVEYOR NOTE FOR HIGH VOLTAGE IN SEE PAGE C SYSTEM BLOCK DIAGRAM LOW VOLTAGE 6 98 HAAS AUTOMATION VF SERIES 96 8100 AAS 265 ELECTRICAL DIAGRAMS E 125 1998 SERVICE MANUAL MANUAL
4. HAAS June 1998 115V 3PH 115V CRT 115V HTX 115V TO CB4 115V SPARE 115V SPARE 115V FROM CB4 115V SPARE A BRAKE SP HD SOLENOIDS SERVO SP DR COMDS SERVO BRAKE TSC COOL TSC 230 IN COOL 230 IN COOLANT AUTO OFF SPIN FAN LUB OIL PUMP 230V 3PH 96 8100 1998 170 PLUG 96 8100 Cries SERVICE MANUAL MANUAL 1 0 PCB P N 32 3080 CABLE CONNECTIONS CABLE c TO c 510 520 540 550 110 930 940 170 710 300 880A 820 900 890 770 960 970 950 830 780 100 190 790 240 21 24 1040 910 390 810 160 90 90A 90B 90C 870 1050 810 300 1060 319 140 1070 200 530 180 350 280 940 9100 SPARE 930A 7708 AHAS LOCATION MOCON PCB MOCON PCB MOCON PCB MOCON PCB SERVO POWER ON POWER PCB COOL PUMP POWER PCB SPINDLE DRIVE SP FAN GEAR BOX SPIN LOCK I F SPINDLE HEAD TOOL CHANGER TSC PUMP LOW TSC SPINDLE HEAD E STOP SWITCH AIR OIL LOW OIL NOT USED AIR OIL LOW REGEN RESISTORS OVERH SPINDLE DRIVE EXTERNAL M FIN SHOT PIN SPARE 2 SPARE 3
5. ITEM PART DESCRIPTIO ITEM PART DESCRIPTION 1 20 0064 ADAPTER ENCODER PULLEY 60 3 45 1700 WASHER INTERNAL LOCK 8 2 20 7011D HOUSING GEARBOX MACHINING 61 3 45 1740 WASHER BLACK HARD 1 2 3 20 7062 BRG FORK CLUSTER 62 6 45 185 WASHER TRANS 4 20 7064 RANSFER SHAFT 63 4 46 1617 8 32 5 20 7374 8 SPROCKET 64 46 1654 NUT 7 16 20 6 20 7430A OIL CATCH 65 2 48 0020 PIN DOWEL 1 4 X 7 20 7435 PLATE 66 48 0050 PIN DOWEL 1 8 X 7 16 8 20 9125 SHAFT GEAR 67 2 51 203 BR 1 RADIAL 6305 8 20 9126 TOP PLATE GEARBOX 68 51 2032 BRNG RADIAL OPEN 6205 0 4 22 7260 STANDOFF 69 51 2033 BRNG RADIAL 6306 1 2 22 7376 SPROCKET FLANCE 70 51 2034 BRNG RADIAL OPEN 6005 2 22 4454 DRAIN TUBE DRY SUMP 71 51 204 BRNG LOCKNUT BH 05 3 22 7446 PICK UP TUBE DRY SUMP 72 54 1013 REMOVED DRIVE SPROCKET 250 RTAP 4 22 7487 OIL FILL CAP MODIFIED 73 54 2125 DRIVE BELT 500 5 09 5 2 22 7520 SOLATOR TRANS 74 54 7127 DRIVE SPROCKET 375 6 6 22 75218 IRANS 75 2 55 0055 SPRING 5 204 7 25 0107 OTOR SHROUD VMC 76 2 55 0036 SPRING WASHER 5 205 8 25 0108 FAN BRACKET MOTOR SHROUD 77 5 56 0060 SNAP RING N5100 66 9 25 7264 SWITCH MOU 78 56 0070 SNAP
6. 3 4 Assembly 15 340 nT v 96 8100 1998 125 ASSEMBLY DRAWINGS SERVICE MANUAL MANUAL 30 5500 TRANS ASSY VF 15HP VD ITEM PART DESCRIP TION QTY PART DESCRIPTION 20 0064 REMOVED ADAPTER ENCODER PULLEY 50 5 45 1700 WASHER INTERNAL LOCK 8 2 20 7011D HOUSING GEARBOX MACHINING 6 3 45 1740 WASHER BLACK HARD 1 2 5 20 7062 BRG FORK GEAR CLUSTER 62 6 45 1851 WASHER TRANS 4 20 7064 TRANSFER SHAFT 65 4 46 1617 NUT HEX 8 32 5 20 7374 1 1 8 SPROCKET 64 46 1654 NUT HEX 7 16 20 6 20 7450 OIL CATCH 65 2 48 0020 PIN DOWEL 1 4 X 7 20 7435 PLATE 66 48 0050 PIN DOWEL 1 8 X 7 16 8 20 9125 SHAFI 67 2 51 2051 BRNG RADIAL OPEN 6303 9 20 9126 TOP PLATE GEARBOX 68 51 2032 BRNG RADIAL OPEN 6205 0 4 22 7260 ENCODER STANDOFF 69 51 2055 BRNG RADIAL 6506 1 2 22 7576 SPROCKET FLANGE 70 51 2054 BRNG RADIAL OPEN 6005 2 22 7445 DRAIN TUBE DRY SUMP 7i 51 2041 BRNG LOCKNUT BH 05 3 22 7446 PICK UP TUBE DRY SUMP 72 54 1013 REMOVED DRIVE SPROCKET 250 4 22 7487 OIL FILL CAP MODIFIED 75 94 2125
7. S HV VA d 4 hez 100 51 111 30 5525A TRANS ASSY VF VDTSC VF 3 4 Gearbox Assembly HT10K TSC 344 _ uy C n ALA 96 8100 1998 125 ASSEMBLY DRAWINGS SERVICE MANUAL MANUAL 30 5525A TRANS ASSY VF HTIOK VDTSC ITEM QTY PART DESCRIPTION ITEM PART DESCRIPTION 20 0064 REMOVED ADAPTER ENCODER PULLEY 61 5 45 1740 WASHER BLACK HARD 1 2 2 20 70110 HOUSING GEARBOX MACHINING 62 6 45 1851 WASHER TRANS 5 20 7062 BRG FORK GEAR CLUSTER 63 4 46 1617 8 32 4 20 7064 TRANSFER 64 46 1654 NUT 7 16 20 5 20 737
8. UMBER 20 22 23 24 25 26 27 28 29 30 32 SPINDLE DRIVE 401 4 402 5 INPUT 15 5 07 10 SHOT PIN IN L 21 1 1 782 PINDLE DRIVE FAULT Mercy Y P21 2 784 20121 i T PINDLE STOPPED PN ay LA 21 3 785 6 PINDLE SPEED ICABLE 780 ELAMN oy ISPINDLE v DRIVE P19 2 Ee cane LOW SPINDLE OIL Leo 52 1 o O SPARE 1 ov v LAIT 24 1 SPARE 2 24 2 122260 SPARE 3 M 23 1 il REMOTE TOOL UNCLAMP 2 Wr nae LOSS DETECT Wr 1297 25 1 o O SPARE 4 av LAN 25 2 0 SPARE 5 Wav LAC M Let GROUND FAULT WM 4 Ti P473 lt SKIP iB SPIGOT Ee 42 CHIP CONVEYOR OVERCURRENT SENSE CIRCUIT IOPCB CABLE 550 CONT SWITCHES SHOWN ARE HAAS AUTOMATION 17 ROUGH 32 V SERIES ON ALARM STATE HIGH GEAR SHUTTLE OUT TURRET AT TOOL 1 POSIT
9. Figure 4 15 Interior of control panel rear ALA _______ 159 ELECTRICAL SERVICE V erfes SERVICE MANUAL MANUAL 160 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 Joc REPLACEMENT The JOG handle is actually a 100 line per revolution encoder We use 100 steps per revolution to move one of the servoaxes 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 panelin 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 16 when reconnecting otherwise damage may occur to the machine Blank pin goes to this side of connector Figure 4 16 Jog handle encoder 4 Using the 5 64 allen wrench loosen the two screws holding the knob to the control panel and remove
10. Driver Geneva Cam Figure 3 61 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 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 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 968100 fff 121 MECHANICAL SERVICE V 125 P T N v n O June 1998 SERVICE MANUAL 3 Remove the turret motor assembly Refer to previous section 4
11. Lead NEU Bearing E Figure 3 54 Z axis bearing sleeve 9 Perform Steps 6 10 of Z Axis Motor Removal 5 nDF 968100 1998 eri 125 MECHANICAL SERVICE SERVICE MANUAL MANUAL 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 SHCS and remove the clamp nut from the motor housing end of the lead screw 11 Loosen the six 4 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 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 14 20 x 1 SHCS into the motor housing Place a drop of blue Loctite amp on each of the SHCS before inserting CAUTION Do not use more than one drop of Loctite amp An excessive amount will cause a film between the sleeve and h
12. 96 8100 AAAS 269 ELECTRICAL DIAGRAMS M r 12S SERVICE MANUAL MAN SPINDLE ENCO 6 98 gt JOG MOCON INPUTS 550 980 IOPCB E VOLTAGE MONITOR 0 5 HOME SWITCHES r SP DRIVE LOAD 510 530 RELAYS 1 8 P24 P10 P21 P22 RELAYS 9 16 P11 P13 520 750 INPUTS RELAYS 25 32 540 FO P18 1 THRU 32 RELAYS 17 245 5 PT4 1000 DER p 20 Bie 720 ENCODER 660 ENCODER 79 7 ENCODER 680 N 640 P5 690 ENCODER PO 630 2 ENCODER 6908 P3 870 De 610 15 ADDRESS BUS BUS 860 P4 P1 VIDE BOARD J13 RS232 FLOPPY m 700 FLOPPY POWER 19 13 760 VIDEO SPARE P11 1 ADDRESS BUS DATA BUS 860 _ P4 P5 EXT BAT J6 850 _ BATTERY 8504 _ 68030 CPU 51 BOARD ADDRESS BUS DATA BUS 860 CNC UNIT HAAS AUTOMATION IOPCB
13. IVIANUAL Figure 4 21 VF 0 encoder installation 13 Place the belt on the 36 tooth pulley then loop over the 18 tooth pulley Place the encoder assembly 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 96 8100 165 ELECTRICAL SERVICE eri Z Y 1998 SERVICE MANUAL MANUAL 166 5 968100 1998 JECT fi TECHNICAL REFERENCE SERVICE MANUAL MANUAL 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 wiring to the tool changer goes through connector on the side of the control cabinet CAUTION If machine is equipped with the optional 50 taper spindle follow these guidelines gt 2510 maximum per tool and 300 Ib maximum total tool weight Extremely heavy tool weights should be distributed evenly CAUTION If machine is equipped with the 20 or 32 pocket tool changer follow these guidelines gt 12 16 maximum per tool 200 Ib maximum total tool weight for 32
14. elele SE fl Figure 4 Transformer with 354 488V Figure 4 9b Transformer with 195 260V range 4 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 overheating components or smoke If such problems are indicated set the main switch to off immediately and call the factory before proceeding 5 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 Figure 4 10 Measure voltage here problems call the factory 150 o2O T ys HAA 5 96 8100 EM SERVICE MANUAL MANUAL 6 Check the DC voltage displayed in the second page of Diagnostic data on the CRT Itis labeled DC BUS This voltage must be between 150 and 175 volts If the voltage is outside the
15. 291 ASSEMBLY DRAWINGS ol lll Co no 292 PART NO 20 9193 20 9324 22 7067F 22 7166A 22 9256 24 2010A 24 9257 25 7249 25 9328 25 9333 40 1500 40 16095 40 1697 40 1704 45 0045 48 0004 Cries TITLE CAROUSEL SUPPORT PLATE CAROUSEL 32 TOOL KEY EXTRACTOR EXTRACTOR BT 40 TOOL CHN BUSHING EXTRACTOR COMPRESSION SPRING SPRING EXTRACTOR SLIDING PANEL 32 TOOL SLIDING PANEL COVER NUMBER RING 32 T C SHCS 5 16 18 X 1 SHCS 10 32 x 1 4 SHCS 1 4 20 x 3 4 FHCS 10 32 x 1 4 WASHER BLK HARD 1 4 x 1 8 THK SPRING PIN 3 8 x 1 AMS 32 Tool Carousel Assembly BT June 1998 96 8100 1998 MI 125 ASSEMBLY DRAWINGS SERVICE MANUAL MANU SERVICE MANUAL 10 46143159 Tool Changer Assembly VF 3 4 96 8100 293 ASSEMBLY DRAWINGS V eri 125 111998 SERVICE MANUAL MANUAL 30 0008 TOOL CHANGER ASSEMBLY 32 TOOL VF 3 4 IT QTY PART TITLE 1 1 20 7035G VERTICAL AXLE 2 1 20 7038A BEARING HOUSING 3 1 20 7475 ARM SLIP CLUTCH 4 1 20 7476 HUB SLIP CLUTCH 5 1 20 9008 TOOL HOLDING ARM 6 1 20 9325 32 TOOL GENEVA STAR 2 PIN 7 1 20 9326 TOOL CARRIAGE MACHINING 8 1 20 9330 32 T C HOLDING PLATE 9 1 22 2065 LOCATING PIN 10 1
16. D A COMMAND TO SPINDLE DRIVE DRIVE SIG DRIVE SIG DRIVE SIG DRIVE SIC DRIVE SIG gt x lt m LOW VOLTAGE USER SERIAL PORT TO OPERATOR TO OPERATOR PENDANT LOW VOLTAGE POWER RS 232 INDEXER LOW VOLTAGE POWER SERIES PAGE 270 HAAS June 1998 96 8100 1998 7 eri eS ELECTRICAL DIAGRAMS SERVICE MANUAL IVIANUAL 15 3 PHASE FROM T1 01 9 Dm CRT DN THESE RELAYS ARE SOLID STATE PENDANT EQUIVALENT C REAR OF CONTROL CABINET 5 WORK LAMP HIGH GEAR LOW GEAR 1222 TOOL UNCLAMP SPINDLE DOOR LOCK KKe 4 PRECHARGE 2 cu k21 4TH AXIS BRAKE K5 STH BRAKE lt OPTION gt 777 es RED BEACON K30 GREEN BEACON 29 AMP FAN FUSE SPINDLE COOLING 02 11 45 SPINDLE LUBE SPINDLE FAN FoR f dc REMO WAY LUBE PUMP 115 VAC CIRCUITS 6 98 HAAS AUTOMATION VF SERIES 5 968400 6 271 m ELECTRICAL DIAGRAMS 125 SS
17. CAPACITOR ESISTOR H BUTTON SWITCH NORMALLY CLOSED PUSH BUTTON EN UU 21 288 1 Di DK 3 ama June 1998 96 8100 96 8100 ASSEMBLY DRAWINGS HAAS ASSEMBLY DRAWINGS 17418 20 0013 ITEM QTY PART NO 1 4 EA 20 0013 2 4 EA 20 0014 5 EA 20 0015 4 EA 20 00168 5 EA 20 0017 6 EA 20 0018 7 2 EA 20 0019 8 EA 20 0020 9 EA 20 0021 0 2 EA 20 0022 2 EA 25 0009 2 2 EA 32 2013 3 8 40 0006 4 40 0007 5 4 EA 40 1632 B 4 40 1800 7 4 EA 45 0014 28 EA 45 0015 290 WF Cries SERVICE MANUAL 0017 0018 0019 0046 16590 1662 0003 0003 0027 0092 0095 1627 1695 3050 3651 0016 0049 TOOL RELEASE PISTON DESCRIP ITEM QTY PART NO SPACER FORK SPINDLE 18 8 EA 45 SPACER 20 12 EA 45 FORK LIFT SPINDLE 21 4 EA 45 SWITCH TRIP 22 8 EA 45 SUB PLATE TRP 50T 25 4 EA 45 SHAFT SOT 24 6 EA 48 PISTON TRP 50 25 4 EA 49 SPACER LOWER TRP 50T 26 EA 52 SPACER UPPER TRP SOT 27 4 57 HOUSING SOT 28 2 57 SWITCH MOUNTING BRACKET 29 SEA 57 TELEMECH 44 CABLE ASSY 50 EA 58 SHCS 2 KO 51 3 EA 58 SHCS 1 2 13 X 3 m 32 EA 58 SHCS 1 4 X 1 ds EA 58 SHCS 8 32 X 34 4 EA 59 W
18. Lead Screw js Support di 8 Bearing Figure 3 51 Reinstalling the lead screw 4 Place the bearing sleeve in the motor housing as shown It may be necessary to align the bearings in the sleeve to facilitate mounting on the lead screw 5 Insert the six 14 20 1 SHCS attaching the bearing sleeve to the motor housing Place a drop of blue Loctite amp on each of the SHCS before inserting Tighten down completely CAUTION Do not use more than one drop of Loctite amp 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 necessary turn the leadscrew to correctly position lube fitting of the ball nut Insert but DO NOT TIGHTEN the five 20 x 1 or 4 20 x 34 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 gt 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 gt 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 nu
19. 1998 174 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 The connectors on the IOPCB are P1 16 relay drivers from MOCON 1 to 8 510 P2 16 relay drivers from MOCON 9 to 16 520 P3 16 pin relay drivers from MOCON 17 to 24 M21 M24 540 P4 34 pin inputs to MOCON 550 P5 Servo power on relay 1 1 110 P6 230V AC from CB3 930 P7 230V AC to coolant pump 940 P8 Auto off relay 1 7 170 P9 Spindle drive commands 710 P10 Spindle fan and oil pump 115V AC 300 P12 115V AC to spindle head solenoids 880A P13 Tool changer st
20. 307 ASSEMBLY DRAWINGS V eri 125 june 1998 SERVICE MANUAL MANUAL ITEM QTY DWG NO TITLE 1 1 20 0150 NUT HOUSING 40 50 BS 2 1 20 9216 Z AXIS BUMPER MTR END 40MM 3 1 20 9217 Z AXIS BUMPER SPRT END 40MM 4 1 20 9801 COLUMN MACHINED 5 1 20 9802 SPINDLE HEAD MACHINED 6 34 22 7458 CAM LINEAR GUIDE 7 2 22 9826A COUNTER WEIGHT HEAD BRACKET 8 2 22 9927 CYL BRKT COUNTER BALANCE 9 1 25 7267 Y AXIS MOUNTING BRACKET 10 2 25 7560B HYD FLUID TANK MOUNT 11 1 25 9813 WAY COVER 12 2 25 9929 STABILIZER BRKT HYD CYL 13 1 30 1211A BL LEADSCREW ASSEMBLY Z AXIS 14 1 30 3250A FLUID TANK ASSEMBLY 15 2 30 3980A HYD CYLINDER ASSEMBLY 16 1 30 7400 COLMUMN OIL LINE ASSEMBLY 17 1 32 2050 TELEMECHANIQUE ASSEMBLY 18 15 40 1628 SHCS 1 4 20 X 1 4 19 14 40 16372 SHCS 3 8 16 X 1 1 2 20 12 40 16391 SHCS 3 8 16 X 1 2 21 2 40 16413 MSHCS X 5 22 16 40 1655 MSHCS M12 X 65 23 34 40 1660 SHCS 1 2 13 X 1 1 2 24 6 40 1712 SHCS 5 16 18 X 1 1 4 25 2 40 1750 BHCS 10 32 X 38 26 24 40 2021 FHCS 1 4 20 X 3 2T 11 45 0045 WASHER BLACK HARD 1 4 X 1 8 THK 28 6 45 1600 WASHER LOCK 5 16 29 12 45 1665 WASHER FLAT 3 8 1 0 30 14 45 1681 WASHER SPLIT LOCK 3 8 MED 31 15 45 1800 WASHER SPLIT LOCK 1 4 MED 32 2 46 1810 JAM NUT HEX 3 8 24 33 6 48 0045 PIN PULL 3 8 X 1 1 2 34 2 48 1699 PIN DOWEL 5 8 X 2 1 4 35 4 50 0001 LINEAR GUIDE 36 1 57 0075 O RING 2 021 BUNA 3
21. X AXIS Figure l 1 Dial indicator in position to check X axis 2 Set dial indicator and the Distance to go display in the HANDLE JOG mode to zero as follows Zero the dial indicator Press the MDI 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 0 0 2 0 3 Set the rate of travel to 001 on the control panel and the machine 010 in the positive X direction 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 3 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 96 8100 6 13 4 43 veoussesnoorne Mi 727 gt ms SERVICE MANUAL Figure 1 2 Dial indica
22. sccuanicar service SERVICE MANUAL MANUAL 96 8100 3 16 THROUGH THE SPINDLE COOLANT SYSTEM ADJUSTMENTS TOOLS REQUIRED v Tool holder with small TSC drill or restrictor with a small orifice T 1461 x TSC Gauge Kit P N 93 9011 includes 0 15 PSI Precharge pressure gauge e 0 160 PSI Purge pressure gauge Not used on newer TSC machines e 0 600 Coolant pressure gauge e 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 coola
23. 4 ASSEMBLY DRAWINGS 30 1219 COUPLING ASSEMBLY ITEM PART No TITLE 1 2 20 7615 COUPLER SERVO DRIVE BRUSHLESS 2 2 51 2014 BEARING LOCKNUT 2 56 0065 SNAP RING 5100 112 4 1 59 2060 FLEXPAK FOR 5 WHERE USED APPLICATION 30 0018 BS ASSY 40 1 57 x 71 94 VF 6B 8B X 30 0053 BS ASSY 40mm 1 57 x 57 90 HL 5 8 Z 30 1211 BS ASSY 40mm 1 57 x 90 86 VF 7B 9B X 30 1212 4 BS ASSY 640mm 1 57 x 47 718 8 8 99 108 8 1 0 2 30 0302 BS ASSY 4 1 57 x 32 7 5 50 Y 2 30 0303 BS ASSY 240 1 57 x 57 90VF 5 50 X 96 8100 AMS 317 ASSEMBLY DRAWINGS MI eri 125 june 1998 SERVICE MANUAL IVIANUAL 30 12203 COUPLING ASSEMBLY WHERE USED APPLICATION 30 0116 BS ASSY 32mm 1 26 x 33 27HL 1 2 2 QTY PART No TITLE 30 0117 BS ASSY 32mm 1 26 x 48 23 HL 3 4 2 1 1 20 7403 COUPLING SERVO DRIVE 30 0118 BS ASSY d32mm 1 26 x 25 65 HL 5 6 X 2 1 207615 COUPLER BRUSHLESS 30
24. Power V7 ZA NI Power amplifiers E amicus XYZ amp A 8 Vector Drive Y Delta Contactors 1 0 Board y Transf 8 8818 ESSE Y Terminal block Inductors 2 Brush 4th Axis Figure 5 1 Control cabinet general overview 96 8100 6 171 TECHNICAL REFERENCE 125 SERVICE MANUAL amp Serial Port 1 Serial Port 2 E X Axis Y Axis Z Axis Axis lt bth Axis Tool Changer lt Limit Switches Coolant Tank lt Chip Conveyor Function Work Light Figure 5 2 Connectors on side of control cabinet June 1998 5 5 SERVOS BRUSH BRUSHLESS 172 SERVO ENCODERS Haas machines are equipped with brushless motors which provides for better performance and no maintenance 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 differences in acceleration parameters 7 21 35 49 and 157 The exponential accel decel time is set by parameters 115 116 and 168 In Position parameters 101 102 103 104 and 165 also affect brushless motors The motor controller board has a d
25. 111 MECHANICAL SERVICE Mi E 125 N VT T A A lt x 1 N June 1998 SERVICE MANUAL MANUAL 112 6 Reinstall the axis motor 7 Check for backlash in the Y axis lead screw Troubleshooting section or noisy operation 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 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 72 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 Bearing Sleeve
26. 96 8100 AAS 275 ELECTRICAL DIAGRAMS Cries SERVICE MANUAL 6 98 U ELAY 2 HAAS AUTOMAT S IHROUGH X24 PIN 1 PIN 1 1 OVDC 7 SPIGUT FORWARD ep lt OPTION gt 12VDC PIN 2 PIN 2 LE 17 PIN 3 5 OVDC uF oh SPIGUT REVERSE EE c OPTION 412VDC PIN 4 PIN 4 LE 18 4 5 PIN 5 OVDC 7 2 SPARE 12VDC PIN 6 PN LE 19 i 4 7 7 i 2 20 SPARE B 12VDC PIN 8 PIN 8 LE 20 PIN 9 PIN 9 OVDC TZ PRECHARGE 12vDC PIN 10 PN 10 iE i 4 PIN 11 11 OVDC 7 E SPARE HTC SHUTTLED 412VDC PIN 12 PIN 12 LE 22 PIN 13 13 OVDC V7 2 STH AXIS BRAKE 412VDC PIN 14 PIN 14 LE 23 J PIN 15 PIN 15 os V UA KZA EUROPE 412VDC PIN 16 PIN 16 LE 24 E135 PS CABL ovoce 1vc PCB 530 170 OTE ANY RELAY K35 REPLACED WITH A SOLID STATE EQUIVALEN VF SERIES PAGE 10 276 HAAS J
27. aiv SHLON WV LAN 1198 1198 Seve X18W3SSV 3598 1v 2317201 A18N3SSV 3 1QQV S Q31V201 i s B 2 f 7 55 L 3l SINWN109 L 211 2 ryt ry 0 Vd Ec 30101133 y SNOLOIMIS3N 710 10 10 HOLIMS 3unssaud LAN Ti vg TIVE 1 UVANI MOVE 8 m LV 9349907 A18WW3SSV 931 001 INVA 2 SOSH isa si Holvino3H INVA 108 d qm 3907 gt lt H 401 JHL OL 9349507 P al 19 312204 m 3 _ Houws YOLWINOSY E 10114 108 2 m La Lp e 2 1 f N z 1no E WSINVHO3N pee 39NVHO 15 rel M 212 aL 3AWA Y vB 28 GION310S WSINVHO3MW AME Nid LOHS 5 9 y ASSY JAYA 1 28101 VELO uada 34185344 bls 5 A XTHW3SSV
28. fJJf4 115 V eriegts June 1998 SERVICE MANUAL MANUAL 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 Tool Carriage Cam Follower Tool Changer Holding Plate Tool 1 Standoff Geneva Driver Geneva Star Figure 3 56 Automatic Tool Changer Mechanical Assembly Side View 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 42 above the carousel 3 Loosen the SHCS that attach the damaged extractor fork to the ATC carousel 116 HAAS 96 8100 1998 96 8100 service SERVICE MANUAL MANUAL Shuttle Motor Tool Holdin
29. 6 29 30 B eries une 1998 SERVICE MIANUAL Lube Air Panel Locating Pins Pallet 2 APC Control Panel Pallet Drive Pin Receiver and Pallet 1 Pallet Clamped Switch TOP VIEW amp Fig 1 Chain Sprocket Rotation Tool Trip Block Pin Clear Switch Pallet Drive Leg Pallet Home Switches Fig 2 DE at i r5 f d e E gt ag aq Pallet Unclamp Solenoid Door Open Solenoid Fig 3 AAAS 96 8100 June 1988 7 TROUBLESHOOTING SERVICE MANUAL 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 e Blown amplifier indicated by a light at bottom of amplifier when power is on Replace amplifier e Amplifier or MOCON is noise sensitive If this is the case the alarm be cleared and the axis will run normally for a while To check an amplifier switch the motor leads and control cables between
30. VI SERVICE IVIANUAL MANUAL Series ELECTRICAL DIAGRAMS 6 98 357 480 VAC IN 24VCT 460V 400V 360 m E POWER SUPPLY PCB FUSES DN POWER SUPPLY POWER ARE 1 84 FAST BLOW ONLY on THEY WILL OPEN IF VOLTAGE 742 EXCEEDS 570 INCOMING 17 3 PHASE POWER DRUPPING E uS 743 3 orr FU1 OPERATOR VN 744 PENDANT FU2 OFF M A iw m K7 S 66 PART OF 1 9 PCB AUX SPINDLE 230 S DRIVE 357 376V 377 400 Pm 1159 426 451 452 m PART OF POWER SUPPLY PCB 230 VAC 0 200 357 376 577 400 PHZ 401 425 115V 426 451 2 452 due 2 230 357 376 377 400 PHa aa 1159 425 451 1 0 PCB 452 ieu M TSC MOTOR PART OF POWER ced seal VAL SUPPLY PCB CB3 6 1 0 PCB COOLANT MOTOR 220 240 VAC 2 MAIN TRANSFORME HIGH VOLTAGE HAAS AUTOMATION SERIES 5
31. Note Refer to Cable Locations for diagram of this board Remove the or MOTIF board as described in Steps 1 5 Disconnect all leads to the Video Keyboard Ensure all cables are properly labeled for reconnecting later The following illustration shows all cable numbers and the locations on the Video Keyboard 5 9658100 1998 96 8100 10 11 12 JE enr dents mense SERVICE MANUAL MANUAL 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 Replace the Video Keyboard attaching it to the PROCESSOR board beneath the Video Keyboard with the standoffs 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 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
32. 87 2 58 16752 90 DEG COMPRESSION TILT 28 30 32608 ASSY 88 5 75FT 58 2001 POLYU HOSE 1 20D X 3 8ID 29 30 3270 REGULATOR 55 89 2 5FT 58 2020 3 8 OD NATURAL TUBING 30 32 14556 ENCODER CABLE 90 58 2065 COUPLING 1 4 51 32 2010 24 LIMIT SWITCH 91 2 58 2070 1 4 MALE 3 8 32 32 2011 TELMECH 30 IN CABLE ASSY 92 4 58 2100 SLEEVE LUBE ASSY 53 33 3200 SOLENOID BRKT CABLE ASSY 93 4 58 2110 SLEEVE NUTS LUBE ASSY 34 33 3008 GRND STRP SPNDL SHRD 94 58 2745 MAGNETIC OIL PLUG 35 35 7065 TRANSFER GEAR 55 95 58 5616 3 8 90 DEG ELBOW 1 4 56 35 170A DRIVE 55 96 58 3657 1 4 FEMALE 1 8 MALE ADPT 37 36 3035 SPINDLE FAN ASSY 97 58 7357 TOP PLATE TUBE 38 2 40 1602 FHCS 1 4 28 X 5 8 98 58 7358 PLATE TUBE 59 40 1628 SHCS 1 4 20 X 1 4 99 58 7377 AIR REG SOLENOID TUBE 40 40 1630 SHCS 1 4 20 X 5 16 00 58 7635 LOW GEAR TUBE VF 3 4 2 40 1632 SHCS 1 4 20 X 1 2 01 58 7636 HIGH GEAR TUBE VF 3 42 8 40 16385 SHCS 5 16 18 X 3 4 02 58 9114B TRANS FILL TUBE 43 4 40 16413 SHCS 3 X 5 03 59 0027 HOSE CLAMP 1 2 HOSE 44 2 40 1644 SHCS 10 32 X 1 1 2 04 2 59 0046 SOUNDCOAT SHROUD RT LT 45 4 40 1645 SHCS 10 32 X 5 8 05 4 59 1482 YLON FINISH PLUG 15 16 FINAL ASSEMBLY 46 5 40 16455 SHES 10 32 X 7 8 06 2 59 2040 CABLE CLAMP 7 16 47 4 40 1669 REMOVED BHCS 8 32 X 3 8 07 59 4006 HOSE CRIMP 35 64 48 4 40 1700 SHCS 10 3
33. PAGE 96 8100 AAS 273 ELECTRICAL DIAGRAMS Cries SERVICE MANUAL 1 4 PIN 1 PIN 1 G 7 p 12VDC PIN 2 PIN 2 LE PIN 3 PIN 3 I 7 amp x2 12VDC PIN 4 PN 4 iE 2 i 4 PIN 5 5 i G OVDC oy 12VDC PIN 6 PIN 6 LE 9 4 PIN 7 7 i OVDC ER 412VDC PIN 8 PIN 8 LE 4 i 4 PIN 9 PIN 9 i V I 412VDC PIN 10 PIN 10 LE 4 PIN 11 PIN 11 V7 12VDC PIN 12 PIN 12 LE 9 4 PIN 13 PIN 13 i e 12VDC PIN 14 PIN 14 LE 7 2 J PIN 15 PIN 15 E G 7 12VDC PIN 16 PIN 16 LE 8 a P11 x _ CABLE 12vDC 510 1 0 PCE NOTE ANY RELAY K535 CAN EPLACED WITH A SOLID STATE EQUIVALEN 6 98 VELA COIL D gt K1 HAAS AUTOMATION T H ROUGH VF SERIES SERVO POWER ON SPINDLE FORWARD SPINDLE REVERSE SPINDLE RESET 4TH AXIS BRAKE COOLANT ON AUTO POWER OFF SPINDLE COOLING 0 SPINDLE LUBE SPINDLE FAN GEAR BOX D
34. 1998 96 8100 Parameter 209 HORIZONTAL RSTSTOPST C UNUSED 50 DOOR ZNO HOME 36 AUXAXIS SPIGOT KEY INV T SUBROUTINE SPIN Y ENCDR REV CONVEYOR M27 M28 CONVYR RESERVED GREEN BEACON RED BEACON CONVY DR OVRD Cries SERVICE MANUAL MANUAL 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 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 Tool changer can be stopped with RESET button Enables chip conveyor if machine is so equipped 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 When enabled the control will look for an additional door switch and will generate an operator message In Horizontal mills only This bit prevents Z axis motion to machine zero prior to a tool change In Horizontal only When set to 1 an M36 rotates the A axis after the PART READY button is pressed In Horizontal mills only When enabled means the tool changer carousel is driven by an
35. 205 5 5 206 Parameter Parameter Parameter Parameter Parameter Parameter Parameter Parameter Parameter Parameter Parameter Parameter Parameter 163 164 165 166 167 168 169 170 171 172 173 174 175 Cries SERVICE MANUAL MANUAL B BACKLASH See Parameter 13 for description B DEAD ZONE See Parameter 14 for description IN POSITION LIMIT B Same definition as Parameter 101 B MAX CURRENT Same definition as Parameter 105 D D GAIN FOR B Second derivative gain in servo loop B ACC DEC T CONST Same definition as Parameter 113 B PHASE OFFSET See Parameter 121 for description B GRID OFFSET See Parameter 125 for description B EXACT STOP DIST See Parameters 134 for description B FRICTION FACTOR See Parameter 138 for description B ACCEL FEED FORWARD Same description as Parameter 145 SPINDLE B TEMP COEF This parameter controls the amount of correction to the B axis in response to heating of the spindle head Itis 10 times the number of encoder steps per degree F 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 Parameter Parameter 176
36. 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 1 Power on the Vertical Machining Center VMC 2 Zero return ZERO RET all axes then HANDLE JOG to center X and Y axes under spindle 3 Protect table surface with a piece of cardboard 4 Loosen the four SHCS that attach top cover to side covers and remove 5 Loosen the six SHCS that attach rear cover to side covers and remove 6 Loosen the eight SHCS that attach front cover to side covers then carefully remove front cover from the bottom until you can disconnect the tool release cable quick disconnect 7 Loosen the seven SHCS that attach each side cover and remove from the top side Jog Z axis as necessary to make screw removal easier CAUTION Be careful not to run head covers into the enclosure 9 8100 9 55 MECHANICAL SERVICE E 125 January 1998 SERVICE MANUAL MANUAL mme Remove side covers Figure 1 1 View of VF 3 4 head covers INSTALLATION 1 Protect table surface with a piece of cardboard 2 Replace each side cover from the top side with seven SHCS Jog Z axis as necessary to make access to screws easier CAUTION Be careful not to run the head covers into the enclosure 3 Reconnect tool release cable
37. m ALARMS cae 48 369 370 371 372 373 374 375 376 377 378 379 380 382 383 384 385 386 387 388 389 M Tool Too Big Pocket Definition Error Invalid 1 J K OR Q Tool Change In Canned Cycle Invalid Code in DNC Missing XYZA in G31 or G36 Missing Z or H in G37 No Cutter Comp In Skip No Skip in Graph Sim Skip Signal Found Skip Signal Not Found X Y A or G49 Not Allowed in G37 G43 or G44 Not Allowed in G36 or G136 D Code Required in 035 Inch Is Not Selected Metric Is Not Selected Invalid L P or R Code In G10 Invalid Address Format Cutter Comp Not Allowed With G103 Cutter Comp Not Allowed With G10 617 018 G19 Illegal in G68 eres SERVICE MANUAL MANUAL June 1998 Use a smaller tool for cut Check geometry for G150 Check G150 Tool change not allowed while canned cycle is active A code found in a DNC program could not be interpreted because of restrictions to DNC G31 skip function requires an X Y Z or A move G37 automatic tool length measurement function requires H code Z value and tool offset enabled X Y and A values not allowed SkipG31 and G37 functions cannot be used with cutter compensation Graphics mode cannot simulate skip function Skip signal check code was included but skip was found when it was not expected Skip signal check code was included but skip was not found when it was e
38. 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 problems following lt ATC shuttle will not move shuttle is getting power Command a tool change and feel for power being applied to the shuttle motor e Disconnect the slip clutch arm from the ATC shuttle and ensure the shuttle can move freely If not appropriate section for shuttle adjustment e Command a tool change with the shuttle disconnected gt Ifthe 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 gt Ifthe 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 shuttle will not move shuttle is not getting power Command a tool change feel for power being applied to the shuttle motor e Check that the TC IN TC OUT LED on the 1 0
39. N LOW VOLTAGE J 22 AUTO OFF 860 12 POWER ON OFF LOW VOLTAGE 860 P27 LOW VOLTAGE COIL 860 P11 SOLENOID COOLANT PUMP MAIN TRANSFORMER LOW VOLTAGE LOW VO IW VOLTAGE 2 LOW VOLTAGE LOW VOLTAGE 5 SERIAL PORT 1 12V CB4 CBS SERIAL PORT 2 12V 90 8 800 P30 099 pog OP LAMP TO SWITCH Figure 4 12 Power supply board fuse locations 4 Using flat screwdriver turn the fuse counterclockwise to remove and replace the blown fuse with ones having the same type and rating operator s lamp amp type AGC 250V 152 n n 5 968100 1998 7 necro servo SERVICE MANUAL MANUAL Servo Driver amp SDIST Fuses 1 2 96 8100 Turn the main switch upper right of electrical cabinet to the off position 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 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 13 the F3 fuses are not shown On the SDIST panel use a flat tip screwdriver to turn the fuse
40. 96 8100 1998 125 ASSEMBLY DRAWINGS O SERVICE MANUAL MANU SERVICE MANUAL 1 30 1210 LEAD SCREW ASSEMBLY 2 32 7528 COLUMN OIL LINE ASSEMBLY 3 32 2041 IELEMECHANIQUE SWITCH ASSEMBLY VF 3 Column 96 8100 fff 333 ASSEMBLY DRAWINGS MI eri eS june 1998 SERVICE MANUAL MANUAL poe 1 20 1200 LEAD SCREW ASSEMBLY 2 30 1401 MOTOR ASSEMBLY 3 30 7527 SADDLE OIL LINE ASSEMBLY 52 2050 TELEMECHANIQUE SWITCH ASSEMBLY VF 3 Saddle 334 O SU bT FMM s AAAG 96 8100 1998 30 59056 PARI 20 7016 20 70181 20 7022 20 7373 20 7442C 20 7550 20 7531 24 4200 30 3415F 40 1610 O 00 gt l O R CA N 96 8100 17 9 18 15 Cries SERVICE MANUAL MANUAL NUN ASSEMBLY DRAWINGS DESCRIPTION SHCS 5 16 18 X 3 4 ess 1 2 13 X 3 4 BEARING 6010 OPEN BRNG DUPLEX MD 36MM SPCR WAVE WASHER W3118 035 SNAP RING 5000 131 O RING 2 158 VITON SPINDLE ASSY TSCHP CARB DESCRIPTION ITEM QTY PART NO SPINDLE HOUSING 1 6 40 16385 SPINDLE SHAFT
41. 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 GENEVA WHEEL POSITION MARK The turret rotation mechanism has switch mounted so that itis activated for about 30 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 this 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
42. June 1998 SERVICE MANUAL v m INPUT NUMBER Ee ld SHUTTLE IN 01 T EE T12V N 5 NP dos 3 2 a SHUTILE OUT 02 P13 3 TOOL 1 MARKER 03 P14 1 LOW TSC COOLANT 04 OPTIONAL P13 4 GENEVA MARK 05 15 1 IN HIGH 06 15 2 JO N LOW GEAR 07 4 2 T 4 EMERGENCY STOP 08 12 LAN P38 1 SE DOOR OPEN 09 Pee i M CODE FINISH 0 eR p 124 P18 1 LOW VOLTAGE M aad 19 1 IO LOW AIR PRESSURE 2 Wr SENSOR 17 1 7 IO LOW WAY LUBE OIL 3 eI 12 20 1 OVERHEAT SERVO REGEN 4 12 P15 3 E DRAW BAR OPEN 5 M 15 4 E DRAW BAR CLOSED 6 CABLE 550 SWITCHES SHOWN ARE ON ALARM STATE HIGH GEAR SHUTTLE OUT TURRET AT TOOL 1 POSIT DISCRETIE INPUTS 1 THROUGH 16 6 98 HAAS AUTOMATION VF SERIES AGE 6 212 40412 968100 1998 VI eres SERVICE MANUAL SERVICE MANUAL ELECTRICAL DIAGRAMS 6 98
43. POWER OFF ee TO VIDEO BOARD VIDEO CABLE 760 CRT REMOTE JOG HANDLE TO P34 115 VAC CABLE 90A 12 VDC 860C CRT FAN TO P13 PSU 150 750B TO MOCON 750A 42 11 13 7500 SERIAL INTERFACE 12 119 2 L 24 PIN FLEX CABLE 16 PIN RIBBON CABLE T CABLE 700A ADJUST LOAD METER AUX START 1 SPEAKER FPANEL FEED HOLD METER 705 5 P6 P3 CABLE 720 gt MOCON 16 CYCLE START o r E CABLE 770 TO 1 0 BOARD INPUT 8 I FEED HOLD 5 lt zx EMERGENCY STOP 860F TO J10 VIDEO BOARD PWR 2104 DATA FROM J12 VIDEO BOARD FLOPPY DRIVE CONTROL CABINET 6 98 HAAS AUT OMATION JAN VL SER PAGE 133 286 HAAS June 1998 96 8100 1998 7 eri Jes ELECTRICAL DIAGRAMS SERVICE IVIANUAL VECTOR DRIVE SPINDLE POU 610 220V 31 HP 207 580 606 SERVI NP MOTOR XYZ AXIS C 11 FP 8900 TA 17 HP 13000 137 e FAN VECTOR
44. SALAS 211 em PARAMETERS N 212 Parameter Parameter Parameter Parameter Parameter Parameter Parameter Parameter Parameter Parameter Parameter Parameter Parameter Parameter 230 231 232 233 234 235 236 237 238 239 240 241 242 243 erfes SERVICE MANUAL Y LEAD 10 9 This parameter sets the Y axis lead screw compensation signed parts per billion Z LEAD COMP 10E9 This parameter sets the Z axis lead screw compensation signed parts per billion A LEAD COMP 10E9 This parameter sets the A axis lead screw compensation signed parts per billion B LEAD COMP 10E9 This parameter sets the B axis lead screw compensation signed parts per billion C RESERVED 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 set to 0 TSC LOW PR FLT After the TSC system has stabilized following startup 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 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
45. SERVICE MANUAL MANUAL Normally Closed Normally Open Outside Diameter Operator Parameter Printed Circuit Board Program Power On Reset Positions Program Pounds Per Square Inch Pulse Width Modulation Random Access Memory Repeat Rigid Tap Return Reverse Conveyor Remote Jog Handle Rotary Pallet Draw Bar Down Rotary Pallet Draw Bar Up Revolutions Per Minute Spindle Speed Servo Distribution PCB Surface Feet Per Minute Socket Head Cap Screw Serial Input Output Serial Key Board Inter Face PCB Spindle Tool Number Tool Changer Total Indicated Runout Tool Nose Compensation Tool Release Piston Tail Stock Through The Spindle Coolant Vertical Mill very first Vertical Mill Extended Vertical Machining Center AAAS June 1998 96 8100 June 1998 f TROUBLESHOOTING SERVICE MANUAL MANUAL 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 problem s source and second solving the problem The troubleshooting tips are organized in this section according to the area of the CNC that may be giving sign of a problem Ex Out of round circles in drilling will be found under the heading General Machine Operation Accuracy If the problem you are experiencing cannot be found under the heading you expect please try several
46. SHORTENED PUMP LIFE REDUCTION OF PRESSURE AND INCREASED MAINTENA THE COOLA T MUST BE CHANGED MORE OFTEN AND THE TANK THOROUGHLY THE BOTTOM A LARGER COOLANT TANK IS RECOMMENDED CE ARE NORMAL AND TO BE EXPECTED IN ABRASIVE ENVIRONMENTS AND IS NOT COVERED BY WARRANTY AAS June 1998 96 8100 1998 V 125 MECHANICAL SERVICE SERVICE MANUAL IVIANUAL THROUGH THE SPINDLE COOLANT SYSTEM FLOW DIAGRAM 50 TAPER SPINDLE CVA CHECK VALE ASSEMBLY ROTATING UNION COOLANT 1 P1 19 FM 30 32758 FLOW 1 0 TAE Fi INTAKE FILTER ASSEMBLY T gt T T 100 MESH 4 1 F2 150 FILTER 20 MICRON pg E USE 20 MICRON FILTER ELEMENT RES AER FAL INTAKE FILTER ASSEMBLY 30 0072 poo d Jn TO DRAIN FA2 FILTER ASSEMBLY 30 3287 EXTENSION esta 3 GI SUCTION GAGE INTAKE FILTER TUBE oN Bese ae s eee G2 FILTER GAGE TSC FILTER AR BLAST 4 1 TSCHP PUMP 300 PSI ADVANCE TRSA TOOL RELEASE SOLENOID ASSEMBL
47. The Precharge and Through the Spindle Coolant system applies low air pressure and releases the clamped switch with 40 taper spindle only UNcLANP SWITCH The Remote Tool Unclamp switch is mounted on the front of the cover to the spindle head It operates the same as the button on the keyboard It must be held for 72 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 96 8100 n ANG 169 TECHNICAL REFERENCE 125 SERVICE MANUAL IVIANUAL June 1998 170 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 51 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 51250 is not recommended High gear operation below 5100 may lacktorque or speed accuracy Spindle speed accuracy is bestatthe high
48. 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 Broken wires or encoder contamination All servos are turned off This can also be caused by loose connectors at P1 P4 same as 153 same as 153 same as 153 The self test of the MOCON has failed Replace the MOCON 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 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 The line voltage to control is too low This alarm occurs when the AC line voltage drops below 190 when wired for 230 volts or drops below 165 when wired for 208 volts 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 amechanical stop It can also be caused by ashortinthe motororashortof one motor lead to ground same as 161 same as 161 same as 161 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 fr
49. HAAS June 1998 96 8100 EM p SERVICE MANUAL MANUAL 5V RED WHT YEL GND B WHT GRN WHT WHT RED BRN Figure 4 17 Jog Handle removal Figure 4 18 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 Note This section is applicable for the POWER ON POWER OFF EMERGENCY STOP CYCLE START and FEED HOLD switches 1 Turn the machine power off 2 Remove the four screws holding the cover panel on the back of the control panel Take care to hold the cover panel in place until all screws have been removed 3 Disconnect all leads to the switch s connectors Ensure all leads are properly marked for reconnecting later Refer to Fig 4 15 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 96 8100 161 ELECTRICAL SERVICE Er SERVICE MANUAL MANUAL 162
50. 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 96 8100 n ANG 181 TECHNICAL REFERENCE er 7 June 1998 SERVICE MANUAL MANUAL 182 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 POWER The low voltage power distribution and high voltage fuses and circuit breakers are mounted on acircuit board called the POWER PCB The following connectors are on it P1 Brings incoming 230 VAC 460 VAC 3 phase from main breaker P2 On Off connections to front panel 740 P3 Coil and aux connections to contactor K1 P4 Auto off connection to IOPCB 170 P5 Primary and secondary connections to transformer 5 230V from to coolant pump 930 P7 115V AC from CB4 to IOPCB for solenoids 910 P8 115V AC from IOPCB to CB4 for solenoids 90 9 5 12 12 GND from low volt supply to logic boards to MOCON 860 P10 5 12 Gnd from low volt supply to logic boards 860 P11 5 12 Gnd form low volt supply to logic boards 860 P12 5 12 Gnd form low volt supply to logic boards 860 P13 5 12 Gnd form low volt supply to logic boards 860 P14 12V AC to operat
51. 06 8100 1998 H 4 R c o gt eri ELECTRICAL DIAGRAMS SERVICE MANUAL MANUAL BRUSHLESS SERVO SPINDLE AMPLIFIER DRIVE POWER SUPPLY LV HV 320 VDC 4 i E BRUSHLESS 2 PWR por MTR CMD X SERVO 490 X SERVO 610 J2 X AXIS MOTOR ENCODER CABLE 660 E 660 ENCODER BRUSHLESS z MTR PWR 2 MTR CMD Y SERVO AMP 490 Y SERVO 620 J2 AXIS MOTOR ENCODER CABLE 670 670 ENCODER 2 E BRUSHLESS MTR PWR e MTR CMD Z SERVO 490 7 SERVO 820 Jz P MOTOR O ENCODER c 680 880 ENCODER lt OPTIONAL MIR PWR z BRUSHLESS _ PWR E NES SERVO AMP 4904 BRUSH 640 J2 AXIS ENCODER CABLE MOTOR id ENCODER OPTIONAL OPTIONAL MTR PWR BRUSHLESS Sr PWR i B SERVO MTR SERVO AMP 490
52. 1998 W 125 ASSEMBLY DRAWINGS SERVICE MANUAL MANUAL SECTION QUT OF POSITION NS PART NO DESCRIPTION ad CAUTION TOOL CLAMPIUNCLAMP SWITCHES MUST BE PROPERLY ADJUSTED BY TRAINED PERSONNEL OR SEVERE DAMAGE TO TOOL CHANGER B 32 5620 SOLENOID VALVE ASSY WILL RESULT PLEASE CONSULT SERVICE MANUAL BEFORE ADJUSTMENT 9 40 1632 HCS 4 4 20 X 7 2 4 40 1800 HCS 8 32 X 3 4 4 5 00 ASHER BLK HARD 1 4 A325 4 RING 5100 62 VIEW B OUT OF POSITION 30 3292 TOOL RELEASE PISTON ASSEMBLY ITEM PART NO DESCRIPTION QTY 1 20 7007A CYLINDER HOUSING MACHINED 20 7043A PISTON TRP RECTANGLE 20 7044C SHAFT TRP 22 7045 SPRING RETAINER TRP 500 SWITCH MNT TOOL RELEASE 29 7397 LABEL TOOL RELEASE PISTON 52 2010 24 LIMIT SWITCH m ocoouzuu 20 UJ gt 58 3618 1 4 STREET
53. 5 5 ADJUSTMENT OF 50 TAPER OPTION See section 2 5 TRP Installation 50 Taper Setting TRP Switches 9 810 9 gt 77 MECHANICAL SERVICE V 125 1998 SERVICE MANUAL MANUAL 6 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 6 1 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 ax
54. 862 8 P6 ADDRESS BUSS DATA BUSS 0 6 0 6 LOW VOLTAGE L J4 J5 222 9 5655500 n SERVICE MANUAL MANUAL June 1998 ernieee CABLE LOCATIONS MICRO PROCESSOR PCB P N 32 3091 CABLE CONNECTIONS PROC PLUG CABLE SIGNAL NAME c TO gt LOCATION PLUG ADDRESS ADDRESS BUSS VIDEO amp DATA DATA BUSS MOTIF PCB 860 LOW VOLTAGE POWER SUPPLY PCB P6 N A EXTERNAL BATTERY EXT BATTERY PORT 1 850 SERIAL PORT 1 SERIAL PORT 1 PORT 2 850A SERIAL PORT 2 SERIAL PORT 2 96 8100 o 5 225 CABLE LOCATIONS FAULT POWER ON 226 M 12 01 93 5550 69 69 69 68 75 ____________ SERVICE MANUAL MANUAL SERVO DRIVE SIGNAL LOW VOLTAGE INPUT m SERVO MOTOR 325VDC FROM HAAS VECTOR DRIVE FUSE OPEN 96 8100 Cries SERVICE MANUAL MANUAL CABLE LOCATIONS 23 1998 BRUSHLESS SERVO AMPLIFIER P N 32 5550B CABLE CONNECTIONS MOCON PLUG CABLE SIGNAL NAME c TO c LOCATION PLUG P 570 LOW VOLTAGE L V POWER SUPPLY MOTOR DRIV
55. COEF This is the coefficient of heating of the lead screw and is used to decrease or shorten the screw length Parameter 133 Z THERMAL 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 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 FACTOR Parameter 139 Y FRICTION FACTOR Parameter 140 Z FRICTION FACTOR Parameter 141 A FRICTION FACTOR 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 204 P n N y3 AAS 26 8100 1998 96 8100 Parameter Parameter Parameter Parameter Parameter Param
56. DO NOT MOVE THE SPINDLE DURING LEAD SCREW SERVICE 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 gt Insert the lead screw into the bearing support Screw the clamp nut on a few turns gt 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 gt Mount the bearing support to the column with SHCS but do not tighten completely Replace the pull pins in the bearing support gt Install the spacer ring on the motor end of the lead screw gt 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 ofthe 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 gt Skip to Step 7 Slide the lead screw up into the nut housing and gently lower it until it is resting in the support bearing 106 96 8100 1998 125 MECHANICAL SERVICE SERVICE MANUAL IVIANUAL
57. 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 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 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 GEAR CHANGE SPEED Command speed used to rotate spindle motor when changing gears Units are maximum spindle RPM divided by 4096 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 SP LOCK SETTLE TIME Required time in milliseconds that the spindle lock must be in place and stable before spindle orientation is considered complete GEAR CH REV TIME Time in milliseconds before motor direction is reversed while in a gear change SPINDLE STEPS REV Sets the number of encoder steps per revolution of the spindle Applies only to rigid tapping option 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 SAAS 201
58. EXTERNAL DOOR LOCK POWER PCB EXTERNAL SHUTTLE MOTOR CHIP CONVEYOR T1 CRT FANS HEAT EXCHANGE POWER PCB 115 VAC SPARE DOOR SWITCH TURRET MOTOR HYD PRESSURE TANK LUBE OIL PUMP NOT USED 5TH BRAKE HTC CHIP CONVEYOR EXTERNAL SPARE 1 SPARE 2 COOLANT TANK MOCON PCB SPARE 1 SPIGOT SENSE SERVO BRAKE TSC RED GREEN LTS TSC PUMP COOL WORK LIGHT 115 VAC SPARE GB IF TSC 230 IN E STOP C CABLE LOCATIONS PLUG P11 P12 P14 P10 231 SERVICE MANUAL MANUAL case Locarions V EDTIEM 00 ss REMOTE JOG HANDLE P N 32 0150 MOCON PCB JOG HANDLE 50 55 z n J2 J3 750 15 15 77 pol 2 DISCRETE FTPANEL INPUTS 55 FAN 12 MIKRON EXTERNAL E MICRO 99 VOLTS KEYBOARD 8 PROCESSOR 18 INPUT 8 KEYBOARD 25 P5 R36 un 5 700 730 8 6 4 R31 es AUX FPANL LOAD METER SPEAKER LOAD METER ADJUST START HOLD 232 n OhT ay 96 8100 1998 U ernieee CABLE LOCATIONS 23 SERVICE MANUAL MANUAL SERIAL KEYBOARD INTERFACE PCB WITH HANDLE JOG P N 32 4030 CABLE CONNECTIONS PLUG CABLE c TO c LOCATION PLUG 4 700B PROCESSOR 850 P2 P3 CYCLE START HOLD SWITCHES P4 730 SP LOAD METER P5 SPEAKER P6 AUX FPANEL J1 JOG HAND
59. O Clean pump intake filter when indicator is in red zone Reset indicator with button All intake filters can be cleaned with a wire brush OntheHigh Pressure System and old 40 taper system after changing or cleaning filter elements run TSC system with no tool in spindle for at least one minute to prime system On old 50 taper TSC system close the P cool and lock line shut off valves and run the normal coolant pump to prime the TSC system TSC Coolant TSC Filter Wing Nuts 4 Pump Assembly Assembly Disconnect Hose for Cleaning Intake Filter Gasket Intake Filter Dirt Indicator Intake Filter Housing Assembly Figure 1 5 coolant pump assembly Figure 2 Cleaning the intake filter CHECKING DRAWBAR HEIGHT New 5 systems have carbide tips and carbide tipped drawbars The coolant tip should last the life of the machine old TSC systems that have a bronze coolant tip the drawbar height must be checked every 6 months or 1000 hours of TSC system use This is done to check for wear on the Coolant Tip Failure to check coolanttip wear regularly will result in tool changer damage Tools Required v Machined aluminum block 2 x 4 x 4 v Tool holder without a tool 1 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 Figure 3 2 POWER ON the Insert a tool holder WITHOUT ANY TYP
60. SPIN COOLANT Enables spindle low oil pressure detection ENA QUIKCODE Enables conversational programming OILER ON OFF Enables oiler power when servos or spindle is in motion NC OVER VOLT Inverts sense of over voltage signal UNUSED 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 Parameter 59 MAX FEED RATE INCH 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 Parameter 61 TURRET STOP DELAY Maximum delay allowed in motion of tool turret Units are milliseconds After this time an alarm is generated Parameter 62 SHUTTLE START DELAY Maximum delay allowed in start of tool shuttle Units are milliseconds After this time an alarm is generated Parameter 63 SHUTTLE STOP DELAY Maximum delay allowed in motion of tool shuttle Units are milliseconds After this time an alarm is generated Parameter 64 Z TOOL CHANGE OFFSET 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
61. THIS GROUP IS ALL M BROWN A CHANNEL 24 AWG WIRES 5 YELLOW B CHANNEL N ORANGE 7 5 L BRUSH SERVO MOTOR WHITE TWISTED PAIR F INDUCTORS amp AMPLIFIERS j BLACK MOTOR H oe G GREEN YELLDW EARTH GROUND BLAC SWITCH o CLOSED OVER HEAT T BLAU TO MOCON RED 5 VDC HALL EFFECT BLACK WHITE i SIGNAL SWITCH HOME NORMALLY OPEN BLAC LOGIC GROUND 4 RELAY R AIR SOLENOID 4TH STH 20 AWG S AXIS 9 AXIS SOLENOID IS ON ROTARY TABLES ONLY NU COLLET OR MULTI COLLET INDEXERS C D C 6 98 HAAS AUTOMATION VF SERIES 15 968400 6 281 ELECTRICAL DIAGRAMS M Cries SERVICE MANUAL MANUAL LM COOLANT PUMP COOLANT MOTOR 230 VAC SINGLE PHASE M 6 98 TSC PUMP NOTE TSC MOTOR 230 VAC SINGLE PHASE CONNECTORS ARE LOCATED ON SIDE OF CONTROL CABI CA BIN HAAS AUTOMATION CONN ECTO S TD MHCHN P24 HOMES X HOME B TO X HOME SWITCH LOGIE GRO
62. have to be ADDED to the tool release fork If the block is loose when the button is pressed shims have to be REMOVED from the tool release fork This is the opposite of 40 taper adjustment If the alumimum 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 movement 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 the position where the block becomes tight is 0 050 or less remove shims from the tool release fork If shims were added to the TRP fork add half that amount to the TRP spacers supporting the This will keep the two clearance gaps between the TRP and the rotating Spindle equal approximately 0 095 each If shims were removed from the TRP fork remove half that number of shims from the TRP spacers Apply red grease to the shoulder bolts used to mount the TRP when the shim adjustments are complete Use blue Loctite on the threads 96 8100 SERVICE MANUAL MANUAL Z Tool Clamped Switch ea 0 093 TRE Sims Nylon Washer 2 ea 0 010 Shim Washer 3 ea 0 015 Shim Washer Figure 2
63. 1 26 X 13 525 24 8548 BALLSCR 32mm 1 26 X 13 525 HL 1 2 X ADD ITEM 7 THESE ASSEMBLIES ONLY VF 1 Leadscrew 96 8100 AAT aa ASSEMBLY DRAWINGS eres SERVICE MANUAL MANUAL of June 1998 3 lei TR 30 1215 COUPLING ASSEMBLY ITEM QTY PART TITLE 20 0105 COUPLER SERVO BRUSHLESS 2 20 7615 COUPLER SERVO DRIVE BRUSHLESS 3 51 2014 BEARING LOCKNUT CL18F 4 51 2019 CLAMP COLLAR 1 1 4 BORE 5 56 0065 SNAP RING 5100 112 6 96 0076 SNAP RING 5100 125 7 59 2060 FLEXPAK FOR AJO5 WHERE USED PART NO DESCRIPTIO 50 10 OPTION VF 10 50 6 TAPER OPTION VF 6 50 7 O TAPER OPTION VF 7 501 8 9g 50 TAPER OPTION 8 9 11 93 8015 50 T AXS MTR UPGRD W AAXIS 316 AMS 96 8100 1998 2 1 Cries SERVICE MANUAL MANUAL mam 6
64. 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 this 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 96 8100 6 189 TECHNICAL REFERENCE V er 125 SERVICE MANUAL IVIANUAL June 1998 5 18 HYDRAULIC COUNTERBALANC
65. 4 Remove the tool release piston assembly Tool Release Piston section 96 8100 85 MECHANICAL SERVICE 125 une 1998 SERVICE MANUAL MANUAL 5 Remove 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 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 Solenoid Assembly Transmissi Tool Release Piston Figure 3 31 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 9 Remove the protective cardboard from the mill table and install the support base assembly on the table using the four SHCS four 75 flat washers and the four T nuts CAUTION Ensure the protective rubber
66. 40 16413 40 1660 40 1712 40 1715 40 1750 40 1950 45 1600 50 9010 57 0075 57 0080 58 1560 58 3031 59 2033 62 0013 99 4521 eres SERVICE MANUAL MANUAL 15 8 18 TITLE NUT HOUSING 40 50mm BS MACH Y AXIS BUMPER BRG END Y AXIS BUMPER MTR END BASE MACHINING CAM LINEAR GUIDE Y AXIS MOUNTING BRACKET COVER PLATE MOTOR MOUNT LEAD SCREW Y AXIS BASE OIL LINE ASSEMBLY LIMIT SWITCH ASSEMBLY MSHCS M10 X 25mm MSHCS X 5 SHCS 1 2 13 X 1 1 2 SHCS 5 16 18 X 1 1 4 SHCS 5 16 18 X 1 1 2 BHCS 10 32 X 3 8 SHCS 10 32 X 3 4 WASHER LOCK LINEAR GUIDE X AXIS VF 3 O RING 2 021 BUNA O RING 2 023 BUNA ADPT 1 8 M BSPT TO 5 16 F BANJO ELBOW 5 16 M6 M 1 2 CONDUIT STRAP SERVO MOTOR YASKAWA ELECTRICAL GREASE VF 10 Base AMS June 1998 96 8100 1998 MI 125 ASSEMBLY DRAWINGS SERVICE MANUAL MANUAL 2824144 o e Lm wi I VF 10 Golumn 98100
67. 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 does 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 122 96 8100 1998 f 125 MECHANICAL SERVICE SERVICE MANUAL MANUAL 3 13 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 t
68. 58 1560 ADPT 1 8 M BSPT TO 5 16 58 3031 BANJO ELBOW 5 16 M6 M 59 2033 1 2 CONDUIT STRAP 62 0013 SERVO MOTOR YASKAWA 99 4521 ELECTRICAL GREASE VF 10 Saddle HAA S 09 ASSEMBLY DRAWINGS MI eri eS luune 1998 SERVICE MANUAL MANUAL ge TM a 566 66 DETAIL SCALE 1 5 A a eL le 9 3 APC Assembly 310 96 8100 1998 1 96 8100 QTY CO 2 4 q amp M oc M d amp c gt 14 7068 20 0046 20 0048 20 0049 20 0050 20 0051 20 0052 20 0053 20 0054 20 0057 20 0060 20 0065 20 0066 20 0071 20 0193 25 0066 25 0072 25 0077 25 0082 25 0085 25 0095 25 0100 25 0101 25 0102 25 010
69. 68030 PROCESSOR BOARD 8g Hs Bo a fee soe G 2 1 2 HBG ZS 1 5 11 MAfAAS OPERATOR PENDANT ala B 48 2 57 3 s a lA AXIS i im i mi us tut l LEES oll LIMIT SWITCHES 8 A 23 ma mma Eo mone ou ges CHIP CONVEYOR O M FUNCTION z WORK LIGHT E SS s O BELL SSS SE E ITEM DESCRIPTION PAGE ITE DESCRIPTIO PAGE CNC LAYOUT A RELAY COIL DRIVERS 8 11 SYSTEM BLOCK DIAGRAM B C SPINDLE DRIVE 2 CABLE INTERCONNECT DIAGRAM D E AXIS MOTOR amp 14 15 SERVO SYSIEM 1 CONNECTORS 6 MAIN TRANSFORMEI 2 3 TOOL CHANGE MOTORS 7 UNIT 4 CHIP CONVEYOR SPIGOT MOTOR 115VAC CIRCUITS 5 OPERATOR PENDANI 9 INPUTS IOPCB 6 ECTRICAL SYMBOLS 21 CONTROL LAYOUT DIAGRA 6 98 HAAS AUTOMATION VF SERIES PAGE A 264 YY 2 968100 1998 VI Cries SERVICE MANUAL MANUAL ELECTRICAL DIAGRAMS 230 VAC INPUT VOLTAGE
70. 9 12 and fuse F1 Tool carousel motor not in position During a tool changer operation the tool turret failed to start moving or failed to stop at the right position Parameters 60 and 61 can adjust the time out times This alarm can be caused by anything that jams the rotation of the turret A loss of power to the tool changer can also cause this so check relays K9 K12 and fuse F1 Spindle did not orient correctly 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 the time out times This be caused by a trip of circuit breaker a lack of air pressure or too much friction with the orientation pin Gearbox did not shift into high gear During a change to high gear the spindle is rotated slowly while air pressure is used to move the gears but the high gear sensor was not detected in time Parameters 67 70 and 75 can adjust the time out times Check the air pressure the solenoids circuit breaker 4 and the spindle drive 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 084 and the spindle drive Incoming line voltage is above maximum The servos will
71. June 1998 f J 7 TROUBLESHOOTING SERVICE MANUAL MANUAL During a tool change spindle crashes into top of the tool holder after 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 bending the upper right roller bolt on the ATC shuttle or completely breaking it off Tool holder is not held correctly in the extractor fork possibly held only in one side of the extractor and at an odd angle e Check all of the extractor forks on the ATC During tool change spindle crashes into top of the tool holder after rotation The balls in the drawbar do not move freely causing the to be forced down far enough to bend the upper right roller bolt or completely break it off e Ensure balls on the drawbar move freely in the holes 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 e Check drawbar height and set according to the appropriate section if necessary AC properly deposits tool holder in the spindle but the tools are dropped onto the machine table when the shuttle retracts e Inspect the balls and the Belleville springs in the drawbar See appropriate section and replace drawbar The part or fixture on the mill table crashes into long t
72. L2 INCOMING 195 260 2 CB1 2 L3 INCOMING 195 260 PHASE 3 CB1 3 71 PROTECTED 195 260 VAC FROM MAIN CB1 4 K1 1 72 PROTECTED 195 260 VAC FROM MAIN CB1 5 T0 K1 2 73 PROTECTED 195 260 FROM MAIN 1 6 K1 3 74 195 260 K1 4 XFORMER 1 75 195 260 1 5 1 76 195 260 1 6 1 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 90A115 VAC TO CRT 2 SHIELD 91A LEG 1 416 92A LEG 2 16 93A SHIELD DRAIN 90B115 VAC TO HEAT EXCHANGER 2 SHIELD 91B LEG 1 416 92B LEG 2 16 93B SHIELD DRAIN 90 115 TO 4 2 SHIELD 916 LEG 1 16 926 LEG 2 416 936 SHIELD DRAIN 253 EN caste usr V eres 254 SERVICE MANUAL MANUAL 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 140 230 3PH POWER
73. PARAMETERS UP ENCL TEMP HAAS RJH SPIN TEMP AIR DRV SHTL GIMBAL SPNDL NO MFIN D Y SWITCH ENABLE D Y SW ON FLY 5 AX TOFS X 5 AX TOFS Y 5 SAFETY INVERT M Cries SERVICE MANUAL MANUAL Microprocessor Enclosure Temperature When set to 1 the enclosure temperature will be displayed on INPUTS2 screen of the diagnostics display Haas Remote Jog Handle This bit must be set to 1 if the machine is equipped with a Haas 5 Axis Remote Jog Handle Spindle Temperature Sensor Normally Closed This bit specifies the type normally open or normally closed of the spindle temperature sensor This bit should be setto 1 for machines with a Haas vector drive and 0 for machines that do not have a vector drive 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 This bit will cause the machine to check that Z A and B axes are at zero before tool change is started If one is 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 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 This bitenables the
74. RS 232 or floppy read of parameter had CRC when loading from floppy or RS 232 Lead screw compensation tables have no CRC when loading from floppy or 5 232 table parameters have when loading from 5 232 Macro variable file has a CRC error Indicates a loss of memory Callyour dealer Generated whenever an M95 Sleep Mode is encountered and the door is open The door must be closed in order to start sleep mode Same as 103 43 m ALARMS cI 44 271 272 273 274 275 276 277 278 279 280 281 282 283 284 285 286 287 288 289 290 291 302 M C Servo Overload C Motor Overheat Motor Z Fault Limit Switch C Axis Z Ch Missing C Axis Drive Fault C Zero Ret Margin Too Small Cable Fault X Axis Linear Scale Z Fault Y Axis Linear Scale Z Fault Z Axis Linear Scale Z Fault A Axis Linear Scale Z Fault X Axis Linear Scale Z Channel Missing Y Axis Linear Scale Z Channel Missing Z Axis Linear Scale Z Channel Missing A Axis Linear Scale Z Channel Missing X Axis Linear Scale Cable Fault Y Axis Linear Scale Cable Fault Z Axis Linear Scale Cable Fault A Axis Linear Scale Cable Fault Low Air Volume Pressure During ATC Invalid R In G02 or G03 eres SERVICE MANUAL MANUAL June 1998 Same as 108 Same as 135 Same as 139 Same as 145 Same as 153 Same
75. 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 with by turning Setting 51 on if Parameter 57 bits DOOR STOP SP and SAFETY CIRC are set to zero but this setting will return to OFF when the control is turned off 96 8100 mn ANG 187 TECHNICAL REFERENCE er 7 June 1998 SERVICE IVIANUAL 188 Note 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 th
76. 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 IGAIN See Parameter 4 for description Parameter 47 A RATIO STEPS UNIT See Parameter 5 for description Parameter 48 A MAXTRAVEL STEPS See Parameter 6 for description 198 HAA 5 968100 1998 96 8100 M Parameter 49 Parameter 50 Parameter 51 Parameter 52 Parameter 53 Parameter 54 Parameter 55 Parameter 56 Parameter 57 REV CRANK DISABLE T C DISABLE G B POF AT E STP RIGID TAP REV SPIN ENC REPT RIG TAP EX ST MD CHG SAFETY CIRC SP DR LIN AC PH LOSS DET COOLANT SPGT OVER T IS NC SKIP OVERSHT NONINV SP ST SP LOAD MONI SP TEMP MONI ENA ROT amp SC ENABLE DNC ENABLE BGEDT ENA GRND FLT KEYBD SHIFT ENABLE MACRO I JEES PARAMETERS GS A ACCELERATION See Parameter 7 for description A MAX SPEED See Parameter 8 for description A MAX ERROR See Parameter 9 for description A FUSE LEVEL See Parameter 10 for description A BACK EMF See Parameter 11 for description A STEPS REVOLUTION See Parameter 12 for description A BACKLASH See Parameter 13 for description A DEAD ZONE See Parameter 14 for description Parameters 57 through 128 are used to control other machine dependent functions They are COMMON SWITC
77. k x BP A Aa PART 45 1800 45 2020 46 1705 48 0005 48 0019 48 0020 48 1750 51 0010 51 0012 51 6000 54 0010 54 0020 54 0030 54 0040 55 0010 57 9139 57 9335 63 1031 70 0050 75 15721 78 1996 79 1000 79 1001 eles v June 1998 SERVICE MANUAL MANUAL TITLE WASHER SPLIT LOCK 1 4 MED WASHER NYLON LOCK NUT ELASTIC 3 4 10 PIN DOWEL 3 16 x 3 8 PIN DOWEL 1 4 x 5 8 PIN DOWEL 1 4 x 1 PIN DOWEL 1 2 x 1 1 2 BEARING DEEP GROOVE BEARING LOCK NUT BH 06 BEARING LOCK NUT NT 05 CAM FOLLOWER TOOL CHANGER BUSHING GUIDE WHEEL GUIDE WHEEL STANDARD BUSHING GD WHEEL SPRING WASHER B2500 080 GASKET TOOL HOLD ARM SHUTTLE COVER GASKET CABLE CLAMP 1 4 PLT4S M CABLE TIES MOLEX BSNG 2 PIN MALE SPLIT FLEX TUBING 1 2 1 0 WIRE CHANNEL 1 x 2 COVER 1 WIRE CHANNEL ALIA 96 8100 1998 7 lrles 1 1 0 ASSEMBLY DRAWINGS 50T CAROUSEL ASSEMBLY CT QTY DWG NO DESCRIPTION 1 1 20 9296 50 TAPER CAROUSEL 20 TOOL 2 40 20 9297 EXTRACTION FINGER 50 TAPER 3 20 20 9298 ALIGNMENT KEY 50 TAPER 4 40 22 9256 BUSHING EXTRACTOR 5 20 24 9257 SPRING VF ALL 6 1 25 9349 20 TOOL NUMBER RING 50 T 7 5 40 16095 SHCS 10 32 X 1 4 8 40 40 1631 SHCS 1 4 20 X 3 8 9 40 40 1860 SHCS 1 4 20 X 7 8 10 40 45 0045 WSHR BLK HRD 1 4 X 1 8 THK 50 Tap
78. replace the hard stop from the lead screw support bearing end of the lead screw 12 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 13 Check for backlash in the lead screw Accuracy Backlash section or noisy operation 6 96 8100 1998 96 8100 M menmen sevo SERVICE MANUAL IVIANUAL Z Axis Leap ScnEw REMOVAL 1 2 WARNING ALWAYS BLOCK THE HYDRAULIC CYLINDER WITH THE SHAFT STOP BLOCK DO NOT MOVE THE SPINDLE DURING LEAD SCREW SERVICE Turn the machine 2 RETURN all axes and put the machine in HANDLE J0G mode 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 Lowerthe spindle head to it s lowest position Install cylinder shaft stop Handle jog Z axis up until the shaft stop blocks the axis 4 5 9 Disconnect electrical power If applicable remove the hard stop from the bearing housing on the lead screw Disconnect the oil line at the ball nut Loosen the 10 32 x SHCS and remove the clamp nut on the lead screw support bearing end Remove the axis motor in accordance with Z Axis Motor Removal NOTE The mot
79. 1 at 9 30 1225A LEADSCREW COUPLING ASS QTY PART No TITLE 2 20 0105A COUPLING SERVO BRUSHLESS 2 51 2019 CLAMP COLLAR 1 1 4 BORE 2 56 0076 SNAP RING 5100 125 1 59 2080 FLEXPAK FOR 5 WHERE USED APPLICATION 30 0037 BS ASSY 50mm 1 97 x 129 42 VF 10B VR 11B X 320 96 8100 1998 96 8100 125 ASSEMBLY DRAWINGS SERVICE MANUAL MANUAL 1 30 1200 LEAD SCREW ASSEMBLY 2 30 7420 BASE OIL LINE ASSEMBLY 5 32 5056 LIMIT SWITCH ASSEMBLY VF 8 Base 045 321 ASSEMBLY DRAWINGS 322 me SERVICE MANUAL MANUAL DUNN 50 1200 LEAD SCREW ASSEMBLY 50 7400 COLUMN OIL LINE ASSEMBLY 52 1780 Z AXIS MOTOR ASSEMBLY 52 2050 TELEMECHANIQUE SWITCH ASSEMBLY VF 8 Column 96 8100 1998 1 EX _______ ssm oraines SERVICE MANUAL MANUAL 30 1240 LEAD SCREW ASSEMBLY 2 30 7410 S
80. 16 18 X 3 4 01 58 7636 HIGH GEAR TUBE VF 3 43 4 40 16413 SHCS M3 X 5 02 58 9114 RANS FILL TUBE 44 2 40 1644 SHCS 10 32 X 1 1 2 03 59 0027 HOSE CLAMP 1 2 HOSE 45 4 40 1645 SHCS 10 32 X 5 8 04 2 59 0046 SOUNDCOAT SHROUD RT LT 46 5 40 16455 SHCS 10 32 X 7 8 05 4 59 1482 YLON FINISH PLUG 15 16 47 4 40 1669 REMOVED BHCS 8 32 X 3 8 06 2 59 2040 CABLE CLAMP 7 16 48 4 40 1700 HCS 10 32 X 2 07 59 4006 HOSE CRIMP 35 64 49 1 40 1800 REMOVED SHCS 8 32 X 3 4 08 0 51 59 7130 REMOVED PROTECTIVE STRIP 50 3 40 1830 HHB 1 2 13 X 1 3 4 09 60 1810 SHAFT ENCODER 2000 LINE 51 7 40 1850 SHCS 10 32 X 3 8 0 36 3078 OK MOTOR 52 4 40 1981 FBHCS 1 4 20 X 1 2 1 2 63 0001 YLON CABLE CLAMP 1 2 53 3 41 1500 PPHS 8 32 X 3 8 2 63 1031 CABLE CLAMP 1 4 54 4 44 0003 SSS HALF DOG PT 1 4 20X1 3 25 70 0020 PLT1 5M CABLE TIES 55 4 45 0040 REMOVED WASHER BLK HARD 1 4 A325 4 3 76 2420 CRIMP RING 12 10 10 STUD 56 4 45 1600 WASHER SPLIT LOCK 5 16MED 8 77 8001 WIRE NUT IDEAL 430 078 1 45 1603 REMOVED WASHER SPLIT LOCK 8 MED 6 20 0125 DRIVE SPROCKET ENCODER 58 4 45 1620 WASHER SPLIT LOCK 10 MED 7 4 57 0048 RUBBER STUD BUMPER 59 1 45 1682 WASHER SPLIT LOCK 7 16MED 8 4 46 1625 UT HEX BLK OX 1 4 20 9 4 45 1800 WASHER SPLIT LOCK 1 4 MED 96 8100 1 83848 ASSEMBLY DRAWINGS 125 June 1998 SERVICE MANUAL MANUAL
81. 177 178 SWITCHES See Parameter 1 for description C P GAIN See Parameter 2 for description C D GAIN See Parameter 3 for description HAS June 1998 96 8100 1998 96 8100 Parameter Parameter Parameter Parameter Parameter Parameter Parameter Parameter Parameter Parameter Parameter Parameter Parameter Parameter Parameter 179 180 181 182 183 184 185 186 187 188 189 190 191 192 193 SERVICE MANUAL MANUAL ______ 8 C I GAIN See Parameter 4 for description C SLIP GAIN The value that the slip rate would assume at maximum speed and maximum current C MIN SLIP The minimum value allowed for the slip rate C ACCELERATION See Parameter 7 for description C MAX The frequency at which the motor will be run when maximum spindle RPM is commanded 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 C FUSE LEVEL See Parameter 10 for description C DECELERATION Maximum deceleration of axis in encoder steps per second per second C HIGH GEAR STEPS REV 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 C ORIENT GAIN The proport
82. 2 20 7626 SHAFT TRP TSC 3 20 7627A COOLANT TIP CARBIDE 4 20 7630 TR PISTON RECTANGLE TSC 5 22 045A SPRING RETAINER TRP 6 25 050B SWITCH MNT TOOL RELEASE 2 7 29 7397 LABEL TOOL RELEASE PISTN 8 50 5286 SEAL HOUSING ASSY 9 32 2010 24 LIMIT SWITCH 2 0 42 5620 SOLENOID VALVE ASSY 1 40 1632 SHCS 1 4 20 X 2 4 2 40 1800 SHCS 8 52 X 3 4 8 3 44 1614 SSS FLAT PT 6 32 X 1 4 5 4 5 0040 WASHER BLK HARD 1 4 25 4 5 45 2000 WASHER SHIM 1 4 010 THK 5 6 56 0040 SNAP RING 5100 62 2 7 957 0040 O RING 2 11 BUNA 5 8 57 2156 QUAD RING 04 BUNA 9 58 0028 HOSE BARB 3 8PL 1 4MP 20 58 00352 HOSE BARB 3 8 5 85 21 58 2046 HOSE 3 8ID PUSHLOC 3OOPSI 75 22 58 2165 FITTING CLOSE NIPPLE 1 4 25 58 2265 AIR MUFFLER 3 8 FLAT 24 58 3050 ELBOW 1 4 NYLON TUBING 25 58 5614 1 4 F 1 8 M STREET ELBOW 26 58 3618 1 4 STREET ELBOW 90 DEG 2 27 58 3670 1 4 148 F REDUCER 28 58 5685 1 4NPT M 3 8 TUBE SVL LBO 29 58 5 27 1 4 X 4 NIPPLE BRASS 50 59 2 60 COMP SPRING LARGE WIRE 51 59 2832B QUICK EXHAUST 4 96 8100 HAAS ASSEMBLY DRAWINGS 329 ASSEMBLY DRAWINGS 330 CA N La QTY PART O 7016B 0 70181 0 7022 0 54100 DESCRIP TIO SPINDLE HOUSING 0 SPINDLE SHAF 1 SPINDLE CAP TAPERED 2 1 7 8 PULLEY 5 OIL INJECTION COVER 4 60MM BEARING 5 SOMM LOCK 7500 SPINDLE 6
83. 22 1034 SPACER CAM FOLLOWER 11 2 22 7106 V TRACK 12 3 22 7163 RIDER TRAP DOOR 13 1 22 7255A TOOL 1 STAND OFF 14 2 22 7263 SWITCH MOUNTING BLOCK 15 1 22 7477 PRESSURE PLATE 16 1 25 7036 CAP TOOL CHANGER 17 1 25 7162 CONNECTOR BRACKET 18 1 25 7168 DOOR OPENER BRACKET 19 1 25 9085 CONDUIT MTG PLATE 20 1 25 9329 DOOR T C COVER 21 1 25 9331 TOOL CHANGER COVER 22 1 25 9334 SHUTTLE COVER PLATE 23 2 26 7239 SPACER RING 24 1 29 7612 CT TOOLING DECAL 25 1 30 0005 GENEVA DRIVER ASSY 26 1 30 0006 CAROUSEL ASSY 32 TOOL 27 1 32 1800 SHUTTLE MOTOR ASSY 28 2 32 2010 24 LIMIT SWITCH 29 1 32 7011 CONDUIT ASSY T C 30 1 32 7611 CONDUIT ASSY TOOL CARRIAGE 31 6 40 1500 SHCS 5 16 18 x 1 32 1 40 16091 BHCS 10 32 x 1 33 3 40 1632 SHCS 1 4 20 x 1 2 34 6 40 1669 BHCS 8 32 x 3 8 35 6 40 1676 SHCS 5 16 18 x 2 36 10 40 1697 SHCS 1 4 20 x 3 4 37 4 40 1803 SHCS 8 32 x 1 1 4 38 12 40 1850 SHCS 10 32 x 3 8 39 4 40 1970 FHCS 1 4 28 x 1 40 8 40 1980 BHCS 1 4 20 x 1 2 41 4 40 2000 SHCS 1 4 20 x 5 8 42 4 43 1602 HHB 1 2 13 x 3 43 9 43 7000 HHB 5 16 18 x 1 3 4 44 1 44 1710 SSS CUP PT 1 4 20 x 3 8 45 1 45 0050 WASHER 5702 313 120 46 17 45 1600 WASHER SPLIT LOCK 5 16 MED 47 1 45 1725 WASHER FLAT CUT 3 4 292 96 8100 1998 IT QTY PART NO 48 4 45 1740 49 10 45 1800 50 2 45 2020 51 1 46 1705 52 1 48 0005 53 1 48 0019 54 1 48 0020 55 2 48 17
84. 7 TRP shim location 2 7 SETTING TRP SwitcHEs Tool Unclamped Switch Tool Clamped Switch Figure 2 8 Tool Clamp Unclamp Switches MECHANICAL SERVICE 1 Setting the upper switch Tool Clamped Push the switch in slowly until it trips then push it 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 96 8100 5 63 MECHANICAL SERVICE 125 1998 SERVICE MANUAL MANUAL 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 64 a c d e Jog the Z Axis to 0 030 above the aluminum block Put a jumper across the air switch to prevent a low pressure alarm Back off the air pressure to around 65 psi 75 psi for old style TRP s 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 While holding the Tool Release Button push the switch in until it just trips the bit on the Diagnostics Page should change to 1 Lock down the screws Double check the switch by turning the TRP on and off a few times Back off the air pressure until the block is l
85. 8 16 X 1 3 4 SHCS 1 4 Air Hose Fitting 3 8 Air Hose Fitting TSC Fitting T Optional switch Figure 4 2 Tool release piston assembly with air solenoid assembly T 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 fitting 14 9 968100 p SERVICE MANUAL MANUAL SPINDLE LuBE Ain SOLENOID 1 Turn the machine power off and remove the air supply from the machine Pressure Gauge Hose Barb Shop Air Tool Changer Air Line 5th Air Line Tool Changer Air Line Air Filter Regulator Bijur Lubricator Figure 4 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 Channel Cover Back side of Lube Panel Figure 4 4 view of spindle lube air solenoid assembly 96 8100 145 ELECTRICAL SERVICE O T eS 21998 SERVICE MANUAL 4 Unscrew the a
86. BELOW 40 PSI WITH NO TOOL IN SPINDLE FOR AT LEAST ONE MINUTE TO PURGE AIR CHECK FOR LOW COOLANT LEVEL IN TANK B CHECK GAGES ON BOTH FILTERS ADJUSTABLE PARAMETER PARAMETER 237 TSC CLNT LINE PURGE C CHECK HOSES FOR KINKS OR DAMAGE AND THAT ALL CONNECTIONS ARE TIGHT MINIMUM DEFAULT VALUE IS 2500 NO MAXIMUM LIMIT 2 PRE CHARGE FAILURE ALARM 198 DOES NOT APPLY TO THIS SYSTEM 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 WHEN MACHINING CASTINGS SAND FROM THE CASTING PROCESS AND THE ABRASIVE PROPERTIES OF CAST ALU 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 CUTOMER 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 A LARGER COOLANT TANK IS RECOMMENDED SHORTENED PUMP LIFE REDUCTION OF PRESSURE AND INCREASED MAINTENANCE ARE NORMAL AND TO BE EXPECTED IN ABRASIVE ENVIRONMENTS AND IS NOT COVERED BY WARRANTY 96 8100 N lt af fff 137 MECHANICAL SER
87. DRIVE CH uc SEM 4 C FAN PENDANT 010 VRUN PRUE SOLENOIDS FAN SERVO ANP PIVER MOTOR LUB PUP 15 VAC 50 60 HZ m ow FIN SPINDLE 277 MOTOR SPINDLE OIL Es 1 20 HE 15 15 VAC OTOR PALLET CHER 9 VIE 14 MOTOR TOOL CHER SHUTTLE Ste Wi 90 VIC 140 ANS 115V tm CHER CAROSEL Sto H 90 VIC 140 APS m LN C FAN DOOR 1 o gt B 1 B MPS W0 H 51 5 1PH 10 AMP 230 gt mm ES SD 12 P 20V PH 74 AS 6l HE c30w 0 C MU CHIP CONVEYOR VG HP 23 3PH J ANPS 017 6 98 HAAS AUTOMATION SERIES 20 968100 287 ELECTRICAL DIAGRAMS M eres SERVICE MANUAL MANUAL CIRCUIT BREAKER SINGLE DIODE GROUND 0 CIRCUIT BREAKER MULTI LIGHT EMITTING DIODE gt LIMIT SWITCH CLOSED LIMIT SWITCH MOTOR D OPTO ISOLATOR FUe FUSE LECTRICAL SYMBOLS 6 98 HAAS AUTOMATION SERIES VARISTOR NEON BULB W NORMALLY OPEN RELAY CLOSED RELAY SINGLE POLE RELAY OPEN DOUBLE THROW RESISTOR 1 SOLENOID
88. Error Queue Cutter Comp Error Insufficient Memory Odd Prog Block Program Integrity Error erles SERVICE MANUAL MANUAL as 108 as 135 as 139 5 148 as 153 5 161 5 168 5 182 Spigot failed to achieve commanded location after two 2 attempts Call your dealer 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 A negative spindle RPM was sensed Parameters lost maybe by low battery Check for a low battery and low battery alarm Settings lost maybe by low battery Check for a low battery and low battery alarm Lead screw compensation tables lost maybe by low battery Check for CRC Error low battery and low battery alarm Offsets lost maybe by low battery Check for a low battery and low battery alarm Users program lost maybe by low battery Check for a low battery and low battery alarm Possible corrupted program Save all programs to floppy disk delete all then reload Check for a low battery and low battery alarm Software Error Call your dealer Software Error Call your dealer Software Error Call your dealer Not enough memory to store users program Check the space available in the LIST PROG mode and possibly delete some programs Possible corrupted program Sav
89. FLBOW 90 DEG 58 3670 1 4 M 1 8 REDUCER 20 58 3685 1 4 M 3 8 TUBE SVL LBO 58 5727 1 4 NPT X 4 NIPPLE BRASS 22 59 2760 COMP SPRING LARGE WIRE 23 59 2832 QUICK EXHAUST 1 4 N x e 03 Cn e Q Sachs Se N 96 8100 492 327 ASSEMBLY DRAWINGS MI eri eS luune 1998 SERVICE MANUAL MANUAL SECTION OUT Or POSITION CAUTION TOOL CLAMP UNCLAMP SWITCHES MUST BE PROPERLY ADJUSTED BY TRAINED PERSONNEL OR SEVERE DAMAGE TO TOOL CHANGER WLL RESULT PLEASE CONSULT SERVICE MANUAL BEFORE ADJUSTMENT VIEW B OUT OF POSITION 250 5290 RELEASE PISTON ASSY TSCHP 828 Y Yn 96 8100 M erles SERVICE MANUAL 1998 21522845 QOL RELEASE PISTON ASSY TSCHP ITEM PART NO DESCRIPTIO QIY 1 20 700 CYLINDER HOUSING MACHINED
90. INPUT 7800B SWITCH TO LAMP 8050 BRAKE DOOR SWITCH MOTOR POWER MOTOR POWER ENCODER 495 496 680 MOTOR POWER MOTOR POWER ENCODER 491 492 660 493 MOTOR TOOL CHANGER OILER LIMIT SWITCHES 300 OILER POWER 960 OILER STATUS 990 LIMIT SWITCHES 1 X AXIS MOTOR 494 MOTOR POWER 670 ENCODER Y AXIS MOTOR Z AXIS MOTOR i A AXIS MOTOR I COOLANT TANK i 900 LOW COOLANT STATUS 940 COOLANT PUMP POWER 190 400 500 650 VF 0 VF 1 VF 2 TOOL UNCLAMP CABLE COAST STOP CABLE ASSY SPINDLE MOTOR TEMP SPINDLE MOTOR CABLE ASSY 880A HILO GEAR LOCK CABLE 890 SPINDLE STATUS SWITCHES 950B LOW AIR SPINDLE 1020 SPINDLE SENSOR TEMP OPTION FLEXIBLE CABLE L FRONT PANEL SUPPORT ARM MOTOR POWER MOTOR POWER ENCODER 100 SIGNAL FUNCTION 1 CONDUIT 251 TOOL UNCLAMP CABLE COAST STOP CABLE ASSY SPINDLE MOTOR TEMP SPINDLE MOTOR CABLE ASSY HI LO GEAR LOCK CABLE SPINDLE STATUS SWITCHES LOW AIR SPINDLE OIL SPINDLE SENSOR TEMP OPTION AAAS ELECTRICAL CABINET 96 8100 CABLE LOCATIONS 252 M erles SERVICE MANUAL MANUAL HAAS June 1998 96 8100 V 27125 uus SERVICE MANUAL 96 8100 9 CABLE LIST JuNE 1998 WIRE TERMINAL FUNCTION NAME NUMBER INCOMING POWER 195 260 353 488 OPTIONAL L1 INCOMING 195 260 1 CB1 1
91. LOCK 10 MED 117 4 57 0049 REI OVE RUBBER STUD BUMPER 59 1 45 1682 WASHER SPLIT LOCK 7 16MED 8 4 46 1625 BLK OX 1 4 20 9 4 45 1800 WASHER SPLIT LOCK 1 4 MED 96 8100 ASSEMBLY DRAWINGS 125 June 1998 SERVICE MANUAL MANUAL 1 mr o P n TSF a 95 11 F Hmm 106 L e NS 112 62 9 3 0951 94 30 25204 TRANS ASSY VF HTIOK VD VF 3 4 Gearbox Assembly HT10K 342 96 8100 1998 125 ASSEMBLY DRAWINGS O SERVICE MANUAL MANUA SERVICE MANUAL 30 55204 TRANS ASSY VF HTIOK VD
92. Lock Commanded Spindle at Speed Spindle Stopped Spindle Fault Spindle is Locked Spindle Overheat Spindle Cable AAS If it is not enabled these will display a 96 8100 1998 DC BUSS uP TEMP SP LOAD SP SPEED RUN TIME TOOL CHANGES VER X XXX YY MM DD MDL VF 96 8100 erles SERVICE MANUAL MANUAL TECHNICAL REFERENCE ANALOG DATA Description Voltage from Haas Vector Drive if equipped Microprocessor enclosure temperature displayed only when Parameter 278 bit uP ENCL TEMP is set to 1 Spindle load in Spindle RPM CW or CCW Total machine run time Number of tool changes Software version number Today s date Machine model 1 SERVICE MANUAL 194 AAG 968100 vx PARAMETERS 5 s 6 PARAMETERS Parameters are seldom modified values that change the operation ofthe 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 chang
93. MANUAL 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 Check air supply Check drawbar height adjustment 1 3 SERVO MOTORS LEADSCREWS Nor OPERATING All problems that are caused by servo motor failures should also register an alarm Check the alarm history to determine the problem s 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
94. MOTOR MOTIF PCB SDIST PCB SDIST PCB Y SERVO MOTOR MOTIF PCB SDIST PCB SDIST PCB Z SERVO MOTOR MOTIF PCB SDIST PCB SDIST PCB A SERVO MOTOR MOTIF PCB SDIST PCB CABLE LOCATIONS PLUG 1 2 2 2 2 TB2 P4 5 TB2 e 245 SERVICE MANUAL MANUAL EXTERNAL PLUG INTERNAL PLUG RS 232 PORT 1 PCB P N 32 4090 CABLE CONNECTIONS PLUG CABLE gt LOCATION PLUG P1 850 VIDEO amp J13 INTERNAL KEYBOARD J1 2 EXTERNAL 246 n T F 96 8100 1998 ernieee CABLE LOCATIONS 23 SERVICE MANUAL MANUAL OOOOOOOO OOOOOOOO P2 O SPINDLE LOCK PCB P N 32 3095 CABLE CONNECTIONS PLUG CABLE c TO gt LOCATION PLUG P1 890 I O PCB P15 P2 520 I O PCB P2 P3 VECT DRV 96 8100 O 247 23 CABLE LOCATIONS 0 059 5 SERVICE MANUAL MANUAL HYD 230 2 340 70 HYD e P4 350 PUMP EN FUSE1 115 TRANSMISSION P3 410 oun GB I F P1 880B 248 AA YY 968100 1998 U eri les CABLE LOCATIONS 23 SERVICE IVIANUAL TRANSMISSION P S HYDRAULIC 32 4095 REV B
95. 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 replac ing 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 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 96 8100 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 AAS 11 22 TROUBLESHOOTING 125 SERVICE MANUAL MANUAL
96. NAME c TO X DRIVER LOW VOLTAGE Y DRIVER LOW VOLTAGE Z DRIVER LOW VOLTAGE A DRIVER LOW VOLTAGE 12VDC FAN VOLTAGE 160VDC VOLTAGE MONITOR REGEN RESISTORS SERVO POWER OVV GND FAULT 115VAC FROM T1 160VDC TO AMPS AAAS P N 32 5020 LOCATION PLUG X SERVO DRIVER P1 Y SERVO DRIVER P1 Z SERVO DRIVER P1 A SERVO DRIVER P1 POWER SUPPLY PCB n FAN SERVO I O P32 MOTIF PCB 47 REGEN RESISTORS I O P5 I O P18 I O P43 T1 SERVO DRIVERS P8 CABLE LOCATIONS e 243 244 CABLE LOCATIONS x AXIS Y AXIS 7 AXIS mess SERVICE MANUAL MANUAL 160VDC r LOW VOLTAGE 1 8 160VDC GRD 5707 1 Y 580 1 610 P3 Z 590 P1 Y 620 P3 A 600 P1 DRIVE SIGNAL Z 630 P3 A 640 P3 A AXIS DRIVE SIDE VIEW 96 8100 1998 PLUG X AXIS P1 P2 P3 P8 Y AXIS P1 P2 P8 Z AXIS P1 P2 P3 P8 A AXIS P1 P2 P3 P8 96 8100 SERVO DRIVER PCBs P N 32 4070 CABLE 570 610 580 620 590 630 600 640 M Cries SERVICE MANUAL MANUAL CABLE CONNECTIONS SIGNAL NAME LOW VOLTAGE MOTOR DRIVE X DRIVE SIGNAL 160VDC LOW VOLTAGE MOTOR DRIVE X DRIVE SIGNAL 160VDC LOW VOLTAGE MOTOR DRIVE X DRIVE SIGNAL 160VDC LOW VOLTAGE MOTOR DRIVE X DRIVE SIGNAL 160VDC D c AAAS LOCATION SDIST PCB X SERVO
97. P12 4 18 AHAS 259 EN caste usr V eres 260 SERVICE MANUAL MANUAL 883 LOW GEAR SOLENOID 10 12 3 18 884 SHIELD DRAIN 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 910115 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 WORK LIGHT 920 REGENERATIVE LOAD RESISTOR FOR SERVO 2 SHIELD 921 LEG 1 18 922 LEG 2 18 923 SHIELD DRAIN 930 FUSED 230 VAC FOR COOLANT PUMP 2 SHIELD 931 LEG 1 14 June 1998 BRUSH SYSTEMS 932 LEG 2 14 933 SHIELD DRAIN 940230 VAC TO COOLANT PUMP 2 SHIELD 941 LEG 1 P7 A 414 942 LEG 2 7 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 720 954 SHIELD DRAIN 950A LOW HYDRAULIC PRESSURE SWITCH FOR LATHE 2 SHIELD 952 LOW HYDRAULIC RETURN D GROUND 65 20 953 LOW HYD
98. PRESSURE SWITCH FOR VERTICAL TRANSMISSION 20 954 SHIELD DRAIN 960 LOW LUB DOOR OPEN SENSORS 4 SHIELD 961 LOW LUB SIGNAL INPUT 13 724 962 LOW LUB RETURN D GROUND 65 24 HAAS 96 8100 C V EH ESS 96 8100 SERVICE MANUAL 127 963 DOOR OPEN SIGNAL INPUT 9 24 OBSOLETE OPTION 964 DOOR OPEN RETURN D 24 OBSOLETE OPTION 965 SHIELD DRAIN 970LOW VOLTAGE SENSOR 2 SHIELD 971 LOW VOL SIGNAL INPUT 11 FROM PMON P9 3 724 972 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 2 724 983 VOLTAGE MON RET A GND PMON P9 2 MOTIF P17 2 724 990 HOME SENSORS 4 SHIELD 991 X HOME SWITCH MOTIF P24 2 TO P5 B 724 992 Y HOME SWITCH MOTIF P24 3 TO P5 D 724 LATHE TAIL STOCK 993 Z HOME SWITCH MOTIF P24 4 TO P5 L 724 994 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 1 724 1002 ENCODER A CHANNEL TO MOTIF P20 2 724 1003 ENCODER B CHANNEL TO MOTIF P20 3 724 1004 5 VDC TO MOTIF P20 4 24 1005 ENCODER Z CHANNEL TO MOTIF P20 5 724 1006 SHIELD DRAIN 1020 SPINDLE TEMPERATURE SENSOR CABLE 3 SHIELD 1021 SIGNAL 1022 ANALOG RETURN 1023 5 VOLTS TO SENSOR 1024 SHIELD GROUND 103
99. Parameter 101 X MAX CURRENT Fuse level in of max power to motor Applies only when motor is stopped Y MAX CURRENT Same definition as Parameter 105 Z MAX CURRENT Same definition as Parameter 105 A MAX CURRENT Same definition as Parameter 105 D D GAIN FOR X Second derivative gain in servo loop AHAS June 1998 96 8100 1998 96 8100 Parameter Parameter Parameter Parameter Parameter Parameter Parameter Parameter Parameter Parameter Parameter Parameter Parameter Parameter Parameter Parameter Parameter 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 Wi a2eries _______ SERVICE MANUAL MANUAL D D GAIN FOR Y Second derivative gain in servo loop D D GAINFORZ Second derivative gain in servo loop D D GAIN FOR A Second derivative gain in servo loop X ACC DEC T CONST Exponential acceleration time constant Units are 1 10000 seconds This parameter provides for a constant ratio between profiling lag and servo velocity It is also the ratio between velocity and acceleration Y ACC DEC T CONST Same definition as Parameter 113 Z ACC DEC T CONST Same definition as Parameter 113 A ACC DEC T CONST Same definition as Parameter 113 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 tim
100. REVERSE RESET TO SPINDLE 4 SHIELD BRUSH SYSTEMS 711 FORWARD COMMAND CN1 19 TO IO P9 3 712 REVERSE COMMAND 1 19 10 9 3 718 RESET COMMAND CN1 21 10 9 2 714 1 14 10 9 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 KBIF 724 723 SHILD DRAIN 730A POWER METER FROM KBIF TO METER 2 SHIELD BRUSH SYSTEMS 733 METER AFTER TRIM POT 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 24 742 POWER ON SWITCH LEG 2 24 N O 743 POWER OFF SWITCH LEG 1 24 VAC 24 744 POWER OFF SWITCH LEG 2 724 N C 745 SHIELD DRAIN 6 257 EN caste usr V eres 258 SERVICE MANUAL MANUAL 750 JOG CRANK DATA CABLE REM JOG SIDE CONNECTION 4 SHIELD ALL 28 CABLE NUMBER 5750 750 1 LOGIC RETURN D GROUND 750 2 ENCODER A CHANNEL 750 3 ENCODER B CHANNEL 750 4 5 VDC 750
101. RING N5000 187 20 25 7336 SOLENOID MOUNTING BRACKET 79 56 2087 SNAP RING 5000 206 21 25 7433 SUMP 80 57 0001 OIL SEAL 22 25 7434 SUMP 81 57 0002 OIL SEAL 23 29 0022 SHROUD CAUTION DECAL 82 57 0006 O RING 2 328 BUNA 24 29 7399 TRANSMISSION MOTOR LABEL 83 57 0013 V RING SEAL CR 400280 25 29 9128 LABEL TRANSMISSIO 84 2 57 0058 O RING 2 014 BUNA 26 30 31306 SHIFTER ASSY 85 57 0105 QUAD RING Q4 114 VITON 27 30 3146 AIR SOLENOID ASSY 86 57 7573 RANS GASKET 28 30 32608 OIL GEAR PUMP ASSY 87 2 58 16752 90 DEG COMPRESSION TIL 29 30 3270 REGULATOR ASSY 88 5 75FT 58 2001 POLYU HOSE 1 20D X 3 8ID 30 32 1455D RTAP ENCODER CABLE 89 2 5FT 58 2020 3 8 OD NATURAL TUBING 31 32 2010 24 L SWITCH 90 58 2065 COUPLING 1 4 32 32 2011 TELMECH 30 IN CABLE ASSY 91 2 58 2070 ANPT MALE TO 3 8 COMP 33 55 3200 SOLENOID BRKT CABLE ASSY 92 4 58 2100 SLEEVE LUBE ASSY 34 33 5008 GRND STRP SPNDL MTR SHRD 93 4 58 2110 SLEEVE NUTS LUBE ASSY 35 35 7065 TRANSFER GEAR ASSY 94 58 2745 AGNETIC OIL PLUG 36 35 7170A DRIVE SHAFT ASSY 85 58 3616 3 8 90 DEG ELBOW 1 4 NPT d 36 3035 SPINDLE FAN ASSY 96 58 3652 4 FEMALE 1 8 MALE 38 2 40 1602 FHCS 1 4 28 X 5 8 97 58 7357 OP PLATE TUBE 39 40 1628 SHCS 1 4 20 X 1 4 98 58 7558 TUBE 40 40 1650 SHCS 1 4 20 X 5 16 99 58 7577 AIR REG SOLENOID TUBE 41 2 40 1632 SHCS 1 4 20 X 1 2 00 58 7635 LOW GEAR TUBE VF 3 42 8 40 16385 SHCS 5
102. SPINDLE Loap METER REPLACEMENT Turn the power off and disconnect power to the machine 2 Remove the four screws holding the cover panel on the back of the control panel Take care to hold the cover panel in place until all screws have been removed 3 Disconnect the two leads at the back of the spindle load meter assembly Ensure the two leads properly marked for reconnecting later 4 Unscrew the four screws that hold the spindle load meter assembly to the control panel Take 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 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 Remove all switches spindle load meter and the jog handle as described in the previous sections 4 Unplug the keypad s 24 pin ribbon cable from the Keyboard Interface board 5 Remove the screws from the front of the control panel Take care to hold the front cover panel and bezel spacer in place until all screws have been removed Remove the two pieces and set aside in a safe place 6 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 To replace fir
103. The left and right cursor arrows are used to select the function being changed All values are 0 or 1 only The function names Y LIN SCALE EN Used to enable linear scales for the Y axis Y INVRT LN SCL Used to invert the Y axis linear scale Y DSBL LS ZTST Used to disable the linear scale Z test Y ZERO AXIS TC Used to return axis to zero prior to tool change ANAS M 213 4 N 214 em PARAMETERS Parameter Parameter Parameter Parameter 268 269 270 271 erfes SERVICE MANUAL IVIANUAL Y 2ND HOME BTN Used to move axis to coordinate specified in Work Ofset 0129 Y NEG COMP DIR Used to negate the direction of thermal compensation Y DELAY AXIS 0 Used with an APL to ensure Y axis is zeroed before A axis of APL 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 Z LIN SCALE EN Used to enable linear scales for the Z axis Z INVRT LN SCL Used to invert the Z axis linear scale Z 0581 LS ZTST Used to disable the linear scale Z test Z ZERO AXIS TC Used to return axis to zero prior to tool change 2 2ND HOME BIN Used to move axis to coordinate specified in Work Offset G129 2 NEG COMP DIR Used to negate the direction of thermal compensation Z DELAY AXIS 0 Used with an APL to ensure Z axis is z
104. 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 MOCON or MOTIF BOARD m 7 Note Refer to Cable Locations diagram of this board Turn machine power off Turn the main switch upper right of electrical cabinet to the off position 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 amplifiers servo drive assembly on brush machines goes out before beginning any work inside the electrical cabinet Disconnect all leads to the Motor Controller or Motor Interface board for brush machines Ensure all cables are properly labeled for reconnecting later 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 Replace the or MOTIF board attaching it to the VIDEO KEYBOARD beneath the MOTIF board with the standoffs Reconnect all leads previously removed to their proper connections VIDEO KEYBOARD
105. X MAXTRAVEL 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 Parameter 9 X MAX ERROR Max error allowed in servo loop before alarm is generated Units are encoder steps Parameter 10 X FUSE LEVEL Fuse level in of max power to motor Applies only when motor in motion Parameter 11 X BACKEMF Back EMF of motor in volts per 1000 RPM times 10 Thus a 63 volt KRPM motor gives 630 Parameter 12 X STEPS REVOLUTION Encoder steps per revolution of motor Thus an 8192 line encoder gives 8192 x 4 32768 196 H ATMA S 9658100 N 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 GAIN See Parameter 4 for description Parameter 19 Y RATIO STEPS UNIT See Parameter 5 for description Parameter 20 Y MAXTRAVEL STEPS See Parameter 6 for description Parameter 21 Y ACCELERATION See Parameter 7 for description Pa
106. 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 96 8100 HAI T 7 43 Mi 727 gt veu SERVICE MANUAL IVIANUAL 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 amp 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 MOTIF 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 d
107. a bad encoder or a cabling error Same as above Same as above Same as above Same as above Same as above In machines equipped with safety interlocks this alarm occurs when the control senses the door is open but itis locked Check the door lock circuit Illegal transition of count pulses in Xaxis 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 Same as above Same as above Same as above Same as above Same as above Same as 224 Same as 224 Cable from jog handle encoder does not have valid differential signals Cable from spindle encoder does not have valid differential signals Same as 139 This alarm is generated in machines equipped with a Haas vector drive if the spindle motor becomes overloaded The error between the commanded spindle speed and the actual speed has exceeded the maximum allowable as set in Parameter 184 DNC program not found or no end of program found 5 232 load bad Data was stored as comment Check the program being received Check input file for a number that has too many digits HAAS 96 8100 1998 96 8100 243 244 245 246 247 248 249 250 251 252 253 254 257 258 259 260 261 262 263 264 265 268 270 Bad Number Missing Unknown Code String Too Long Cursor Data Ba
108. 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 HAAS 96 8100 1998 Mw erles SERVICE MANUAL MANUAL TECHNICAL REFERENCE 5 20 DISCRETE INPUTS OUTPUTS 1000 1001 1002 1003 1004 1005 1006 1007 1008 1009 1010 1011 1012 1013 1014 1015 1100 1101 1102 1103 1104 1105 1106 1107 1108 1109 1110 1111 1112 1113 1114 1115 96 8100 The inputs outputs that are followed by an asterisk are active when equal to zero 0 Name TC IN TC OUT T ONE LO CNT TC MRK SP HIG SP LOW EM STP DOORS M FIN OVERVT LO AIR LO LUB OVRHT DB OPN DB CLS Name SRV spare spare spare 4TH BK COOLNT AUT OF SP FAN TC IN TC OUT TC CW TC CCW SP HIG SP LOW T UNCL spare DISCRETE INPUTS Descri
109. as 161 Same as 165 Same as 182 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 connectors at P1 P4 Same as alarm 279 Same as alarm 279 Same as alarm 279 Broken wires or encoder contamination All servos are turned off This can also be caused by loose connectors at P1 P4 Same as alarm 283 Same as alarm 283 Same as alarm 283 Cable from X axis encoder does not have valid differential signals Same as alarm 287 Same as alarm 287 Same as alarm 287 An automatic tool change was not completed due to insufficient volume or pressure of compressed air Check air supply line Check your geometry R must be less than or equal to half the distance from start to end within an accuracy of 0 0010 inches AHAS a 96 8100 1998 96 8100 303 304 305 306 307 309 310 311 312 313 314 315 316 317 318 319 320 321 322 324 325 326 Invalid X Y or Z In 002 603 Invalid 4 or K In G02 or G03 Invalid Q In Canned Cycle Invalid 1 J K or Q In Canned Cycle Subroutine Nesting Too Deep Exceeded Max Feed Rate Invalid G Code Unknown Code erles SERVICE MANUAL MANUAL Check your geometry Check your geometry Radius at start must match radius at end of arc within 0 0010 inches Q in a ca
110. 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 When investigating complaints of gearbox noise also refer to Spindle troubleshooting section Gearboxes can be damaged by failed air solenoids gearshift cylinders or bearings resulting in noisy operation While gearbox vibration can cause a poor finish on a workpiece noisy gearbox operation may not Q Excessive or unusual noise coming from the gearbox and or spindle motor Operate the machine in both high and lowgears 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 gt 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 amp Transmission section gt Ifthe 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 amp 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 Gears WILL CHANGE Machine will not execut
111. at top of travel 750 psi 1150 psi 1150 psi Machine at full travel 790 psi 1210 psi 1210 psi Figure 3 67 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 HAAS 129 MECHANICAL SERVICE 2172 125 F M 2 June 1998 SERVICE MANUAL MANUAL 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 Extended Cylinder Rod Washer Lock Nuts Safety Cotter J Pin Cotter Pin Spindle Head Z Axis Brackets Leadscrew Figure 3 68 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 130 T 96 8100 1998 V 7 7 125 MECHANICAL SERVICE SERVICE MANUAL MANUAL 4 Remove the band clamp that holds the cylinder to the stabilizer
112. be set to 0 as they are unaffected by it 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 298 MAX FEED DEG MIN 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 200 For all other mills this bit should be set to 99999 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 96 8100 6 217 4 N 218 Qiu MI SERVICE MANUAL IVIANUAL 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 t
113. bracket Loosen the two SHCS that attach the bracket to the column 5 Remove the hydraulic cylinder from the top of the column Filter Hydraulic Cylinder Hydraulic Hose Hydraulic Hydraulic Fluid Tank Cylinder Tank Mount Extended Cylinder Rod Hydraulic Cylinders Hydraulic Cylinder Brackets Hydraulic Fluid Tanks Spindle Head Brackets Fig 3 70 VF Series hydraulic counterbalance view left side view Note Do not disassemble unit Keep the hose attached to the cylinder 968100 9 131 MECHANICAL SERVICE Mi 125 1998 SERVICE MANUAL MANUAL 6 Return complete assembly to HAAS Automation 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 t
114. card and the user should never attempt to replace these fuses The POWER PCB contains three fuses located at the top right FU2 FU3 Ifthe 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 The two fuses FU4 and FU6 are not used On the servo drive assembly there is a printed circuit board SDIST containing three one amp fuses FU1 FU2 Two of these fuses protect the contactor and small transformers They are never expected to blow The third fuse protects the regen load circuit load from shorts FUSE NAME FU1 FU2 FU3 not used Lamp FU1 FU2 FU3 FU4 1 55 Motors TYPE AGC AGC AGC AGC AGC AGC AGC ABC ABC ABC ABC ABC ABC ABC RATING VOLTAGE LOCATION amps 250V POWER pcb upper right 250V 250 I 250V lower left 250V SDIST pcb right center 250 5 250V top center 20 250V SDRIVER pcb s X Y Z 20 250V 10 250V 5 250V 0 PCB 5 250V 0 PCB 5 250V 0 PCB 5 250V 10 PCB Each brushless amplifier contains a fuse which will only blow if there is a failure of the amplifier The user should never attempt to replace these fuses 184 ATA 5 968100 1998 er 7i TECHNICAL REFERENCE SERVICE MANUAL MANUAL The POWER PCB contains three 72 fuses located at
115. changer and run through all tools Replace coolant and thoroughly clean the coolant tank Check all hoses and lubrication lines for cracking 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 ALA 219 MAINTENANCE V mers SERVICE MANUAL MANUAL LUBRICATION CHART SYSTEM WAY LUBE AND PNEUMATICS TRANSMISSION COOLANT TANK Under the control panel at the rear of Above the spindle head Rear of machine the machine DESCRIPTION Piston pump with 30 minute cycle time Pump is only on when spindle is turning or when axis is moving 40 taper 2 QT 40 Gallons 1 5 QT Tank 50 taper 36 0Z 80 Gallons VF 6 10 LUBRICANT 2 25 Water soluble synthetic 220 M4 96 8100 EIE SERVICE MANUAL TSC MAINTENANCE 96 8100 O Check dirt indicator on 100 micron filter with TSC system running and no tool in the spindle Change element when the indicator reaches the red zone
116. data will be lost Check parity settings number of data bits and speed 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 A code found on input of a DNC program could not be interpreted The 0 code in the program being loaded did not match the 0 code entered at the keyboard Warning only Floppy memory was almost full when an attempt was made to read the floppy directory Check your program An ASCII EOF code was found in the input data before program receive was complete This is a decimal code 26 Need name in programs when receiving ALL otherwise has no way to store them Check files being loaded Program must be Onnnn and must be at the beginning of a block Check your program Between and there was no program found Program received doesn t fit Check the space available in the LIST PROG mode and possibly delete some programs Could not read disk Could not find floppy file Only one assignment is allowed per block Divide block in error into multiple blocks An expression element was found where it was not preceded by or that start expressions 5 96 8100 1998 96 8100 503 504 505 506 507 508 509 510 511 512 513 514 515 516 517 518 519 520 521 Macro Variable Reference Unbalanced Paren In Expression Value Stack Err
117. drop of blue Loctite amp 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 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 4 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 5 968100 1998 96 8100 SERVICE MANUAL MANUAL Note For the angular contact design bearing no pre load is necessary Do the follow ing 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 Y 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 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 Remo
118. equipped with TSC loosen the three set screws and remove the TSC coolant tip 3 Add or subtract required shim washers See previous section for correct amount to add or remove 4 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 5 Install tool release piston assembly in accordance with the Tool Release Piston Installation section and recheck settings If within specifications continue if not readjust LOWER UNCLAMP SWITCH 1 Push the PARAM DGNOS button top center twice You are now in diagnostics mode Look at the bottom left corner of the page and you should see DB OPN 0 tool unclamped and directly under that DB CLS 1 tool clamped If not push PAGE DOWN until you do A 1 means that particular switch is being tripped A 0 means it is not being tripped 2 With the tool holder resting on the block and set at zero Setting Drawbar Height section jog Z axis in the positive direction 06 3 Press the tool release button and hold it DB OPN should change from a 0 to a 1 If it does not slightly loosen the two 4 20 x SHCS holding the unclamp switch bracket switch on right to the tool release assembly 3 8 16 X 1 3 4 SHCS 1 4 Air Hose Fitting 3 8 Air Hose Fitting TSC Fitting Optional Clamp switch Unclamp s
119. eri eS ELECTRICAL DIAGRAMS IVIANUAL SPIGOT ror MOTOR 12 K17 SPIGOT SPIGOT FORWARD REVERSE THREE PHASE 230 VAC IN THESE WIRES FOR 5 MOTOR OPTIONAL CHIP CONVEYOR SINGLE PHASE REVERSIBLE 4 B _ 5 K33 D FU K33 ovp C FUA K34 pa x 1 nm Lo 1 6 G CHIP OVERCURRENT CONVEYOR DETECTION K35 ON CIRCUIT 140 CONVEYOR REVERSE GND CHIP CONVEYOR AND SPIGOT MOTORS 6 98 HAAS AUTOMATION VF SERIES PAGE 18 968100 GOB ELECTRICAL DIAGRAMS M SERVICE MANUAL SERVICE MANUAL erles JOG HANDLE FRONT PANEL KEY BOARD POWER ON TO POWER SUPPLY PCB CABLE 740
120. 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 67 Note For VF 6 8 follow installation procedure for each hydraulic tank Note gt Do not use compressed air oxygen or flammable gas Refertothe table below and verify pressure according to machine and spindle head position Verify cylinder is seated in counterbore VF 0 1 2 6 7 8 10 _ VF 6 7 10 w 50T spindle Machine
121. 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 a an air mist lubricated spindle gt 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 gt If the spindle is getting lubrication replace the spindle Spindle Assembly section 96 8100 se June 1998 gt O gt wsn Q gt O TROUBLESHOOTING SERVICE MANUAL MANUAL 96 8100 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 broken in In order to run a valid test on a new spindle ensure that it is properly broken in To break 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 54000 M03 G04 P900 G04 P900 G04 P900 N800 57500 M03 M05 M05 G04 P900 G04 P900 G04 P900 M05 N300 S2000 M03 G04 P900 G04 P900 G04 P900 N600 S5000 M03 G
122. level see Installation section e Check the sweep of the machine see Spindle Sweep Adjustment section Bored holes are out of round or out of position e Check for thermal growth of the leadscrew see Thermal Growth section e 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 Machine mis positions holes Check for thermal growth of the leadscrew see Thermal Growth section e Check that the machine is level see Installation section e Check for backlash see Servo Motors Leadscrews section e Check the squareness of the X axis to the Y axis Machine leaves large steps when using a shell mill e Check that the machine is level see Installation section e Check the sweep of the machine see Spindle Sweep Adjustment section e Cutter diameter too large for depth of cut Boring depth inaccurate e Check for thermal growth of the leadscrew see Thermal Growth section e Check the hydraulic counterbalance system pressure pressure is low check for gt abnormal noises from counterbalance system gt oil leaks esp at fittings and at filter at top of cylinder gt bound cylinder Finish lt gt Machining yields a poor finish e Check gearbox vibration This is the most common cause of a poor finish Check for backlash Accu
123. 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 5 Reset Parameter 236 to 1000 134 Y U 96 8100 MECHANICAL SERVICE 1998 3 17 AIR OIL LINE DIAGRAM N r TX EV a uV3NI1 5019101939 MOLOMISAY 10 m uivan YOLOIMLSSY x Y 301911534 SANYA 10 1 3019151535 1 10 LAN 1198 sanaavs TIVE
124. orientation lock pin The diagnostic display can be used to display the status of the relay output and the switch inputs Circuit breaker CB4 will interrupt power to this solenoid 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 Vector drive only Spindle encoder rotates past a reference mark 6 Vector drive only 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 HAAS 96 8100 1998 er 7 TECHNICAL REFERENCE SERVICE MANUAL MANUAL 5 4 CONTROL PANEL Probe Option T5 Transformer Low volt power supply 3 phase breaker 1 Motor control PCB Hatta 2 Video amp keyboard PCB 3 Micro processor ES 1
125. pocket tool changer Extremely heavy tool weights should be distributed evenly gt Ensure there is adequate clearance between tools in the tool changer before running automatic operation This distance is 3 6 for 20 pocket and is 3 4 for 32 pocket 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 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 FU1 on the 1 0 or the Power PCB is 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 When a tool change operation is performed the following sequence of events occurs Zaxis moves up to machine zero If the spindle is turning it is commanded to stop coolant stopped Spindle oriented to Tool Changer Turn TSC pump off optional T
126. position This can occur if a pallet change is interrupted for any reason such as an alarm or an E STOP To correctthis 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 WARNING Do not move the limit switches for any reason CAUTION The pallets weigh 300 Ibs each and can cause serious injury Use extreme caution when moving them 1012 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 Ibs each and can cause serious injury Use extreme caution when moving them 54 5 96 8100 January 1998 125 MECHANICAL SERVICE SERVICE MANUAL MANUAL 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 Ib 5 16 18 30 ft Ib 3 8 16 50 ft M10 100 50 tt 10 12 65 100 ft Ib 1 2 13 80 ft Ib 3 4 10 275 ft Ib 1 8 450 ft Ib 3 8 16 SHCS used on tool release piston torqued to 35 ft Ib 1 HEAD COVERS REMOVAL INSTALLATION Please
127. spindle when commanded Check air pressure and solenoid circuit breaker Can also be caused by misadjustment of drawbar assembly 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 same as 135 same as 135 same as 135 Encoder marker pulse count failure This alarm usually indicates that encoder has been damaged and encoder position data is unreliable This can also be caused by loose connectors at P1 P4 same as 139 same as 139 same as 139 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 Time allocated for use prior to payment exceeded Call your dealer 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 limitswitches and connector P5 atthe 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 same as 145 same as 145 Normally disabled for rotary axis Spindle not at zero speed for tool change A signal from spindle drive indicating that the spindle drive is stopped is not present
128. switching of spindle motor windings provided the hardware 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 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 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 ofthe X Position must be inverted Normally this bit should be set to 0 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 ofthe Y Position must be inverted Normally this bit should be set to 0 This bit is used with the G143 modal 5 axes tool length compensation on machines with a Gimbaled Spindle The B axes normally moves the A axes but if this is not true this bit can be to change which is the inner axes Normally this bit should be set to 0 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 do
129. three screws on the door should be secured at all times except during installation and service At those times only qualified electricians should have access 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 temperatures Therefore extreme caution is required Probe Option Low volt power supply T5 Transformer 3 phase breaker 1 Motor control PCB 2 Video amp keyboard 3 Micro processor PCB K1Contactor Power Power amplifiers X Y Z amp g HAAS Vector Drive Y Delta Contactors I 0 Board Transformer Terminal block Inductors 2 Brush 4th Axis Figure 4 6 Control cabinet general overview 1 Hook up the three power lines to the terminal 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 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 sec
130. 0 BHCS 1 4 20 x 1 2 44 13 40 2000 SHCS 1 4 20 x 5 8 45 5 43 7000 5 16 18 1 3 4 46 1 44 1710 SSS CUP PT 1 4 20 x 3 8 47 9 45 0045 WASHER HRD 1 4 X 1 8 THK 96 8100 297 ASSEMBLY DRAWINGS Mi eri 125 June 1998 SERVICE MANUAL MANUAL 30 0009 TOOL CHANGER ASSEMBLY 32 TOOL VF 6 10 ITEM PART DESCRIPTION QTY 96 58 3657 1 4 FEMALE 1 8 MALE ADPT 1 97 58 7357 TOP PLATE TUBE A 1 98 58 7358A OP PLATE TUBE B 1 99 58 7377 AIR REG SOLENOID TUBE 1 100 58 7635 LOW GEAR TUBE VF 3 1 101 58 7636 HIGH GEAR TUBE VF 3 1 102 58 9114B TRANS FILL TUBE 1 103 59 0027 HOSE CLAMP 1 2 HOSE 1 104 59 0046 SOUNDCOAT SHROUD RT LT 2 105 59 1482 NYLON FINISH PLUG 13 16 2 106 59 2040 CABLE CLAMP 7 16 2 107 59 4006 HOSE CRIMP 35 64 1 108 59 7130 PROTECTIVE STRIP 0 5 109 60 1810 SHAFT ENCODER 2000 LINE 1 110 62 3010 SPINDLE MTR 10 HP 1 111 63 0001 NYLON CABLE CLAMP 1 2 2 112 63 1031 CABLE CLAMP 1 4 1 113 70 0020 PLT1 5M CABLE TIES 25 114 76 2420 CRIMP RING 12 10 10 STUD 3 115 71 8001 WIRE NUT IDEAL 430 076 1 298 ALIA T 96 8100 1998 M eret SERVICE MANUAL ITEM QTY 1 1 1 1 1 Cn 4 1 20 21 22 24 24 25 P N 40 1639 40 2000 51 0005 51 20
131. 0 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 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 261 7 7 mes SERVICE MANUAL MANUAL 262 hIIVPSA Y 968100 1998 l O 7 eri Jes ELECTRICAL DIAGRAMS SERVICE MANUAL MANUAL ELECTRICAL WIRING DIAGRAMS 98100 6 263 k m ELECTRICAL DIAGRAMS V 3 3 3 3 June 1998 SERVICE MANUAL
132. 0 taper TSC e Check for broken or disconnected pre charge air line and replace if necessary e Check if the Tool Clamped limit switch is sticking and replace if necessary e Check the Tool limit switch adjustment refer to Tool Clamp Unclamp Switch Adjustment e Check for low pre charge pressure refer to Pressure Regulator Adjustment section e Check pre charge solenoid for proper operation e May be generated if another alarm occurs during TSC operation 2 968100 June 1998 les TROUBLESHOOTING SERVICE MANUAL MANUAL 1 7 CHIP CONVEYOR Chip conveyor does not turn e Check that Parameter 209 bit switch CNVR is enabled e Check that the front enclosure door is competely closed and door switches function properly Check that hub is connected to auger with bolt e Checkthat 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 e 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 Board conveyor relays Chip is moving the wrong direction e Toggle Parameter 209 bit switch REV CNVR to reverse direction of conveyor e Check 1 0 Board conveyor relays Chip conveyor reverses then shuts down e Check that the conveyo
133. 04 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 either 5000 or 7500 RPM at regular intervals of time stop the spindle and allow it to cool to room tempera ture then restart it so the temperature can be monitored e fatany time during this procedure the spindle temperature rises above 150 degrees start the procedure over from the beginning If the spindle fails this test for any reason check the following e Check for correct amount of lubrication Note Over lubrication is a common source of overheating Check the oil flow carefully e Check the drive belt tension Too tight belts will cause heating of the top bearing in the spindle housing e Ensure that the correct oil is being used refer to Maintenance Schedule STALLING Low Torque Generally complaints of stalling or low torque relate to incorrect tooling or machining practices A spindle that is tending to seize will yield a poor finish machining run very hot and very loud Investigate machining problems before concluding the problem exists with the spindle or spindle drive AHAS 43 727 gt ms SERVICE MANUAL SPINDLE DRIVE Low line voltage may prevent the spindle from accelerating properly If the spindle takes a long time to accelerate slows down or stays at a speed below the commanded speed w
134. 1110A BS ASSY 32mm 1 26 x 35 65 28 X 3 2 51 2014 BEARING LOCKNUT CL18F 50 1200 BS ASSY 32mm 1 26 48 25 Vr 3B X 2 4 2 56 0065 SNAP 5100 112 30 1210 BS ASSY 32mm 1 26 X 33 27 W 3B 48 112 0 2 5 1 59 2060 FLEXPAK FOR AJOS 30 1270 BS ASSY 232mm 26 x 58 47 4 30 1290 BS ASSY 32mm 1 26 x 13 53 HL 1 2 30 1295 BS ASSY 32mm 1 26 x 16 78 HL 3 4 X 30 1100 BS ASSY 32mm 1 26 x 25 65 HL 5 6 VF 1 2 0 318 96 8100 2 4 val g g 30 1220P COUPLING ASSEMBLY QTY PART TITLE 1 20 7403 COUPLING SERVO DRIVE 2 2 51 2014 BEARING LOCKNUT CL18F 3 2 56 0065 SNAP RING 5100 112 4 1 59 2060 FLEXPAK FOR 5 WHERE USED APPLICATION 50 1100 BS ASSY 32mm 1 26 x 25 65 EXT X Y 2 30 1110E BS ASSY 32mm 1 26 x 35 65 X 96 8100 319 ASSEMBLY DRAWINGS 3 1998 SERVICE MANUAL MANUAL
135. 13 27 and 41 e Worn lead screw 96 8100 6 15 16 TROUBLESHOOTING MI 125 SERVICE MANUAL VIBRATION o Excessive servo motor vibration e A axis is present swap the suspected bad servo motor with the A driver and check to see if there is a driver problem If needed replace the DRIVER PCB Electrical Service section e 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 PARAMETER LOCK should normally be on e 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 o Servo motor overheating e f 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 e fthe motoris actually getting hot to the touch there is excessive load on the motor Check the user s application for excessive load or high duty cycle Check the lead screw for binding Accuracy Backlash section If the motor is binding by itself rep
136. 2 2 44 1698 SPINDLE TAPERED 3 2 251 0021 1 7 8 PULLEY 4 1 21 1012 OIL INJECTION COVER 5 1 55 0020 LOCK 60MM BEARING 6 1 56 0075 50MM LOCK 7500 SPINDLE 7 1 57 2984 BRONZE FILTER ELEMENT 8 1 57 2990 DRAWBAR ASSY HC TSCHP 19 1 58 1627 SHCS 1 4 20 X 1 AMS O RING 2 348 BUNA 1 8 27 PIPE PLUG 335 ASSEMBLY DRAWINGS eri 125 June 1998 SERVICE MANUAL MANUAL 15 90 3910 SPINDLE ASSEMBLY QTY PART NO DESCRIPTIO ITEM QTY PART NO DESCRIPTIO 1 20 7016B SPINDLE HOUSING 0 0 1610 SHCS 1 4 20 X 1 2 20 7018L SPINDLE SHAFT 1 6 40 16385 SHCS 5 16 18 X 3 4 3 20 7022C SPINDLE TAPERED 2 1 51 1002 LT CONT DUPLEX 4 20 7373 1 7 8 PULLEY 3 1 51 1012 BRNG DUPLEX LT 36MM SPCR 5 20 7442C INJECTION COVER 4 1 56 0075 SNAP RING N5600 131 6 20 7530 LOCK 60 BEARING 5 1 57 2984 O RING 2 158 7 20 7552 LOCK 50 ANG BRNG 16 1 57 2990 O RING 2 348 BUNA 8 24 4200 BRONZE FILTER ELEMENT 7 1 58 1627 1 8 27 PLUG 9 30 3410D DRAWBAR ASSY HIGH CLAMP 33 AAAG _ 96 8100 1998 125 ASSEMBLY DRAWINGS SERVICE MANUAL MANUAL e 30 3911D 10K 12K SPINDLE ASSEMBLY 12 ITEM QTY PART NO DESCRIPTIO ITEM QTY PART DESCRIPTIO 1 1 20 7016B
137. 2 X 2 08 59 7130 REMOVED PROTECTIVE STRIP 49 1 40 1800 REMOVED 8 32 X 3 4 09 60 1810 SHAFT ENCODER 2000 LINE 50 5 40 1830 HHB 1 2 1 1 3 4 0 36 3078 10K 10HP MOTOR KIT 51 7 40 1850 SHCS 10 P M 1 2 63 0001 YLON CABLE CLAMP 1 2 52 4 40 1981 FBHCS 1 4 20 X 1 2 2 63 1051 CABLE CLAMP 1 4 83 5 41 1500 5 8 32 3 8 5 25 70 0020 PLT1 5M CABLE TIES 54 4 44 0003 555 HALF DOG 1 4 20 1 4 3 76 2420 CRIMP RING 12 10 10 STUD 55 4 45 0040 REMOVED WASHER BLK HARD 1 4 A325 5 77 8001 WIRE NUT IDEAL 30 076 56 4 45 1600 WASHER SPLIT LOCK 5 16MED 6 30 3276 PURGE SOLENOID VALVE ASSY al 1 45 1603 REMOVED WASHER SPLIT LOCK 8 MED 7 20 0125 DRIVE SPROCKET ENCODER 58 4 45 1620 WASHER SPLIT LOCK 10 MED 8 4 57 0049 RUBBER STUD 59 1 45 1682 WASHER SPLIT LOCK 7 16MED 9 4 46 1625 UT HEX BLK OX 1 4 20 60 5 45 1700 WASHER INTERNAL LOCK 8 20 4 45 1800 WASHER SPLIT LOCK 1 4 MED 96 8100 1 345 ASSEMBLY DRAWINGS MI eri 125 june 1998 SERVICE MANUAL IVIANUAL 0012 VF 3 4 COLUMN RIGHT SIDE HYDRAULIC PRESSURE SENSOR CABLE NOT SHOWN 5 VF Series Hydraulic Couterbalance System 346 _ 96 8100
138. 210 Parameter 211 Parameter 212 Parameter 213 Parameter 214 Parameter 215 Parameter 216 June 1998 erfes SERVICE MANUAL set to 1 low coolant input will not be used Discrete pallet rotate part ready inputs enabled if set to 1 set to 1 allows use of remote tool release button spindle head If set to 1 enables the optional floppy drive If set to 1 enables tool changer restore button on keypad If setto 1 adds 8 additional relays for a total of 40 These additional relays 21 28 become available on a secondary board and are shown on the discrete outputs page When 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 Does not allow accumulation on auxiliary axis jog Alias M codes during program restart Disables the encoder test for the jog handle Used on horizontal mills only Used on horizontal mills only 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 X TOOL CHANGE OFFSET This parameter is not used Y TOOL CHANGE OFFSET Horizontal mills For Y axis displacement from the home position to tool change position On Ve
139. 27 55 0001 56 0001 57 0016 57 0017 5 0065 57 2106 58 1627 59 0015 ASSEMBLY DRAWINGS E ESCRIPTION 3 8 16 X 1 SHCS 1 4 20 X 5 8 BEARING LOWER BRNG DEEP GROOVE 46016 LOCKNUT BEARING RETAINING RING O RING 2 167 BUNA O RING 2 368 BUNA O RING 2 214 BUNA O RING 223 ALL SEALS 1 8 27 PIPE PLUG SPRING WAVE Spindle Assembly VF 50 Taper 20 10 0 SPINDLE ASSY ITEM P N DESCRIPTION 1 1 20 0001 SPINDLE LOC 2 20 0002 CAP TOP SPINDLE 3 20 0003 OL INJECTION COVER 4 20 0004 SPINDLE HOUSING 50 TAPER 2 20 0007 GUIDE COLLET DRAWBAR 6 20 0008 SPACER BEARING INNER UPPR 7 20 0009 SPACER BEARING OUTER UPPR 8 20 0010 PULLEY 45 TOOTH 9 20 0011 SPINDLE SHAFT 50 TAPER 10 20 0023 MATCHED SPACERS 118 1 1 24 4200 BRONZE FILTER ELEMENT 12 30 0067 ASSY 15 8 40 1636 SHCS 3 8 16 X 1 1 4 96 8100 AMS 299 SERVICE MANUAL MAN ASSEMBLY DRAWINGS V erles C _ June 1998 27 46 13 23445 50 55 31 60X56X3104 01 32 50 Taper Tool Changer Assembly 300 n P y A0 96 8100 1998 96 8100 ITEM ql ll 4 4 Q HP AB pp 4 k x 125 ASSEMBLY DRAWINGS SERVICE MANUAL MANUAL 30 0015 TOOL CHANGER ASSEMB
140. 3ATVA 3ound 8 IV OF 135 HAAS 96 8100 MECHANICAL SERVICE 136 eres SERVICE MANUAL IVIANUAL THROUGH THE SPINDLE COOLANT SYSTEM FLOW DIAGRAM tss 0 FAI 1 762 jap CV CHECK VALVE Gl ZOR CHECK VALVE ASSY TSC TA Q3 2 Fi INTAKE FILTER 100 MESH m PI E E F2 TSC FILTER 100 MICRON 2 Fi FAI INTAKE FILTER ASSEMBLY FA2 TSC FILTER ASSEMBLY G1 DIRT INDICATOR INTAKE FILTER PURGE AIR COOLANT TANK 62 DIRT INDICATOR 100 MICRON FILTER TSC PUMP PRA 4 PVA 4 Ri PRECHARGE REGULATOR 2 3 Pup mE SET AT sb Pel TOOL RELEASE AIR UR ul AIR PRA REGULATOR ASSY 1 Cy 4 30 3270A AIR PRECHARGE L SESS 5 3 PS PRESSURE SWITCH VENT AIR SET 40 3 4 ft PVA PURGE VALVE ASSEMBLY 5 2 svi 9 30 3970 T La P ER m Lr SVI SOLENOID VALVE PRECHARGE eni P 48 2 POSITION 3 WAY SP RET TT 5 2 SOLENOID VALVE TOO
141. 4 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 830 OVERHEAT THERMOSTAT 2 SHIELD 831 OVERHEAT SIGNAL INPUT 14 720 832 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 724 850A SERIAL PORT 2 INTERFACE CABLE 16 WIRE RIBBON 724 860 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 8600 5 12 12 POWER TO 68030 870115VAC TO 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
142. 4 1 1 8 SPROCKET 65 2 48 0020 PIN DOWEL 1 4 X 6 20 7430 CATCH 66 48 0050 PIN DOWEL 1 8 X 7 16 7 20 7445 PLATE 67 2 51 2031 RADIAL OPEN 6303 8 20 9125 68 51 2032 BRNG RADIAL 6205 9 20 9126 TOP PLATE GEARBOX 69 51 2033 BRNG RADIAL 6306 0 4 22 7260 ENCODER STANDOFF 70 51 2034 BRNG RADIAL 6005 1 2 22 7376 SPROCKET FLANGE 71 51 2041 BRNG LOCKNUT 05 2 22 7445 DRAIN SUMP 725 54 1013 REMOVED DRIVE SPROCKET 250 RTAP 3 22 7446 PICK UP TUBE DRY SUMP 75 54 2125 DRIVE BELT HTD 500 5 09 4 22 1487 OIL FILL CAP MODIFIED 74 54 7127 DRIVE SPROCKET 575 5 2 22 7520 SOLATOR TRANS 75 2 55 0035 SPRING 5 204 6 6 22 7571 TRANS 76 2 55 0056 SPRING WASHER BS 205 7 25 0107 OTOR SHROUD 77 3 56 0060 SNAP RING 5100 66 8 25 0108 FAN BRACKET MOTOR SHROUD 78 56 0070 SNAP RING N5000 187 9 25 7264 SWITCH MOUNTING BRACKET 79 56 2087 SNAP RING 5000 206 20 25 7336 SOLENOID MOUNTING 80 57 0001 OIL SEAL 21 25 7433 SUMP BRACKET 81 57 0002 OIL SEAL 22 25 7434 SUMP 82 57 0006 O RING 2 328 BUNA 24 29 0022 SHROUD CAUTION DECAL 83 57 0013 V RING 5 CR 400280 24 29 7399 TRANSMISSION MOTOR LABEL 84 2 57 0058 O RING 2 014 BUNA 25 29 9128 LABEL TRANSMISSION 85 5 0105 QUAD RING Q4 114 VITON 26 30 31306 SHIFTER ASSY 86 57 7573 TRANS MOTOR GASKET 27 30 3146 AIR SOLENOID ASSY
143. 5 30 0054 30 0055 32 1800 40 0017 40 16081 40 1614 40 1617 40 1636 40 1654 40 1667 40 1703 40 1850 40 1920 40 1950 40 1961 40 1970 40 1981 44 1700 45 1666 46 1625 48 0012 49 16201 51 0300 51 2836 51 4000 56 0085 59 1057 SERVICE MANUAL Cries TITLE CASTING LEVEL PAD SUPPORT IDLER SPROCKET DRIVE LEG APC DETENT APC SUPPORT MOTOR APC GUIDE CHAIN APC TENSIONER BLOCK PALLET CLAMPING RAIL IDLER SPROCKET JOURNAL IDLER SPROCKET FRICTION BLOCK PALLET STOP APC WIPER APC BASE MACHINED SHIELD SPLASH LOW PROFILE LEG APC PALLET SKIRT REAR SWITCH BRACKET CHAIN LOW SWITCH BRACKET ARM 1 PALLET DRIP PAN BRACKET WIPER SWITCH BRACKET ARM 2 SWITCH BRACKET CHAIN HIGH PALLET SKIRT FRONT CHAIN ASSEMBLY APC SLIP CLUTCH ASSEMBLY SHUTTLE MOTOR 507 01 110AH FHCS 5 16 18 X 3 4 BHCS 6 32 X 5 16 SHCS 1 4 20 X 1 1 4 FHCS 1 4 20 X 1 SHCS 3 8 16 X 1 1 4 SHCS 1 2 13 X 1 SHCS 5 16 18 X 1 1 4 5 10 32 X 1 2 SHCS 10 32 X 3 8 5 1 4 20 X 5 8 SHCS 10 32 X 3 4 SHCS 3 8 16 X 2 5 1 4 28 X 1 5 1 4 20 1 2 SSS CUP PT 3 4 10 X 4 WASHER FLAT 1 2 1 0 NUT HEX BLACK 0X 1 4 20 DOWEL PIN 12mm X 30 mm LG BHCS 10 32 X 38 BUSHING DRILL 6260 1 0 BEARING RADIAL 60052RS BEARING RADIAL12 X 32 X 10MM RETAINING RING 5100 100 BUMPER PALLET AMS ASSEMBLY DRAWINGS 311 ASSEMBLY DRAWING
144. 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 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 65 420 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 24 424 783 AT SPEED INPUT 20 TO CN1 23 424 784 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 1 14 812 SHIELD DRAIN 810A TOOL CHANGER MOTORS 2 SHIELD 20 813 SHUTTLE MOTOR IO P30 4 TO 6 14 814 SHUTTLE MOTOR 10 P30 3 TO P6 B 414 812 SHIELD DRAIN HAAS June 1998 96 8100 C Mi 770 1 96 8100 SERVICE IVIANUAL 820 001 CHANGER STATUS 7 SHIELD 7 821 LOGIC RETURN D GROUND 06 F H L M 24 822 GENEVA MARK INPUT 5 P6 G 24 LATHE PART DOOR 823 TOOL 1 INPUT 3 TO P6 E 24 824 SHUTTLE IN INPUT 1 TO P6 C 2
145. 5 minutes an automatic shutdown will begin Overheat or failure of spindle drive or motor The exact cause is indicated in the LED window of the spindle drive inside the control cabinet This can be caused by a stalled motor shorted motor overvoltage undervoltage overcurrent overheat of motor or drive failure 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 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 Gearshifter is out of position when a command is given to 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 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 M Fin was active at power on Check the wiring to your M code interfaces This test is only performed at power on The tool appeared to be unclamp
146. 50 56 2 51 0010 57 1 51 0012 58 1 51 6000 59 1 54 0010 60 2 54 0020 61 4 54 0030 62 2 54 0040 63 2 55 0010 64 1 57 9139 65 1 57 9335 66 6 63 1031 67 1 70 0050 68 1 75 15721 69 1 78 1996 70 1 75 79 1000 71 1 70 79 1001 96 8100 125 ASSEMBLY DRAWINGS SERVICE MANUAL MANUAL TITLE WASHER BLACH HARD 1 2 WASHER SPLIT LOCK 1 4 MED WASHER NYLON LOCK NUT ELASTIC 3 4 10 PIN DOWEL 3 16 x 3 8 PIN DOWEL 1 4 x 5 8 PIN DOWEL 1 4 x 1 PIN DOWEL 1 2 x 1 1 2 BEARING DEEP GROOVE BEARING LOCK NUT BH 06 BEARING LOCK NUT NT 05 CAM FOLLOWER TOOL CHANGER BUSHING GUIDE WHEEL GUIDE WHEEL STANDARD BUSHING GD WHEEL SPRING WASHER B2500 080 GASKET TOOL HOLD ARM SHUTTLE COVER GASKET CABLE CLAMP 1 4 PLT4S M CABLE TIES MOLEX BSNG 2 PIN MALE SPLIT FLEX TUBING 1 2 I D WIRE CHANNEL 1 x 2 COVER 1 WIRE CHANNEL HAA I 295 ASSEMBLY DRAWINGS MI eri eS june 1998 SERVICE MANUAL MANUAL o E 70 mm o 49445 64 lt 7 i 8 1 15 OGBO 48 8 Gd 8 LL 36 2 3 87 25 49 49 Tool Changer Assembly VF 6 10 296 96 8100 1998 eri 125 ASSEMBLY DRAWINGS SERVICE MANUAL 30 0009 TO
147. 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 assembly is heavy so use great care when removing it 2 5 TRP INSTALLATION 50 TAPER Tool Clamped Switch S Unclamped Switch Fork Shims TRP Shims zT D 1 ea 0 093 Nylon Washer AL 2 0 010 Shim Washer SS 3 ea 0 015 Shim Washer E 1ea 0 010 Shim Washer 7ea 0 018 Shim Washer Spindle Fork 11 Drawbar Gap Figure 2 4 Shim and spacer location diagram 60 968100 January 1998 eS MECHANICAL SERVICE SERVICE MANUAL MANUAL 1 Install Nominal Shims in Fork and on TRP Spacers 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 Spacers 45 0019 0 093 Nylon Washer 1 ea 1 ea 45 0017 0 010 Shim Washer 2 ea 2 45 0018 0 015 Shim Washer 3 ea 2 ea Note TRP Spacers t
148. 6 8100 1998 125 ASSEMBLY DRAWINGS SERVICE MANUAL MANUAL 5 2 Y 10 30 3916F SPINDLE ASSY VFO 1OK TSCHP CARB ITEM QTY PART DESCRIP TION ITEM QTY PART DESCRIP TION 1 20 70168 SPINDLE HOUSING 10 4 40 1610 SHCS 1 4 20 X 1 2 20 70181 SPINDLE SHAFT 11 6 40 16 385 SHCS 5 16 18 X 3 4 5 20 7022C SPINDLE TAPERED 12 1 51 1002 LT ANG CONT DUPLEX 4 20 7442C OIL INJECTION COVER 1 1 51 1012A BRNG DUPLEX LT 36MM SPCR 5 20 7530 LOCK 60MM BEARING 14 1 56 0075 SNAP RING 5000 151 6 20 7532 LOCK 50MM BRNG 15 5 2984 O RING 2 158 VITON 7 20 75 59 28 PULLEY MOD 16 4 57 2990 O RING 2 548 BUNA 8 24 4200 BRONZE FILTER ELEMENT 1 1 58 1627 1 8 27 PIPE PLUG 9 50 5415 DRAWBAR ASSY TSCHP CARB 96 8100 49 3 39 ASSEMBLY DRAWINGS MI eri eS June 1998 SERVICE MANUAL MANUAL
149. 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 machine s configuration The maximum number of tool positions is 32 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 200 n G AAS 968100 1998 96 8100 Parameter Parameter Parameter Parameter Parameter Parameter Parameter Parameter Parameter Parameter Parameter Parameter Parameter 68 69 70 71 72 73 74 75 76 77 78 79 80 SERVICE MANUAL MANUAL WEES 8 DRAW MAX DELAY Maximum delay allowed when clamping and unclamping tool Units are milliseconds After this time an alarm is generated A AIR BRAKE DELAY Delay provided for air to release from brake on A axis prior to moving Units are milliseconds MIN SPIN DELAY TIME Minimum delay time in program after commanding new spindle speed and before proceeding Units are milliseconds 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
150. 7 1 57 0080 O RING 2 023 BUNA 38 4 58 1560 ADPT 1 8 M BSPT TO 5 16 F 39 1 58 3031 BANJO ELBOW 5 16 M6 M 40 34 59 2033 1 2 CONDUIT STRAP 41 2 59 4002 HOSE CLAMP 42 6 59 4016 HYD HOSE CLAMP 43 2 59 9829 CLEVIS COUNTER WEIGHT 44 1 62 0013 SERVO MOTOR YASKAWA 45 05 99 4521 ELECTRICAL GREASE 308 96 8100 1998 96 8100 co B PR RA S o a 7 Cres ASSEMBLY DRAWINGS 19 14 26 14 28 28 0 DWG 0 TITLE 20 0150 NUT HOUSING 40 50 mm BS 20 0153 SADDLE VF 10 MACHINED 20 0154 TABLE VF 10 MACHINED 20 0156 BUMPER 1 40 amp 50 LD SCREW 22 7458 GUIDE 25 7459 TRIP TABLE 25 9219 LIMIT SWITCH BRACKET X AXIS 25 9220 TRIP BRACKET X AXIS 30 0036 X AXIS OIL LINE ASSEMBLY 30 0037 LEADSCREW ASSEMBLY X AXIS 32 2051 LIMIT SWITCH X HOME 40 16372 SHCS 3 8 16 X 1 1 2 40 16413 MSHCS X 5 40 16455 SHCS 10 32 X 88 40 1660 SHCS 1 2 13 X 4 1 2 40 1712 SHCS 5 16 18 X 1 1 4 40 1750 BHCS 10 32 X 38 45 1600 WASHER LOCK 45 1681 WASHER SPLIT LOCK 48 0045 PULL PIN 3 8 X 1 1 2 50 0001 LINEAR GUIDE 57 0075 O RING 2 021 BUNA 57 0080 O RING 2 023 BUNA
151. 7 897 VF 5 50 X 30 0302 BS ASS Y 40mm 1 57 X 32 696 24 0006 BALLSCR 40mm 1 57 X 32 696 VF 5 50 Y 2 FOR 30 0303 amp 30 0302 USE 40 1667 SHCS 5 16 18 X 1 4 FOR 30 0053 ONLY VF 6 8 5 Lead Screw Assembly 304 N 96 8100 1998 125 ASSEMBLY DRAWINGS SERVICE MANUAL MANUAL C QJ d p 30 0037 SCREW ASS Y 50mm vF 10B 11B VR 11B ITEM PART NO DESCRIPTIO QTY 1 20 0151 TR MOUNT 40 50MM BS MAC 1 2 20 0152 BRNG HSNG 40 50 BS 1 5 20 9213 SPACER RING 40MM BALLSCRW 1 4 24 00026 5 BALLSCREW 10 1 5 30 1222 SCREW SUPP BRNO ASSY 1 6 40 1715 SHCS 5 16 18 X 1 1 2 6 7 51 0007 BEARING DEEP GROOVE 4 8 51 0008 BEARING LOCK NUT 06 2 VF 10 Leadscrew 98100 9 305 ASSEMBLY DRAWINGS ITEM 306 0 gt gt gt 4 5 A wo 05 26 PART NO 20 0150 20 9215 20 9218 20 9800 22 7458 25 7267 25 9203 30 1212 30 7420 32 5056 40 0011
152. 70 rj P35 90B E STOP A B C 4 P40 770A es E 61 770 P36 90C E DOOR P38 1050 poy pog M FIN E P22 100 P37 910B m OVERV l P18 970 P57 910D o al LO AIR OIL 19 950 e E P17 960 y 28 910 P58 910C OVERH 2 20 830 af 29 390 SP STAT 15 890 B U P59 GB SP 5 21 780 SPARE1 P52 P12 880A P5 110 SPARE2 P24 790 REM UNCL P23 190 P9 710 SPARE3 P25 240 RI p SKIP P47 1070 SPIGOT P53 180 P54 350 5 56 940 P60 930A P 57 6 930 P7 940 8423 170 93 1055 10 300 R127 P27 1040 FU2 42 r pod 44 P48 49 P50 55 up W0 P45 FU3 a DOOR LOCK 230 250 270 260 200 280 P46 140 ien oko nm TER i 5 TH BRK PAL RDY HTC SHUT TSC PURGE SPIGOT MOTOR CHIP CONVEYOR 230 CABLE LOCATIONS M erles SERVICE MANUAL MANUAL
153. 8 m 6408 92 3 6 1B Axis MOTOR 6908 LLL 6908 ENCODER OPTIONAL 640 3 2 6 98 HAAS AUTOMATION VF SERIES AGE 1 968100 267 ELECTRICAL DIAGRAMS V Cries SERVICE MANUAL June 1998 6 98 195 260 VAC IN 195 260 VAC 24VCT CN POWER SUPPLY PCB 741 7 FUSES ON POWER SUPPLY POWER ARE 1 2A FAST BLOW ONLY 742 ON THEY WILL OPEN IF VOLTAGE DR EXCEEDS 285 VAC ON INCOMING 3 PHASE POWER DROPPING ve POWER 5 g OFF FU2 222 PENDANT 7 OFF 172 wte 67 K7 pow um 66 PART OF 1 0 PCB AUX K1 SPINDLE DRIVE R s UNT 115V PH1 PART OF POWER SUPPLY PCB CB2 115V J 3 i 2 me 1 0 PCB PH3 36 TSC 220 240 IPTIDNAL PART OF POWER SUPPLY PCB e COOLANT MOTOR 220 240 5 N IRANSFO AUTOMATION LOW VOL 5 268 HAAS 96 8100 1998
154. A ENCODER OUTPUT MOTIF INPUTS OUTPUTS 1 0 RELAYS 1 8 1 0 RELAYS 9 16 1 0 RELAYS 17 24 1 0 RELAYS 25 32 LOW VOLTAGE SP SPEED COMMAND VOLTAGE MONITOR JOG INFO SP ENCODER OUTPUT SP TEMP SP DRIVE LOAD HOME SENSORS AHAS D LOCATION VIDEO PCB MICRO PROC PCB X SERVO DRIVE Y SERVO DRIVE Z SERVO DRIVE A SERVO DRIVE X ENCODER Y ENCODER Z ENCODER A ENCODER 1 0 PCB 1 0 PCB I O PCB 1 0 PCB 1 0 POWER SUPPLY PCB SPINDLE DRIVE SDIST PCB JOG HANDLE SPINDLE ENCODER SPINDLE SPINDLE DRIVE X Y amp Z LIMIT SW CABLE LOCATIONS PLUG P51 n 241 CABLE LOCATIONS 1998 80 8 160VDC 93W DRIVERS 160VDC 115 1 910 TB1 O 110 11 SERVO POWER O O 980 P9 d VOLTAGE MON NE2 X DRIVER LOW VOLTAGE 570 P1 O OV V NE1 Y DRIVER LOW VOLTAGE 580 P2 1060 P13 15 GND FAULT Z DRIVER LOW VOLTAGE 590 P3 920 P10 RESISTORS A DRIVER LOW VOLTAGE 600 P4 860A P5 12VDC FAN FAN P7 O 22 6 968100 1998 SERVO DISTRIBUTION SDIST PCB PLUG 1 2 4 5 7 P8 P9 P10 P11 P12 P13 TB1 TB2 96 8100 CABLE 570 580 590 600 860A FAN 80 980 920 110 970 1060 N A N A U Cries SERVICE MANUAL MANUAL CABLE CONNECTIONS SIGNAL
155. ACTOR 3 HIGH VOLT 488 448 447 429V 428 403V 402 377V 376 354V LOW VOLT 260 244V 243 227V 226211 210 195V e Fig 5 3a Transformer with 354 488V range Fig 5 3b 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 195 260 VAC 354 488 VAC to T1 is connected to the appropriate tap on T1 96 8100 n ANG 183 TECHNICAL REFERENCE VoLTAGE SELECTION TAPS erles June 1998 SERVICE MANUAL IVIANUAL There are five labeled plastic terminal blocks for high voltage Each block has three connections for wires labeled 74 75 and 76 Follow the instructions printed on the transformer SECONDARY CONNECTION To T 1 The secondary output from T1 is 115V AC three phase CB2 protects the secondary of transformer T1 and is rated at 25 amps Brush Motors The servo drive DRIVER cards have three fuses on each of the X Y Z and APCB s F1 F2 F3 If these fuses are ever blown the associated motor will stop This will only happen if there is a failure of the drive
156. ADDLE OIL LINE ASSEMBLY 5 32 1406 X AXIS MOTOR ASSEMBLY 22802921 TELEMECHANIQUE SWITCH ASSEMBLY 96 8100 VF 8 Saddle 045 323 ASSEMBLY DRAWINGS MI eri eS june 1998 SERVICE MANUAL MANUAL 1 30 1200 LEAD SCREW ASSEMBLY 2 50 420 BASE OIL LINE ASSEMBLY 5 32 1 60 Z AXIS MOTOR ASSEMBLY 4 352 5056 LIMIT SWITCH ASSEMBLY VF 6 Base 324 D AVhCA 96 8100 1998 125 ASSEMBLY DRAWINGS SERVICE MANUAL MANUAL 30 1200 LEAD SCREW ASSEMBLY 2 50 7400 COLUMN OIL LINE ASSEMBLY 2 3 S AXIS MOTOR ASSEMBLY 4 352 2050 ELEMECHANIQUE SWITCH ASSEMBLY VF 6 Column 96 8100 fff 3 ASSEMBLY DRAWINGS MI eri eS june 1998 SERVICE MANUAL MANUAL 1 50 1240 EAD SCREW ASSEMBLY L 2 SU 7 410 SADDLE OIL LINE ASSEMBLY 5 32 1406 X AXIS MOTOR ASSEMBLY 4 352 2051 TELEMECHANIQUE SWITCH ASSEMBLY VF 6 Saddle 326 96 8100
157. AKE 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 4907 Z AXIS 500 OVERTEMP SENSOR FROM SPINDLE MOTOR 2 SHIELD 501 OVERTEMP WIRE 1 20 502 OVERTEMP WIRE 2 20 503 SHIELD DRAIN 510RELAY CARD 1 DRIVE CABLE 16 WIRE RIBBON 24 520RELAY CARD 2 DRIVE CABLE 16 WIRE RIBBON 24 530RELAY CARD 3 DRIVE CABLE 16 WIRE RIBBON 24 540RELAY CARD 4 DRIVE CABLE 16 WIRE RIBBON 24 550 INPUTS CARD CABLE MOTIF P10 34 WIRE RIBBON 24 610X AXIS HAAS AMPLIFIER CABLE TO MOTOR CONTROLLER BOARD MOTOR CONTROLLER BOARD SIDE CONNECTION 610 1 A CHANNEL 610 2 ANALOG GROUND AHAS 255 e CABLE LIST 256 610 3 610 4 610 5 610 6 610 7 610 8 610 9 610 10 22 1245 SERVICE MANUAL MANUAL B CHANNEL ANALOG GROUND ENABLE LOGIC GROUND FAULT LOGIC GROUND NOT USED SHIELD ANALOG GROUND 620 Y AXIS HAAS AMPLIFIER CABLE TO MOTOR CONTROLLER BOARD SAME AS 610 1 THRU 610 10 630Z AXIS HAAS AMPLIFIER CABLE TO MOTOR CONTROLLER BOARD 640A 640B 6400 SAME AS 610 1 THRU 610 10 A AXIS HAAS AMPLIFIER CABLE CONTROLLER BOARD SAME AS 610 1 THRU 610 10 B AXIS HAAS AMPLIFIER CABLE MOTOR CON
158. ASHER STL 505X1 00X 01 38 S WASHER STL 505X1 00X 018 56 4 40 16627 June 1998 19120421 PIN RIPTION ER 1 4 DOWEL ER STL 625X1 239X 01 ER STL 625X1 239X 015 ER NYLON 625X1 25X 093 ER SAE 5 8 ID X5 8 00 SAE 1 2 X 1 SHLDR SCR HX HD 5 8X3 1 2 O R 0 0 8 6 2 1 2 4 T CLAMP 1 1 4 7 21 48 G 2 327 1 8 27 PIPE PLUG CONN ELBOW 1 4 REDUCER BUSH SPRI SPRI SHCS 50 Taper Tool Release Piston AMS 6 CO 6 CO ELBOW 1 2 PUSH 1 4MP YLON TUBING 1 28 1 8F PRESSION PRESSION 1 2 3 31 2 96 8100 1998 7 lrles 1 1 0 ASSEMBLY DRAWINGS IT QTY PART_NO TITLE 1 1 20 9193 CAROUSEL SUPPORT 2 1 20 9324 CAROUSEL 32 TOOL 3 32 22 7067 KEY 4 64 22 9256 BUSHING 5 64 22 9574 6 32 24 2010A COMPRESSION SPRING 7 32 24 9257 SPRING EXTRACTOR 8 32 25 7249 SLIDING PANEL 9 32 25 9328 32 TOOL SLIDING PANEL COVER 10 1 25 9333 NUMBER RING 32 T C 11 8 40 1500 SHCS 5 16 18 X 1 12 64 40 16095 SHCS 10 32 x 1 4 13 64 40 1697 SHCS 1 4 20 x 3 4 14 64 40 1704 FHCS 10 32 x 1 4 15 64 45 0045 WASHER HARD 1 4 x 1 8 THK 16 32 48 0004 SPRING PIN 3 8 x 1 32 Tool Carousel Assembly CT 96 8100 Y TNT T R L HVTSa O
159. An overcurrent is sensed when chips jam the conveyor By reversing and then forwarding the conveyor the chip jam may be broken Default is 3 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 MAX TIME NO DISPLAY The maximum time in 1 50 sec between screen updates ROTARY AXIS INCRMNT For Horizontal mills only This parameter sets the degrees of rotation of the A axis at an M36 or Pallet Rotate 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 ROT AXIS ZERO OFSET This parameter shifts the zero point of A for a wheel fixture or tombstone 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 EDITOR CLIPBOARD This parameter assigns a program number nnnn to the contents of the clipboard FLOPPY DIR NAME This parameter sets the program numbers to store in the floppy directory QUICKCODE FILE This parameter set the program numbers to store in the Quickcode definition X LEAD COMP 10E9 This parameter sets the X axis lead screw compensation signed parts per billion
160. BRONZE FILTER ELEMENT 7 DRAWBAR ASSY HIGH CLAMP 18 Cries SERVICE MANUAL MANUAL QTY PART 40 1610 40 16585 51 0021 51 1012 55 0020 56 0075 5 2984 092 2990 98 1627 VF Series Spindle 7 5 K AMS ESCRIP I HCS 1 4 20 X D 5 SHCS 5 BEARING B ON 6 18 X 6010 OP RNG DUPLEX MD June 1998 3 4 56MM SPCR WAVE WASHER W35118 035 SNAP RING N5000 1431 O RING 2 158 VITON O RING 2 346 BUNA 1 27 PIP PLUG 96 8100 1998 125 ASSEMBLY DRAWINGS SERVICE MANUAL MANUAL 1 32 1800 SHUTTLE MOTOR ASSEMBLY 2 52 1900 GENEVA DRIVER ASSEMBLY 32 2010 TELEMECHANIQUE SWITCH ASSEMBLY 4 32 7011 TOOL CHANGER CONDUIT ASSEMBLY 20 Pocket Tool Changer 968100 331 ASSEMBLY DRAWINGS MI eri eS june 1998 SERVICE MANUAL MANUAL 1 30 1210 LEAD SCREW ASSEMBLY 2 32 1600 MOTOR ASSEMBLY E 352 2051 TELEMECHANIQUE SWITCH ASSEMBLY 30 7526 BASE OIL LINE ASSEMBLY VF 3 Base 332
161. CABLE CONNECTIONS PLUG CABLE c TO gt 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 96 8100 G mM 249 23 CABLE LOCATIONS r eS _ june 1998 SERVICE MANUAL MANUAL Y DELTA SWITCH ASSEMBLY P N 32 5850A TO K5 AUX 1 d Ng TO 5 COIL TO K5 COIL TO SPINDLE MOTOR TO K4 COIL TO IO PCB P12 TO IO PCB P58 K5 KD 7 u K4 COIL 650B TO HAAS VECTOR DRIVE 250 O O lQRM9 0 gt v l hfflfi6 oo s lt P 968100 CABLE LOCATIONS o 5 CABLE LOCATION DIAGRAM 90A 700 740 750 760 770 VF 0 VF 1 VF 2 115V AC TO MONITOR CABLE INPUT CARD CABLE TO FRONT PANEL JOG DATA VIDEO DATA EMERGENCY STOP INPUT 800B SWITCH TO LAMP 1050 DOOR SWITCH 810 TURRET MOTOR 810A SHUTTLE MOTOR 820 TOOL CHANGER STATUS 7090 115V AC MONITOR CABLE 7700 7740 7750 7760 7770 INPUT CARD CABLE ON OFF TO FRONT PANEL JOG DATA VIDEO DATA EMERGENCY STOP
162. CHAIN 5 Remove the two screws that mount the coverplate over the sprocket located at the far end of the APC as shown 988400 98 141 MECHANICAL SERVICE 2715 J 9 June 1998 Figure 3 74 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 below 10 Re tension the chain in the reverse order 142 yf Go 100 a EM SERVICE MANUAL MANUAL 4 ELECTRICAL SERVICE 4 1 SOLENOIDS Please read this section in its entirety before attempting to replace any solenoid assem blies REMOVAL 1 Turn machine power 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 1 0 PCB SOLENOID VALVES and the plu
163. CONVEYOR TIMEOUT The amount of time in minutes the conveyor will operate without any machine motion or keyboard action After this time the conveyor will automatically shut off PALLET LOCK INPUT Used in horizontal mills only 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 orient ation position LS PER INCH The number of steps on the linear scale per inch of travel LS PER REV The number of steps between Z pulses on the linear scale 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 XLIN SCALE EN Used to enable linear scales for the X axis X INVRT LN SCL Used to invert the X axis linear scale X DSBL LS ZTST Used to disable the linear scale Z test XZERO AXIS TC Used to return axis to zero prior to tool change X 2ND HOME BTN Used to move axis to coordinate specified in Work Ofset G129 X NEG COMP DIR Used to negate the direction of thermal compensation X DELAY AXIS 0 Used with an APL to ensure X axis is zeroed before A axis of APL Y SWITCHES Parameter 267 is a collection of single bit flags used to turn servo related functions on and off
164. DRIVE BELT HTD 500 5 09 5 2 22 7520 SOLATOR TRANS 74 54 7127 DRIVE SPROCKET 375 RTAP 6 6 22 1521 SPACER TRANS 75 2 55 0055 SPRING WASHER BS 204 7 25 0107 OTOR SHROUD VMC 75 2 55 0056 SPRING WASHER 5 205 8 25 0108 FAN BRACKET MOTOR SHROUD ff 9 56 0060 SNAP RING N5100 66 9 25 7264 SWITCH MOUNTING BRACKET 78 56 0070 SNAP RING 5000 187 20 25 7536 SOLENOID MOUNTING BRACKET 79 56 2087 SNAP RING N5000 206 21 25 7433 SUMP 80 57 0001 OIL SEAL 22 25 7434 SUMP TANK 81 5 0002 OIL SEAL 25 29 0022 SHROUD CAUTION DECAL 82 5 0006 O RING 2 528 24 29 7399 TRANSMISSION LABEL 85 57 0013 V RING SEAL CR 400280 25 29 9128 LABEL TRANSMISSION 84 2 57 0058 O RING 2 014 BUNA 26 30 5150 SHIFTER ASSY 85 5 0105 QUAD RING 04 114 VITON 27 30 5146 AIR SOLENOID ASSY 86 57 7573A MOTOR GASKET 28 30 52608 OIL GEAR PUMP ASSY 87 58 16752 90 DEG COMPRESSION TILT 29 30 3270 REGULATOR ASSY 88 Tm 58 2001 POLYU HOSE 1 20D X 3 8ID 30 32 14550 CABLE 89 251 58 2020 5 8 OD NATURAL TUBING 31 32 2010 24 LIMIT SWITCH 90 58 2065 COUPLING 1 4NPT 32 32 2011 TELMECH 30 IN CABLE ASSY 91 2 58 2070 1 ANPT MALE 3 8 COMP 35 33 3200 SOLENOID BRKT CABLE ASSY 92 4 58 2100 SLEEVE LUBE ASSY 34 35 5008 GRND STRP SPNDL SHRD 95 4 58 2110 SLEEVE NUTS LUBE ASSY 35 35 7065 TRANSFER GEAR ASSY 94 58 2745 MAGNETIC OIL PLUG 36 35 7170A DRIVE SHAFT ASSY 95 58 3616 3 8 90 DEG ELBOW 1 4
165. E 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 190 5 19 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 Section 2 5 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 Inthis case there are two sources of diagnostic data these are the audible beeper and the LED s on the processor PCB If the audible beeper is alternating gt second beep there is a problem with the main control program stored in EPROM s on the processor PCB If any of the processor electronics cannot be accessed correctly the LED s on the processor PCB will or will not be lit If the machine powers up but has a fault in one of its power supplies it may not be possible to flag an alarm condition If this happens all motors will be kept off
166. E IN TO INPUT 02 D uie INPUT 03 o SHUTTLE INPUT 05 6 TOOL 1 MARKER TO RELAY GENEVA MARK TO RELAY J AN a Low TSC Y TU LOGIC GND P6 TOOL CHANGER IDPCR P14 900 1 e LOGIC 2 GND 4 M COOLANT MOTOR 230 SINGLE PHASE Li B TRATAT DPSTAT D TSC MOTOR Le A 230 VAC THREE PHASE G P7 COOLANT PUMP NOTE CONNECTORS ARE LOCATED ON SIDE OF CONTROL CABINET CABINET GONNECIORS 6 98 HAAS AUTOMATION VF SERIES AGE 16A 968100 n n c T 283 ELECTRICAL DIAGRAMS SERVICE MANUAL MANUAL 82 CURRENT LIMIT CIRCUIT BLACK WHITE 81 160V DC FU 1 E 5A ABC FUSE K W mo 6 OHM api 160VDC ov BLACK WHITE K11 W K12 6 8 Ek o4 25W 160VDC TOOL CHANGE MOTORS 6 98 HAAS AUTOMATION ize 1 284 HAAS June 1998 96 8100 1998 7
167. E OF into the spindle taper 3 Go to the HANDLE JOG mode Choose Z axis and set jog increments to 01 4 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 You will notice that the tool holder comes out of the taper ALA 221 MAINTENANCE Mi 774 1 mers SERVICE MANUAL MANUAL Mounting Bolt Locations Tool Releas Coolant Tip paper Aluminum Block aw E i Shim Washers Figure 3 Placement of aluminum block under spindle Figure 4 Coolant TSC machines only 5 The clearance from the tool holder to the block should be zero 0 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 it will cause an overcurrent in the Z axis 6 Press MDI and turn hand wheel to zero 0 Press HANDLE JOG button Jog the Z axis in the positive 4 direction 0 100 7 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 gt If block moves at 100 jog the Z axis in the negative direct
168. E X SERVO MOTOR 610 X DRIVE SIGNAL MOCON PCB P2 TB HV HV 320VDC SPINDLE DRIVE Y AXIS AMP P 580 LOW VOLTAGE L V POWER SUPPLY TBA 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 MOTOR DRIVE Z SERVO MOTOR P 630 Z DRIVE SIGNAL MOCON PCB P4 TB HV HV 320VDC SPINDLE DRIVE A AXIS P 600 LOW VOLTAGE L V POWER SUPPLY TBA B C MOTOR DRIVE A SERVO MOTOR P 640 A DRIVE SIGNAL MOCON PCB P5 TB HV HV 320VDC SPINDLE DRIVE 96 8100 AAAS 227 228 LOCATIONS MI eries SERVICE MANUAL MANUAL P20 PR1 MOVs P1 P5 5 FU1 FU3 O P13 EE 1 O AJ ui T M M P29 P28 z P12 P27 93 1085 1 4 41 P26 El 21 10A 115V 7 115 10 230 10A 115V 5 TSC Solenoids Coola
169. EMENT REMOVAL 1 Turn the machine power off 2 Move the door to the fully closed position so the window is accessible Use atrim 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 4 Remove the seal from the enclosure s cutout 126 n 96 8100 1998 MI eri 125 SERVICE SERVICE MANUAL MANUAL Opening for window Opening for Sheet Metal Locking Tab Figure 3 65 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 96 8400 05 127 MECHANICAL SERVICE E 125 r N v v U June 1998 SERVICE MANUAL IVIANUAL 3 15 HYDRAULIC COUNTERBALANCE TOOLS REQUIRED v 1 4 4 14 head support block v Hydraulic counterbalance service kit consists of e Pressure tank with manifold assembly prefilled with 2 quarts DTE 25 hydraulic oil e Hydraulic cylinder with hose attached if necessary REMOVAL CAUTION While performing this procedure the spindle head may drop if the control lose
170. H 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 function being changed All values are 0 or 1 only The function names are Reverses direction of jog handle Disables tool changer operations Disables gear box functions Stops spindle then turns the power off at EMERGENCY STOP Indicates hardware option for rigid tap Reverses sense direction of spindle encoder Selects repeatable rigid tapping Selects exact stop in moves when mode changes This enables safety hardware if machine is so equipped Selects linear deceleration for rigid tapping 0 is quadratic When enabled will detect a phase loss Enables coolant spigot control and display Selects control over temp sensor as N C Causes Skip G31 to act like Fanuc and overshoot sense point Non inverted spindle stopped status Spindle load monitor option is enabled Spindle temperature monitor option is enabled Enables rotation and scaling Enables DNC selection from MDI Enables BACKGROUND EDIT mode Enables ground fault detector Enables use of keyboard with shift functions Enables macro functions SAAS 199 Qe SERVICE MANUAL IVIANUAL INVERT SKIP Invert sense of skip to active low closed HANDLE CURSR Enable use of jog handle to move cursor NEG WORK OFS Selects use of work offsets in negative direction
171. H THE SPINDLE COOLANT To begin troubleshooting check the alarm history to determine the problem s cause before any action is 96 8100 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 0 D nylon tubing Check for coolant flowing from a failed fitting or check valve Check pre charge pressure in accordance with TSC Pressure Regulator Adjustment section and reset if necessary Low pre charge pressure can cause coolant to dump into the spindle head Ensure the coolant pump relief valve has not been tampered with yellow paint band is intact Check the coolant pump pressure should be 300 psi 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 Q Excessive coolant flow out of drain line Pulsating flow through tool and drain line Check pre charge pressure in accordance with TSC Pressure Regulator Adjustment section Reset precharge pressure if necessary Low pre charge pressure
172. IL PUMP WAY LUBE PUMP 274 HAAS June 1998 96 8100 Cries ELECTRICAL DIAGRAMS June 1998 7 SERVICE MANUAL MANUAL 4 PIN 1 1 ps TOOL SHUTTLE IN Y 12VDC PIN 2 PIN 2 LE 8 PIN 3 PIN 3 OVDC A K TOOL SHUTTLE Y b 1240 PIN 4 4 LE 10 4 PIN 5 PIN 5 i OVDC Z 2 TOOL TURRET CW 12 6 6 LE 1 4 7 7 i i V 2 TOOL TURRET CCW 12VDC PIN 8 PN 8 4 9 9 i V7 K 5 HIGH GEAR SHIFT a 12VDC PIN 10 PIN 10 LE 13 4 11 PIN 11 i V7 2 K 4 LOW GEAR SHIFT Y amp 12VDC PIN 12 PIN 12 LE 14 1 4 PIN 13 PIN 13 i I Z 7 es TOOL UNCLAMP 12VDC PIN 14 14 LE 151 J PIN 15 PIN 15 OVDC Z 2 SPINDLE LOCK 12VDC PIN 16 PIN 16 LE 161 12 2 1 1 icc 24112580 1 0 PCB NOTE A RELAY TH 3E EPLACED WITH A SOLID STATE EQUIVALEN COIL DRIVERS THROUGH K16 6 98 HAAS AUTOMATION VF SERIES 9
173. INPUTS BOARD 18 19 20 COMMON 78 COMMON SD 27 40 1 5 STOP MRS 8 402 gt TO SPINQUE ILOGK PINDLE HAAS AUTOMATION UNIT PAGE 12 278 HAAS June 1998 96 8100 1998 VI IVIANUAL Cries 15 W VOLTAGE PUWER SUPPLY 5 12 GND p POWER SUPPLY PCB 860 TO PROCESSOR 880 BOARD ASSEMBLY 860 MODULE 860 TO SWITCH SPINDLE REGEN RESISTOR HAAS R DRIVE SPINDLE MOTOR FROM MOCON BOARD P33 IOPCB BOARD HAAS AUTOMATIO VECTOR SPINDLE DRIVE UNIT PAGE 1 96 8100 AAS ELECTRICAL DIAGRAMS 279 ELECTRICAL DIAGRAMS M Cries SERVICE MANUAL MANUAL 17 PIN CONNECTOR PCB THROUGH CABLES 52 1425 32 1430A X AXIS 660 Y AXIS 670 Z AXIS 680 A AXIS 690 B AXIS 690B TO BRUSHLESS SERVO AMP
174. L MANUAL P11 SPARE P12 FLOPPY DR SIGNAL P13 VIDEO SIGNAL 760 J9 RS422 B J13 SERIAL DATA 850 INTERFACE PCB MOTIF The Motor Interface PCB provides all of the interfaces to motors and discrete inputs and outputs It contains a single pot R54 to adjust the output of the D A converter The MOTIF PCB connectors are P1 Data buss P2 X drive control and overcurrent sense P3 Y drive control and overcurrent sense P4 2 drive control and overcurrent sense 630 P5 drive control and overcurrent sense 640 P6 X axis encoder Z home and overheat 660 P7 Y axis encoder Z home and overheat 670 P8 Z axis encoder Z home and overheat 680 P9 A axis encoder Z home and overheat 690 P10 32 discrete inputs 550 P11 Relay drives 1 to 8 510 P12 Relay drives 9 to 16 520 P13 Relay drives 17 to 24 530 P14 Relay drives 25 to 32 540 P15 Power connector 5 12 P16 D to A output and 12V DC 720 P17 A to D inputs for DC buss voltage 980 P18 Jog Crank input and aux 1 2 750 P19 Address buss P20 Spindle encoder inputs 1000 P21 A to D input for spindle temperature 1020 P22 A to D input for spindle load monitor 730B P24 Home switch inputs X Y Z 990 Motor 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 th
175. L DRIVERS Kao IHROUGH 8 57 6 98 HAAS AUTOMATION VF SERIES 11 968100 6 277 ELECTRICAL DIAGRAMS Cries SERVICE MANUAL MANUAL nan 15 230 6 98 SUPPLY w VOLTAGE 860 SUPPLY sgo PROCESSOR BOARD IN 5 12 GND ASSEMBLY 860 MODULE gt gt gt IO Sen O O duo 9 00 00 00 CO 2 BRAKE UNIT 2 FOR 15HP AND MORE N L E N SPINDLE DRIVE UNIT P O SPINDLE REGEN RESISTOR 20220212 R 5 DTE SPINDLE MOTOR T PINHUTS ARE LISTED FOR MFG AS SHOWN W M ITSUBISHI MAGNE TEK SPEED COMMAND SPEED REF FORWARD oH 13 THERMAL REVERSE 80 17 OVERLOAD SPEED COMMAND 1K 13 721 TO MOCON SPEED REF 5 722 Z BOARD P16 FORWARD STF 1 71 REVERSE STR 2 712 RESET RES 4 713 COMMON E 11 714 LOAD METER LMO FM 21 73 B LOAD METER LM2 SD 22 732 210 OPERATOR PANEL SOLID STATE STOPPED RU 25 784 SP AT SPEED SU 26 785 B 2 yo
176. L RELEASE em AIR SUPPLY AIR SUPPLY AIR SUPPLY 3 TN 85 PSI 45 5V3 SOLENOID VALVE PURGE 85 PSI 2 POSITION 3 WAY SP RET lt SHUTTLE VALVE TO a DRAWBAR ASSENBLY TSC PURGE AIR TOOL CODLANT TIP LOCATION 1 REAR DF MACHINE amp COOLANT TANK ASSEMBLY LOCATION 1 REAR OF MACHINE amp CODLANT TANK ASSEMBLY HMC 2 REAR SIDE OF TRANSMISSION ASSEMBLY VNC 2 SIDE DF GEAR BOX SPINDLE MOTOR ASSEMBLY 3 ON TOOL RELEASE PISTON ASSEMBLY 3 ON TOOL RELEASE PISTON ASSEMBLY 4 TOP amp SIDE OF TRANSMISSION ASSEMBLY 4 REAR OF GEAR BOX SPINDLE MOTOR ASSEMBLY THROUGH SPINDLE COOLANT SYSTEM FLOW DIAGRAM 5 REAR INSIDE OF ENCLOSURE PAN 5 AT BOTTOM REAR OF SPINDLE HEAD THROUGH SPINDLE COOLANT 150 WARNINGS 1 5 REQUIRES TOOL HOLDER WITH THROUGH HOLE IN PULL STUD AND TOOL 1 FAILURE DO 50 CAN FLOOD SPINDLE HEAD WTH COOLANT 2 DO RUN TSC WITH LOW CODLANT LEVEL IN TANK 3 WEAR SAFETY GLASSES WHEN MANUALLY CHANGING TSC TOOLS COOLANT CAN SPRAY OUT THROUGH SPINDLE COOLANT ALARMS 1 LOW THRU SPINDLE COOLANT ALARM 1515 CAUSE COOLANT PRESSURE IN SYSTEM FELL BELOW 40 PSI 2 CHECK LOW COOLANT IN TANK 2 PRE CHARGE FAILURE ALARM 198 CAUSES B CHECK DIRT INDICATORS ON BOTH FILTERS PRESS RESET AND RUN TSC AGAIN TO PURGE AIR FROM SYSTEM TOOL RELEASE PISTON DID NOT MOVE DOWN WHEN COMMANDED OR IT MOVED UP DURING TSC OPERATION OR ANOTHER ALARM OCC
177. LE 12 REMOTE JOG HANDLE J3 750 MOCON P18 5 ONLY 37 EXTERNAL KEYBOARD J12 860C FT PANEL FAN See Keyboard Diagnostic section of this manual for Troubleshooting information 96 8100 5 233 SERVICE MANUAL MANUAL CABLE LOCATIONS 7 4 RS 422 CHIP 85232 RS 232 CHIP SHOWN FOR LOCATION ONLY WILL ONLY HAVE 1 CHIP 0000000000000000 lOOOOOOOOOOOOOOOO FLOPPY POWER P N 32 3201 A 700 KEYBOARD EC INFO SPARE O O 760 P13 9 VIDEO ADDRESS BUSS 4 DATA BUSS J5 LOW VOLTAGE 234 AY ff 968100 1998 VIDEO PLUG 96 8100 P1 J3 J4 J5 10 11 12 13 9 13 M Cries SERVICE MANUAL MANUAL CABLE LOCATIONS VIDEO amp KEYBOARD PCB W FLOPPY DRIVE P N 32 3201A CABLE CONNECTIONS CABLE 860 700 SIGNAL NAME LOW VOLTAGE KEYBOARD INFO ADDRESS BUSS DATA BUSS FLOPPY DR POWER SPARE FLOPPY DR SIGNAL VIDEO SIGNAL RS422 B SERIAL DATA Not used with Serial Keyboard Interface AHAS LOCATION POWER SUPPLY PCB KEYBOARD INT MICRO PROC PCB MOTIF PCB FLOPPY DRIVE N A FLOPPY DRIVE CRT N A N A PLUG e 235 CABLE LOCATIONS 2712 SERVICE MANUAL MANUAL VIDEO amp KEYBOARD PCB P N 32 3200 ADDRESS BUSS DATA BUSS HAAS 700 760 P13 IOO
178. LENGTHS AVOID EXCESSIVE TOOL LENGTHS 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 aloud 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 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 ADC 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 low RPM and then connected to an arm that rotates through 180 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 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 HAAS June 1998 96 8100 1998 w f
179. LIFIERS THROUGH PIN CONNECTOR 32 1425 T 32 1430 491 492 Y 493 494 B WHITE m 7 495 496 497 498 B 497B 498B T c C OTOR CHASSIS D GREEN YELLOW B AXIS OPTIONAL 6 98 E H RED 5VDC e RED WHITE LOGIC GND WHITE YELLOW A CHANNEL G WHITE BROWN B CHANNEL ORANGE C CHANNEL BLACK Z CHANNEL NOT USED YELLOW CHANNEL B BROWN WHITE ORANGE WHITE BLACK Z CHANNEL NOT USED B CHANNEL C CHANNEL A B X Y Z AXIS MOTOR amp E HAAS AUTOMATION CODE PULSE ENCO OTO DE 242 280 HAAS June 1998 96 8100 1998 7 eri eS ELECTRICAL DIAGRAMS E IVIANUAL 5 L 7 RED WHITE LOGIC GND THROUGH BROWN WHITE A CHANNEL CABLE 690 A AXIS ENCODER YELLOW WHITE B CHANNEL 690B B AXIS ENCODER B FNGLIDEK C ORANGE WHITE Z CHANNEL
180. LY 50 TAPER PART NO TITLE 20 7035G VERTICAL AXLE 20 7038A BEARING HOUSING 20 7475 ARM SLIP CLUTCH 20 7476 HUB SLIP CLUTCH 20 9008 TOOL HOLDING ARM 20 9325 32 TOOL GENEVA STAR 2 PIN 20 9326 TOOL CARRIAGE MACHINING 20 9330 32 T C HOLDING PLATE 22 2065 LOCATING PIN 22 7034 SPACER FOLLOWER 22 7106 V TRACK 22 7163 RIDER TRAP DOOR 22 7255A TOOL 1 STAND OFF 22 7263 SWITCH MOUNTING BLOCK 22 7477 PRESSURE PLATE 25 7036 CAP TOOL CHANGER 25 7162 CONNECTOR BRACKET 25 7168 DOOR OPENER BRACKET 25 9085 CONDUIT MTG PLATE 25 9329 DOOR T C COVER 25 9331 TOOL CHANGER COVER 25 9334 SHUTTLE COVER PLATE 26 7239 SPACER RING 29 7612 CT TOOLING DECAL 30 0005 GENEVA DRIVER ASSY 30 0006 CAROUSEL ASSY 32 TOOL 32 1800 SHUTTLE MOTOR ASSY 32 2010 24 LIMIT SWITCH 32 7011 CONDUIT ASSY T C 32 7611 CONDUIT ASSY TOOL CARRIAGE 40 1500 SHCS 5 16 18 x 1 40 16091 BHCS 10 32 x 1 40 1632 SHCS 1 4 20 x 1 2 40 1669 BHCS 8 32 x 3 8 40 1676 SHCS 5 16 18 x 2 40 1697 SHCS 1 4 20 x 3 4 40 1803 SHCS 8 32 x 1 1 4 40 1850 SHCS 10 32 x 3 8 40 1970 FHCS 1 4 28 x 1 40 1980 BHCS 1 4 20 x 1 2 40 2000 SHCS 1 4 20 x 5 8 43 1602 HHB 1 2 13 x 3 43 7000 HHB 5 16 18 x 1 3 4 44 1710 555 CUP PT 1 4 20 x 3 8 45 0050 WASHER 5702 313 120 45 1600 WASHER SPLIT LOCK 5 16 MED 45 1725 WASHER FLAT CUT 3 4 45 1740 WASHER BLACH HARD 1 2 AMA 301 ASSEMBLY DRAWINGS 302 ITEM
181. LY REPLACEMENT 1 2 gt 96 8100 Turn the power off and disconnect power to the machine 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 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 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 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 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 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 15 for the order of replacement Once all washers have been attached and nuts have been hand tightened tighten down completely with the socket
182. 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 e Check parameters e Check for a mechanical slip at the contact points of all components between the spindle and the spindle encoder 5 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 If sticking only occurs during these situations no service is necessary If tool is pulled out of extractors due to a tool stuck in the taper then the unclamp switch is not adjusted correctly or the switch could be bad e 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 different tooling e 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 10 96 8100 1998 se 0 Jes TROUBLESHOOTING SERVICE MANUAL
183. MANUAL MANUAL CABLE LOCATIONS V 7 74 VOLTAGE MON 0 5V SP DRIVE LOAD 980 1020 730 17 21 22 RELAYS K1 8 MOTIF INPUTS OUTPUTS OOOOOOOO OOOOOOCOO 550 P10 RELAYS 520 12 22 K9 16 OOOOOOOOOOOOOODO OOOOOOOOOOOOOOOO JOG INFO 750 P18 RELAYS 530 P13 K17 24 OOOOOOOO 660 P6 RELAYS K25 32 X ENCODER OUTPUT 540 P14 720 16 SP SPEED CMD Y ENCODER OUTPUT 670 P7 A DRIVE 640 P5 SIGNAL Z DRIVE 630 P4 SIGNAL 2 ENCODER OUTPUT 680 P8 ENCODER OUTPUT X DRIVE 610 P2 SIGNAL SP ENCODER OUTPUT HOME SENSORS 1000 P20 24 ADDRESS BUSS DATA BUSS LOW VOLTAGE 24 T s Af4 n vJ 968100 1998 96 8100 MOTIF PLUG ADDRESS amp DATA P2 P3 P4 P5 P6 P7 P8 P9 P10 P11 P12 P13 P14 P15 P16 P17 P18 P20 P21 P22 P24 CABLE 610 620 630 640 660 670 680 690 550 510 520 530 540 860 720 980 750 1000 1020 730B 990 M MOTIF PCB Cries SERVICE MANUAL MANUAL P N 32 4020 CABLE CONNECTIONS SIGNAL NAME ADDRESS BUSS DATA BUSS X DRIVE SIGNAL Y DRIVE SIGNAL Z DRIVE SIGNAL A DRIVE SIGNAL X ENCODER OUTPUT Y ENCODER OUTPUT Z ENCODER OUTPUT
184. Manual Archive Cover Page Rev June 6 2013 Haas Technical P ublications HAAS SERVICE AND OPERATOR MANUAL ARCHIVE VF Series Service Manual 96 8100 English June 1998 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 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 Mi erfes SERVICE MANUAL MANUAL TROUBLESH
185. NPT 57 36 5055 SPINDLE ASSY 96 58 3657 4 FEMALE 1 8 MALE ADPT 38 2 40 1602 FHCS 1 4 28 X 5 8 97 58 55 TOP PLATE TUBE 39 40 1628 SHCS 1 4 20 X 1 4 98 58 7358A PLATE TUBE 40 40 1830 SHCS 1 4 20 X 5 16 99 58 7577 AIR REG SOLENOID TUBE 41 2 40 1632 SHCS 1 4 20 X 1 2 00 58 7635 LOW GEAR TUBE 42 8 40 18385 SHCS 5 16 18 X 3 4 01 58 76 46 HICH GEAR TUBE 45 4 40 16413 SHCS M3 X 5 02 58 9114B FILL TUBE 44 2 40 1644 SHCS 10 32 X 1 1 2 05 59 0027 HOSE CLAMP 1 2 HOSE 45 4 40 1645 SHCS 10 32 X 5 8 04 2 59 0046 SOUNDCOAT SHROUD RT LT 46 5 40 16455 SHCS 10 32 X 7 8 05 4 59 1482 YLON FINISH PLUG 13 16 FINAL ASSEMBLY 475 4 40 1669 REMOVED BHCS 8 32 X 5 8 06 2 59 2040 CABLE CLAMP 7 16 48 4 40 1700 5 10 52 X 2 07 59 4006 HOSE CRIMP 55 64 49 1 40 1800 REMOVED a 8 32 X 3 4 08 O 5FT 59 7130 REMOVED PROTECTIVE STRIP 50 40 1850 1 2 1 1 5 4 09 60 1810 SHAFT ENCODER 2000 LINE 51 7 40 1850 SHCS 5 8 0 62 5010 SPINDLE 10 52 4 40 1981 FBHCS 1 4 20 X 1 2 1 2 63 0001 YLON CABLE CLAMP 1 2 53 3 41 1500 PPHS 8 32 X 3 8 2 635 1031 CABLE CLAMP 1 4 54 4 44 0003 555 HALF DOG 1 4 20X1 3 5 70 0020 5 CABLE TIES 4 45 0040 REMOVED WASHER BLK HARD 1 4 A325 4 3 76 2420 CRIMP RING 12 10 10 STUD 56 4 45 1600 WASHER SPLIT LOCK 5 16MED 5 77 8001 WIRE NUT IDEAL 50 076 5 1 45 1603 REMOVED WASHER SPLIT LOCK 8 MED 6 20 0125 DRIVE SPROCKET ENCODER 58 4 45 1620 WASHER SPLIT
186. NUAL MANUAL 1 2 Any time 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 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 ofthe list The CURSOR 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 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 During a self test of communications between the MOCON and main processor the main processor does not respond and is suspected to be dead Check cable connections and grounding 102 Servos Off Indicates that the servo motors are off the tool change
187. OL CHANGER ASSEMBLY 32 TOOL VF 6 10 IT QTY PART NO TITLE 1 2 20 0031 ADJ SWITCH BLOCK 2 1 20 70350 VERTICAL AXLE 3 1 20 7038A BEARING HOUSING 4 1 20 7475 ARM SLIP CLUTCH 5 1 20 7476 SLIP CLUTCH 6 1 20 9325 32 TOOL GENEVA STAR 2 PIN 7 1 20 9326 TOOL CARRIAGE MACHINING 8 1 20 9330 32 T C HOLDING PLATE 9 1 20 9834 TOOL CHANGER CLUTCH ARM 10 1 22 2065 LOCATING PIN 11 1 22 7034 SPACER CAM FOLLOWER 12 2 22 7106 V TRACK T C 13 4 22 7163 RIDER TRAP DOOR 14 1 22 7255A TOOL 1 STAND OFF 15 1 22 7477 PRESSURE PLATE 16 1 22 9805 HOLDING ARM 17 1 25 0014 BRACE 18 1 25 7036 CAP TOOL CHANGER 19 1 25 7162 CONNECTOR BRACKET 20 1 25 7168 DOOR OPENER BRACKET 21 1 25 9329 DOOR T C COVER 22 1 25 9331 TOOL CHANGER COVER 23 1 25 9334 SHUTTLE COVER PLATE 24 1 25 9912 CONDUIT MOUNTING PLATE VF 6C 25 2 26 7239 SPACER RING 26 1 29 7612 CT TOOLING DECAL 27 1 30 0005 GENEVA DRIVER ASSY 28 1 30 0006 CAROUSEL ASSY 32 TOOL 29 1 32 1800 SHUTTLE MOTOR ASSY 30 2 32 2013 TELMECH 44 CABLE ASS Y 31 1 32 7012B MOLDED ATC CABLE ASSY 32 1 32 7611 CONDUIT ASSY TOOL CARRIAGE 33 6 40 1500 SHCS 5 16 18 X 1 34 1 40 16091 BHCS 10 32 x 1 35 8 40 1632 SHCS 1 4 20 x 1 2 36 6 40 1669 BHCS 8 32 x 3 8 37 6 40 1676 SHCS 5 16 18 x 2 38 10 40 1697 SHCS 1 4 20 x 3 4 39 8 40 1800 SHCS 8 32 X 3 4 LG 40 4 40 1830 HHB 1 2 13 x 1 3 4 41 12 40 1850 SHCS 10 32 x 3 8 42 4 40 1970 FHCS 1 4 28 x 1 43 8 40 198
188. OOOOOOOOOOOOOO IOOOOOOOOOOOOOOOO KEYBOARD INFO VIDEO LOW VOLTAGE June 1998 96 8100 U Cries CABLE LOCATIONS 23 SERVICE IVIANUAL VIDEO amp KEYBOARD PCB P N 32 3200 CABLE CONNECTIONS VIDEO PLUG CABLE SIGNAL NAME c TO gt LOCATION PLUG ADDRESS amp ADDRESS BUSS MICRO PROC PCB DATA DATA BUSS MOTIF PCB 1 860 LOW VOLTAGE POWER SUPPLY PCB P13 760 VIDEO SIGNAL CRT P4 700 KEYBOARD INFO KEYBOARD INT 96 8100 AHAS 237 r TES SERVICE MANUAL MANUAL CABLE LOCATIONS M VCTR DRV CUR VOLTAGE MON 0 5V SP DRIVE LOAD HOME SENSORS MOCON INPUTS RELAYS K1 8 K17 24 510 11 530 P13 OOOOOOOO OOOOOOOO OOOOOOOO OOOOOOOO OOOOOOOO OOOOOOOO 00000000 OOOOOOOO D1 520 P12 540 P14 RELAYS RELAYS K9 16 K25 32 D2 RELAYS 1 0 o 298 24 990 00000000000000 OOOOOOOOOOOOOO 550 P10 Er JOG INFO 17 640 21 980 P22 730B 750 P18 SP ENCODER INPUT 1000 P20 720 16 X ENCODER 660 P6 640C P33 640B P32 Y ENCODER INPUT 670 P7 7 ENCODER INPUT 680 P8 MOCON PCB P N 32 4023G 630 P4 A ENCODER INPUT 690 P9 620 P3 B ENCODER INPUT 690 B P30 610 P2 C ENCODER INPUT 690 C P31 ADDRESS BUSS P19 238 AHAS June 1998 SP LOAD METER VCTR DR CUR CMD B DRIVE SIGNAL A DRIVE
189. OOTING 96 8100 COMMON ABBREVIATIONS USED IN HAAS MACHINES E Stop FHCS FT FU FWD LO CLNT LOW AIR PR LVPS MCD RLY BRD MDI MEM M FIN MM MOCON MOTIF MSG NC Alternating Current Ampere Automatic Pallet Changer Automatic Parts Loader American Standard Code for Information Interchange Automatic Tool Changer Automatic Tool Change Forward Automatic Tool Changer Reverse Button Head Cap Screw Circuit Breaker Cubic Centimeter Counter Clock Wise Computerized Numeric Control Concurrent Spindle with axis motion Cyclic Redundancy Check Digit Cathode Ray Tube Clock Wise Draw Bar Direct Current Diagnostic Directory Direct Numerical Control Enable Conveyor End Of Block End Of File Erasable Programmable Read Only Memory Emergency Stop Flat Head Cap Screw Foot Fuse Forward Gauge Hex Head Bolts Horse Power Horizontal Series Of Machining Centers Inside Diameter Inch Input Output Printed Circuit Board Pound Light Emitting Diode Low Coolant Low Air Pressure Low Voltage Power Supply M Code Relay Board Manual Data Input Memory M Code Finished Millimeter Motor Control Motor Interface Message Numerical Control HAAS 83 TROUBLESHOOTING PSI PWM RAM REPT RIG TAP RET REV CNVR RJH RPDBDN RPDBUP RPM S SDIST SFM SHCS SI0 SKBIF SP T TG TIR TNC TRP TS TSC VF VF E VMC V 1 je
190. PCB is illuminated when a tool change takes place gt Ifthe LED lights check the fuse 5 on the POWER PCB or FU1 on the 1 0 PCB Otherwise replace the I O PCB Electrical Service gt the LED does not light check cables 1 0 1 510 and 1 0 2 520 96 8100 YY ffi 6 21 43 V 727 gt SERVICE MANUAL IVIANUAL Q ATC turret will not rotate turret motor is getting power e Command tool change feel for power being applied to the turret motor e f 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 Q ATC turret will not rotate turret motor is not getting power e Command a tool change feel for power being applied to the turret motor e Check that the TC CW TC CCW LED on the 1 0 PCB is illuminated when a tool change takes place gt Ifthe LED lights check the fuse FU5 on the POWER PCB FU1 on the 1 0 PCB Otherwise replace the 1 0 PCB Electrical Service gt If the LED does not light check cables 1 0 1 510 and 1 0 2 520 1 5 GEARBOX AND SPINDLE MOTOR The gearbox cannot be serviced in the field and must be replaced
191. 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 casting 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 carousel 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 Trap Door REPLACEMENT Note If the 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 under the center of the carousel 4 Loosen the nutinside the carriage casting that attaches the carousel assembly to the casting There is a socket head the top of the shaft to hold it stationary while loosening the nut
192. 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 Servo Driver amp 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 at least the red CHARGE light on the servo drive assembly goes out before beginning any work inside the electrical cabinet SDIST BOARD 4 Note Refer to Cable Locations for diagram of this board Disconnectall leads to the Servo Distribution SDIST board Ensure all cables are clearly marked for reconnecting later ELECTRICAL SERVICE 7 7 0 eS June4i998 SERVICE MANUAL MANUAL 156 7 Note The connectio
193. RIVE 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 10 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 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 180 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 successio
194. RO 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 KEYBOARD BEEPER There is a speaker inside the control panel that is used as an audible response to pressing keyboard buttons and as a warning beeper The beeper is a one 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 speaker Check that the problem occurs with more than one button and check that the speaker volume is not turned down 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 AII three boards of the processor assembly receive power from the low voltage power supply The three PCB s are interconnected by a local buss on dual 50 pin connectors At p
195. S MI eri eS june 1998 SERVICE MANUAL MANUAL 1 350 1100 LEAD SCREW ASSEMBLY F 50 7524 BASE OIL LINE ASSEMBLY 5 52 1600 AXIS MOTOR ASSEMBLY 4 52 2050 TELEMECHANIQUE SWITCH ASSEMBLY VF 1 Base 312 96 8100 eres _ ASSEMBLY DRAWINGS SERVICE MANUAL MANUAL VIEW B WITHOUT 20 7005 QUT OF POSITION SO OO LEA EAD SCREW ASSEMBLY 2 30 17525 COLUMN OIL LINE ASSEMBLY Qe aa 2040 TEL SWITCH ASSEMBLY EMECHANIQUE VF 1 Column 96 8100 5 313 ASSEMBLY DRAWINGS MI eri eS y SERVICE MANUAL IVIANUAL 1 520 1100 LEAD SCREW ASSEMBLY 2 50 7523 SADDLE OIL LINE ASSEMBLY 5 32 1400 X AXIS MOTOR 52 2050 ELEMECHANIQU VF 1 Saddle 34 2 55 5 EMBLY WITCH ASS EMBLY June 1998 96 8100 MI 7 70 SERVICE MANUAL MANU SERVICE MANUAL BALL SCREW 1
196. SEE TABLE 1 EC MLE _ ___ DIT T4 15 SNAP LOCK RING BMPR B SEE TABLE BALL SCREW ROTATED 50 1100 BALL SCREW ASSEMBLY 32mm ITEM QTY PART NO TITLE 1 1 20 7009 BEARING HOUSING 2 1 20 7010A MOTOR MOUNTING 3 1 350 1221 BALL SCREW SUPP BRNG ASSY 4 B 40 0008 SHCS 1 2 20 X 3 4 5 2 51 2012 BEARING LOCKNUT 6 1 51 2025 BEARING FAFNIR RADIAL 304PP 7 1 51 2025 PLUG BALL SCREW ASS Y BALL SCREW SNAP LOCK RING BMPR B APPLICATION 30 1100 BS ASS Y 32mm 1 26 X 25 650 24 7146 BALLSCR 32mm 1 26 X 25 650 HL 5 6 VF 1 2 0 X 30 0116 BS ASS Y 32mm 1 26 X 33 268 24 9013 BALLSCR 32mm 1 26 X 33 268 20 0142 SNAP LOCK RING BMPR 8 00 HL 1 2 2 30 0117 BS ASS 32mm 26 X 48 228 24 9012 32mm 26 X 48 228 20 0145 SNAP LOCK RING BMPR 7 00 HL 3 4 Z 30 0118 BS ASS Y 32mm 1 28 X 25 650 24 0118 BALLSCR 32mm 1 26 X 25 650 20 0141 SNAP LOCK RING BMPR 4 00 HL 5 6 X 30 11104 BS ASS Y 32mm 1 26 X 35 650 24 7147 BALLSCR 32mm 1 26 X 35 650 VF 2 OEB X 30 1200A BS ASS Y 32mm 1 26 X 48 228 24 9012 BALLSCR 32mm 1 26 X 48 228 VF 3 2 30 1210A BS ASS Y 32mm 26 X 33 268 24 9013 BALLSCR 32mm 26 X 33 268 HS 1 1R 1RP 2RP VF 3 4 Y 7 N 30 1295 BS ASS Y 32mm 26 X 16 475 24 8765 BALLSCR 32mm 26 X 16 475 3 4 X 30 1290A BS ASS Y 32mm
197. SIGNAL Z DRIVE SIGNAL Y DRIVE SIGNAL X DRIVE SIGNAL LOW VOLTAGE 96 8100 1998 PLUG CABLE P1 P2 P3 P4 P5 P32 P6 P7 P8 P9 P30 P10 P11 P12 P13 P14 P15 P16 P17 P18 P19 P20 P21 P22 P24 P33 96 8100 610 620 630 640 640B 660 670 680 690 690B 550 510 520 530 540 860 720 640 750 1000 980 730B 990 640 Cries MI SERVICE MANUAL MOCON PCB P N 32 4023 CABLE CONNECTIONS SIGNAL NAME DATA BUSS X DRIVE SIGNAL Y DRIVE SIGNAL Z DRIVE SIGNAL A DRIVE SIGNAL B DRIVE SIGNAL X ENCODER INPUT Y ENCODER INPUT Z ENCODER INPUT A ENCODER INPUT B ENCODER INPUT MOTIF INPUTS 1 0 OUTPUTS 1 0 RELAYS 1 8 1 0 RELAYS 9 16 1 0 RELAYS 17 24 1 0 RELAYS 25 32 LOW VOLTAGE SP LOAD METER VCTR CR CUR CMDS JOG INFO ADDRESS BUSS SP ENCODER OUTPUT VOLTAGE MONITOR SP DRIVE LOAD HOME SENSORS VCTR DR CUR CMD AAAS D LOCATION VIDEO PCB MICRO PROC PCB X SERVO DRIVE AMP Y SERVO DRIVE AMP Z SERVO DRIVE AMP A SERVO DRIVE B SERVO DRIVE X ENCODER Y ENCODER Z ENCODER A ENCODER B ENCODER 1 0 PCB I O I O I O I O POWER SUPPLY PCB LOAD METER SPINDLE DRIVE JOG HANDLE VIDEO PCB MICRO PROC PCB SPINDLE ENCODER N A SPINDLE DRIVE X Y amp Z LIMIT SPINDLE DRIVE CABLE LOCATIONS PLUG P4 P1 P2 P51 n 239 SERVICE
198. SPINDLE HOUSING 9 4 40 1610 SHCS 1 4 20 X 1 2 1 20 7018L SPINDLE SHAFT 10 6 40 16585 SHCS 5 16 18 X 3 4 5 1 20 7022C SPINDLE CAP TAPERED 11 1 51 1002 LT ANG CONT DUPLEX 4 1 20 7442C OIL INJECTION COVER 12 1 51 1012 BRNG DUPLEX LT 36MM SPCR 5 1 20 7530 LOCK 60MM BEARING 13 1 56 0075 SNAP RING 5000 151 6 1 20 7532 LOCK 50MM ANG CNTACT BRNG 14 1 57 2984 O RING 2 158 VITON 7 1 200 7839 28 PULLEY MOD 15 1 5 2990 O RING 2 548 BUNA 8 1 30 3410D DRAWBAR ASSY HIGH CLAMP 16 1 58 1627 1 8 27 PIPE PLUG 96 8100 ASSEMBLY DRAWINGS 11 lt 338 QIY 16 9 7 40 5050 SPINDLE ASSEMBLY 10K TSCHP CARD DESCRIP TIO ITEM QT 20 7016B SPINDLE HOUSING 0 20 70181 SPINDLE SHAFT 1 20 7022C SPINDLE CAP TAPERED 2 20 7375 1 7 8 PULLEY 20 7442C INJECTION COVER 4 20 7530 LOCK 60 BEARING 5 20 7532 LOCK 50 ANG 6 24 4200 BRONZE FILTER ELEMENT 7 30 3415F DRAWBAR ASSY HC TSCHP CARB 18 AMS Cries SERVICE MANUAL MANUAL June 1998 Y PART DESCRIP TION 0 1610 5 1 4 20 1 6 40 16385 SHCS 5 16 18 X 3 4 2 44 1698 555 1 2 13 3 4 1 514 1002 LT ANG CONT DUPLEX 1 51 1012 BRNG DUPLEX LT 36MM SPCR 1 56 0075 SNAP RING 5000 131 157 2984 2 158 1 257 2990 2 348 BUNA 1 58 16527 1 8 27 PLUG 9
199. Switch section and replace if necessary Check LO CLNT bit in the diagnostics display 0 pressure on 1 pressure off Leaking pressure switches can also give intermittent alarms e 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 e Another alarm generated during TSC operation can cause this alarm 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 e Check the filtration system and that the coolant is not contaminated e Check pre charge pressure refer to the TSC Pressure Regulator Adjustment section Heavy wear will occur if this pressure is too high e Main air supply below 85 psi can cause excessive pre charge 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 war ranty Notify HAAS Service Dept if machine is being used for this application Q 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 4
200. TO CHIP CONVEYOR MOTOR 5 SHIELD 141 PHASE 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 170AUTO 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 3 FLOPPY DISK DRIVE 40 PINS 220 SERVO BRAKE 115VAC 2 SHIELD 221 115VAC COMMON 222 115VAC SWITCHED 223 SHIELD DRAIN 2305 th AXIS BRAKE 240 SPARE INPUTS FROM IOPCB P25 250 SPARE OUTPUTS FROM IOPCB P45 260K210 CABLING FOR EC 270K111 CABLING FOR EC AAAS June 1998 96 8100 C Mi 96 8100 SERVICE MANUAL MANUAL 280 RED GREEN STATUS LIGHT WIRING 3 SHIELD 281 RED LAMP 115 282 GREEN LAMP 115VAC 283 COMMON 115VAC 284 SHIELD DRAIN 300 115 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 390115VAC TO 4 AXIS BR
201. TROLLER BOARD SAME AS 610 1 THRU 610 10 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 651 652 653 654 650A 651A 652A 653A 654A 650B 651B 652B 653B 654B LEG 1 OF 230VAC LEG 2 LEG 3 SHIELD DRAIN THREE PHASE POWER TO SPINDLE MOTOR 3 SHIELD LEG 1 OF 230VAC LEG 2 LEG 3 SHIELD DRAIN THREE PHASE POWER TO SPINDLE MOTOR 3 SHIELD LEG 1 OF 230VAC LEG 2 LEG 3 SHIELD DRAIN 660 X ENCODER CABLE ALL 24 660 1 660 2 660 3 660 4 660 5 660 6 660 7 660 8 660 9 660 10 660 11 660 12 660 13 LOGIC RETURN D GROUND ENCODER A CHANNEL ENCODER B CHANNEL 5 VDC ENCODER Z CHANNEL OR C HOME LIMIT SW OVERHEAT SWITCH ENCODER A ENCODER B ENCODER Z OR C X HALL A NOT USED X HALL B NOT USED X HALL C NOT USED 96 8100 C Mi EH ESS 7 0 ouo 96 8100 SERVICE MANUAL IVIANUAL 660 14 X D 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 6900 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 710 FORWARD
202. UND o Y SWITCH Y HOME D Io Z SWITCH E r LOGIC GROUND LOW LUBE LEVEL TO INPUT 13 H LOW LUBE PRESSURE SWITCH Z HOME 15 VAC lt XM WAY LUBE PUMP LOGIC G LOGIC GROUND SPINDLE COOLING SOLENOID P5 0 HOME SENSORS DOOR LUBE SHUTTLE MOTOR TO RELAY K9 A TO RELAT B INPUT 01 C 7 SHUTTLE IN TH INPUT 02 p p INPUT 03 o SHUTTLE TH INPUT 05 G TOOL 1 MARKER TO RELAY TO RELAY Ki2 J AN TURRET 1 P6 TOOL CHANGER im P14 900 1 LOW TSC 2 LOGIC 3 GND 4 5 4 16 1998 282 HAAS 96 8100 June 1998 J v lt WL Ores ELECTRICAL DIAGRAMS gt TO MOCON P24 HOMES x HOME B O X HOME SWITCH peec erue 0 0 Y HOME SWITCH Y HOME D 0 0 Z HOME SWITCH E ft LOGIC GROUND 2 LOW LUBE LEVEL TO INPUT 13 H ro LOW LUBE PRESSURE SWITCH Z HOME lt XM WAY LUBE PUMP MDTDR LOGIC GND LOGIC GROUND SPINDLE COOLING SOLENOID VF 0 ONLY HOME SENSORS DOOR LUBE SHUTTLE MOTOR TO RELAY K9 A TO RELAT Kid B L INPUT 01 C o SHUTTL
203. URED DURING TSC OPERATION A CHECK FOR LOW AIR SUPPLY PRESSURE CHECK FOR T R P FAILURE THROUGH SPINDLE COOLANT TSC MAINTENANCE SCHEDULE TOP OFF COOLANT TANK DAILY EVERY 8 HOUR SHIFT DURING HEAVY TSC USAGE 2 CHECK GAGE 02 ON 100 MICRON FILTER WITH TSC SYSTEM RUNNING AND TOOL IN SPINDLE CHANGE ELEMENT WHEN THE INDIGATOR REACHES THE RED ZONE USE 100 MICRON FILTER ELEMENT 58 6045 OR CONMERCIALLY AVAILABLE EQUIVALENT 3 CLEAN PUMP INTAKE FILTER WHEN INDICATOR 01 IS IN RED ZONE RESET WITH BUTTON SPECIAL INSTRUCTIONS AFTER CHANGING OR CLEANING FILTER ELEMENTS RUN TSC SYSTEM WITH NO TOOL IN SPINDLE FOR AT LEAST ONE MINUTE TO PURGE ADJUSTABLE TSC PARAMETER PARAMETER 237 TSC CLNT LINE PURGE MINIMUM DEFAULT VALUE 15 2500 MAXIMUM LIMIT THE TSC PUMP IS A PRECISION GEAR PU PRESSURE IF ABRASIVE WARNING P AND WILL WEAR OUT FASTER A PARTICLES ARE PRESENT IN THE COOLANT D 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 THE 100 MESH SUCTION FILTER CONTACT HAAS FOR RECOMMENDATIONS MACHINING OF CERAMICS AND THE LIKE VOIDS ALL WARRANTY CLAIMS FOR WEAR AND 15 DONE ENTIRELY AT CUTOMER S RIS INCREASED MAINTENANCE SCHEDULES ARE ABSOLUTELY REQUIRED WITH ABRASIVE SWARF CLEANED OF SEDIMENT ON
204. VICE MI 125 1998 SERVICE MANUAL IVIANUAL 138 3 18 AUTOMATIC PALLET PALLET REPLACEMENT TOOLS REQUIRED v Hoist v Straps or Chains v Eyebolts 2 CAUTION Be careful when changing out pallets each 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 reciever 1 Remove the old pallet from the APC using the supplied eyebolts and a hoist 2 Set 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 overtight 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 Alignment pins Receiver 2 pins in opposite corners bolts Clamping Receiver Wiper 7 Alignment bushing 2 Figure 3 71 Pallet Replacement ATA 5 n 968100 1998 125 SERVICE SERVICE MANUAL MANUAL IMPORTANT New pallets should be machined on the VMC in order for them to be p
205. WN HANDLE ZERO LIST EDIT J0G RET 20 AUTO SINGLE 0001 SELECT 21 INSERT BLOCK COOLNT 1 AXES PROG amp DRY ORIENT 22 ALTER RUN SPNDLE 7 4 1 CANCEL ZERO e OPT ATC 01 SINGL 23 DELETE STOP FWD 10 AXES RS232 8 SPACE BLOCK ATC 01 HOME ERASE PERIOD 24 DELETE REV 100 628 PR0G 3 WRITE KEYBOARD GRID The following is an example of how to troubleshoot the keypad Note Keypad Diodes 1 24 correspond to chart numbers 1 24 Example 1 Pressing the RESET button will cause diodes 1 and 17 to conduct e With the POWER OFF read across diode 1 e Atypical 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 e If your reading was 486 and it dropped to 460 for a difference of 026 the diode is good e 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 e Press and hold RESET The meter should read a short 0 ohms if not the keypad is bad AHAS 7 r TROUBLESHOOTING SERVICE MANUAL MANUAL 1 2 3 4 5 6 T 8 9 10 11 eg fafej POSIT DGNOS Y 33 B V SERVICE MANUAL 34 96 8100 SERVICE MA
206. Y y 30 00664 SPINDLE ASSEMBLY S1 PRESSURE SWITCH DRAWBAR RETRACT TOOL REREASE 52 40 PSI d SVI SOLENOID VALVE TOOL RELEASE aja SV 2 POSITION 4 WAY SP RET ExH in SV2 SOLENOID VALVE PURGE 2 POSITION 3 WAY SP RET odo VI COOLANT CHECK VALVE PER Y V PURGE CHECK VALVE SUPPLY V3 SHUTTLE VALVE 85 PSI THROUGH SPINDLE COOLANT SYSTEM SCHEMATIC LOCATION 7 REAR OF MACHINE 8 COOLANT TANK 2 SIDE OF SPINDLE MOTOR 50 TAPER SPINDLE OPTION 5 OF SPINDLE MOTOR THROUGH SPINDLE COOLANT TSC WARNINGS THROUGH SPINDLE COOLANT TSC MAINTENANCE SCHEDULE 1 TSC REQUIRES TOOL HOLDER WITH HOLE THROUGH PULL STUD AND TOOL 1 TOP OFF COOLANT TANK BEFORE EACH SHIFT DURING HEAVY TSC USAGE FAILURE TO USE PROPER TOOLING CAN DAMAGE PUMP 2 CHECK GAGE 62 ON TSC FILTER WITH NO TOOL IN SPINDLE AND TSC RUNNING CHANGE 2 DO NOT RUN TSC WTH LOW COOLANT LEVEL IN TANK ELEMENT WHEN THE INDICATOR IS IN THE YELLOW ZONE USE 20 MICRON FILTER ELEMENT 58 6046 OR COMMERCIALLY AVAILABLE EQUIVALENT 3 CLEAN INTAKE FILTER WHEN SUCTION GAGE 61 IS IN THE RED ZONE 5 WEAR SAFETY GLASSES WHEN MANUALLY CHANGING TSC TOOLS COOLANT CAN SPRAY OUT THROUGH SPINDLE COOLANT ALARMS 1 LOW THRU SPINDLE COOLANT ALARM 151 SPECIAL INSTRUCTIONS AFTER CHANGING OR CLEANING FILTER ELEMENTS RUN TSC SYSTEM CAUSE COOLANT PRESSURE IN SYSTEM FELL
207. ad 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 e The self test of the MOCON has failed Replace the MOCON DISCONNECT CABLES FROM A NORMAL OPERATING SYSTEM lt gt Remove low voltage cable from the Video amp Keyboard PCB e Processors LED s are normal e Runs fine and the CRT is Normal e No keypad beep lt Remove low voltage cable from the MOTIF PCB e Processors LED s are normal then RUN goes out e No screen Remove the Data amp or Address buss from the Video amp Keyboard PCB e Processors LED s Normal then Run goes out lt Remove the Data amp or Address buss from the MOTIF PCB e Processors LED s Normal then Run goes out lt Remove the Data amp or Address buss from the Micro Processor PCB e Processors LED s CRT and Run are out 1 13 KEvBoARnp DiAGNosric Note Refer to the Cable Locations section of this manual for a drawing of the Key board Interface PCB 32 96 8100 1998 96 8100 12 13 PRGRM ALARM CLNT CLNT AUX 14 CONVRS MESGS UP DOWN CLNT SHIFT L X 15 POWER UP TOOL J0G 50 16 RESTART F3 RELEASE 2 LOCK Zz 10 10 RAPID B NEXT 25 17 RESET TOOL A X Y 100 100 STOP RAPID TOOL OFSET CHIP CHIP CHIP 5 18 MESUR FWD STOP REV cw RAPID CURNT PAGE PAGE 19 COMDS HELP UP DO
208. 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 T Reconnect all leads to all boards at this time Ensure the red and black leads go to the appropriate connections 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 large flat screwdriver loosen the three screws the cabinet door and then open the door enough to safely work on the electrical panel 4 Disconnect all leads to the Input Output board and move aside for removal Ensure all cables are properly labeled for reconnecting later The following illustration shows all cable numbers and the locations on the 1 0 board 5 968100 1998 96 8100 7 JE enr dens SERVICE MANUAL MANUAL 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 Replace the 1 0 board attaching it to the cabinet with the twelve screws previously removed Reconnect all leads to the 1 0 board at
209. 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 e 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 the handle You will notice the vibration more at individual clicks than when you are turning the handle faster This is normal Th
210. ame value This alarm is generated if the mill is in Inverse Time Feed mode and a G12 G13 G70 G71 672 6150 or any Group 9 motion command is issued Cutter compensation has been cancelled without exit move Potential damage to part There are too many non movement blocks between motions when cutter comp is being used Remove some intervening blocks In a block with G103 Block Lookahead Limit a value between 0 and 15 must be used for the P code Aux B C U V or W axis indicate servo off Check auxiliary axes Status from control was OFF A ZERO RET has not been done yet on the aux axes Check auxiliary axes Status from control was LOSS Aux axes not responding Check auxiliary axes and RS 232 connections Mismatch between machine and aux axes position Check aux axes and interfaces Make sure no manual inputs occur to aux axes Aux axes are attempting to travel past their limits Aux axes are disabled Can only move one auxiliary axis at a time Check your geometry Check Parameter 57 Not a normal condition for VF Series CNC Mill Check Parameter 57 Not a normal condition for VF Series CNC Mill Tool life limit was reached To continue reset the usage count in the Current Commands display and press RESET Override is off and program tried to turn on coolant Only rapid or feed is allowed with aux axes G01 cannot be done with tool size Tool too big to enter cut HAAS 47
211. and SERIAL PORT 2 SERIAL PORT 1 being the upper connection VIDEO amp KEYBOARD SERIAL PCB KEYBOARD INTERFACE P1 PCB MICRO PROCESSOR ____ PORTI Serial interface replaces cable 700 with cable 7008 Figure 4 14 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 158 ALIAS 968100 1998 JE enr dens SERVICE IVIANUAL 4 5 PANEL Please read this section in its entirety before attempting to replace any component of control panel CRT AssEMB
212. and Casting Nut Housing Figure 3 48 Y axis lead screw and components 5 Remove the motor in accordance with Y Axis Motor Removal 36 8100 F T Cf ffli6 F 101 MECHANICAL SERVICE E 125 une 1998 SERVICE MANUAL MANUAL 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 gt Loosen the six 14 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 gt Remove the five SHCS attaching the ball nut to the nut housing gt 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 gt 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 gt Loose
213. 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 3 2 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 96 8100 A af fff G 65 MECHANICAL SERVICE 125 January 1998 SERVICE MANUAL MANUAL within tolerance continue if not sweep must be readjusted Note Drive belt tension must be adjusted af
214. atus inputs 820 P14 Low TSC 900 P15 Spindle head status inputs 890 P16 Emergency stop input 770 P17 Low Lube input 960 P18 Over Voltage Input 970 P19 Low Air Input 950 P20 Overheat input 830 P21 Spindle drive status inputs 780 P22 M FIN input 100 P23 Remote Unclamp input tool release 190 P24 Spare 2 790 P25 Spare 3 200 P26 Spare terminals for M21 to M24 P27 Door lock 1040 P28 115V AC from CB4 910 P29 A axis brake solenoid output 390 P30 Tool changer shuttle motor output 810A P31 230 VAC for Chip Conveyor 160 P33 115V AC three phase input from power supply assembly 90 P34 115V AC to CRT 90A P35 115V AC to heat exchanger 90B P36 115V AC to 90C P37 115V AC spare 870 P38 Door open 1050 HAAS 96 8100 1998 fi TECHNICAL REFERENCE SERVICE MANUAL MANUAL P39 Tool changer turret motor output 810 P40 770A A B P43 Ground fault sense signal input 1060 Axis Brake P44 5TH axis brake 319 P45 HTC Shuttle P46 Chip Conveyor 140 P47 Skip input signal 1070 P48 spare 1 P49 spare 2 P50 Spigot Motor 200 P51 16 PIN Relay drivers 17 24 530 P52 spare 1 P53 Spigot Sense 180 P54 Servo Brake 350 P55 Red green lights 280 P56 Thru spindle coolant pump 940A P57 115V spare P58 115V spare 5 7 TWO SPEED GEAR TRANSMISSION The spindle head contains a two speed gear transmission The spindle motor
215. aux axis When 1 the commands to the conveyor motor are reversed so that forward becomes reverse Ifthe conveyor is wired incorrectly this bit can be set so that the conveyor runs in the proper direction Reserved for future use For Lathe only When enabled spindle encoder input is to the Y axis Reverses the direction of the chip conveyor Usually the chip conveyor motor and direction relays are attached to the user relays M21 and M22 When this bitis set the control expects to see the conveyor hooked up to M27 and M28 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 00 M01 M02 M30 feedhold or single block state then the beacon will flash 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 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 HAAS PARAMETERS 5 N 209 4 210 em PARAMETERS N CLNT IN DSC INP PR RMT TOOLS RLS FLOPPY ENABL TCR KEYPAD MCD RLY BRD TSC ENABLE AUX JOG ALISM PRGRST DSBL JOG TST AIR DR M24 UNDEFINED RDY Y160 SPNDL NOWAIT Parameter
216. be separately turned on and off using M codes M51 M53 and M61 M63 M51 to M53 will turn on one of the relays and M61 to M63 will turn the relays off M51 and M61 correspond to M21 etc Note If the M code relay board is installed 51 58 will turn on the relays and M61 M68 will turn off the relays M51 and M61 correspond to M21 etc on the M code relay board WIRING THE RELAYS relays are marked on both the IOPCB and the M code relay board with their respective terminals forward of them If the optional M code 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 figures below and the Probe Option figure in the Electrical Diagrams section for the terminal labeling Maximum voltage for the relays is 125 VAC with a maximum amperage of 3 amps WARNING Power circuits and inductive loads must have snubber protection M21 M22 M23 M24 IOPCB Relays M Code Relay Board CAUTION If a screw terminal is already in use DO NOT connect anything else to it Call you dealer Relay M24 on the IOPCB is reserved for Through the Spindle Coolant AUXCLT AVA 5 968100 1998 MI 8 TECHNICAL REFERENCE SERVICE IVIANUAL 5 16 LUBRICATION SYSTEM The lubrication system is a resistance type system which forces oil through metering units at each of the 16 lubrica
217. be turned off and the spindle tool changer and coolant pump will stop If this condition remains for 4 5 minutes an automatic shutdown will begin Air pressure dropped below 80 PSI for a period defined by Parameter 76 The Low Air alarm will appear on the screen as soon as the pressure gets low and this alarm appears after Parameter 76 has elapsed Check your incoming air pressure for least 100 PSI and ensure that the regulator is set at 85 PSI HAAS 96 8100 1998 96 8100 121 122 123 124 125 126 127 129 130 131 132 Low Lube or Low Pressure Regen Overheat Spindle Drive Fault Low Battery Shuttle fault Gear Fault No Turret Mark M Fin Fault Tool Unclamped Tool Not Clamped Power Down Failure Way lube is low or empty there is lube pressure or too high 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 The control internal temperature is above 150 degrees F This can be caused by almost anything in the control overheating But is usually caused by overheat of the two regen resistors for servos and spindle drive This alarm will also turn off the servos spindle drive coolant pump and tool changer One common cause of this overheat condition is an input line voltage too high If this condition remains for 4
218. cation 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 Check Through the Spindle Coolant TSC filters Clean or replace element if needed Check automatic dump air line s water trap for proper operation 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 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 Check air filter at top of spindle motor Clean exterior surfaces with mild cleaner DO NOT use solvents Check the hydraulic counterbalance pressure according to the machine s specifications Check oil level in gear box For 40 taper spindles Remove inspection cover beneath spindle head Add oil slowly from top until oil begins dripping from overflow tube at bottom of sump tank For 50 taper spindles Check oil level in sightglass Add from side of gearbox if necessary Inspect way covers for proper operation and lubricate with light oil if necessary Dump the oil drain bucket Place a dab of grease on the outside edge of the guide rails of the tool
219. ccurs If the spindle is turning it is commanded to stop Pause until spindle is stopped Gear change spindle speed is commanded forward Pause until spindle is at speed Command high or low gear solenoid active Pause until in new gear or reversal time Alarm and stop if max gear change time elapsed If not in new gear reverse spindle direction Turn off high and low gear solenoids 1 Co erm NES 5 8 CONTROL PANEL June 1998 176 The JOG handle is actually 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 SwiTcHEs The POWER ON switch engages the main contactor 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 The Load meter measures the load on the spindle motor a
220. change something you will incorrectly install it or break something else in the process Consider for a moment changing the processor s board First you have to download all parameters remove a dozen connectors replace the board reconnect and reload and if you make one mistake or bend one tiny pin it WON T WORK You always need to consider the risk of accidentally damaging the machine anytime you work on it Itis cheap insurance to double check a suspect part before physically changing it The less work you do on the machine the better 96 8100 HAI T 3 43 727 o 2 SERVICE MANUAL IVIANUAL 1 1 GENERAL MACHINE OPERATION Macuine Nor RUNNING Machine cannot be powered e 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 Replace IOPCB see Electrical Service Replace POWER PCB see Electrical Service lt Machine can be powered on but turns off by itself e Check settings 1 and 72 for Auto Off Timer or Off at M30 Check alarm history for OVERVOLTAGE or OVERHEAT shutdo
221. chine 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 An overheat condition persisted for 4 5 minutes and caused an automatic shutdown An overvoltage condition persisted for 4 5 minutes and caused an automatic shutdown Software Error Call your dealer Spindle coolant oil is low or low pressure condition in lines The APC pallet changer 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 Cable from X axis encoder does not have valid differential signals Same as 182 Same as 182 Same as 182 Status from spindle drive indicates it is not at speed when expected Same as 103 5 96 8100 1998 96 8100 188 189 190 191 192 193 194 195 196 197 198 199 201 202 203 204 205 206 207 208 209 210 211 212 Overload Motor Overheat B Motor Z Fault B Limit Switch B Axis Z Ch Missing B Axis Drive Fault B Zero Ret Margin Too Small B Cable Fault Coolant Spigot Failure 100 Hours Unpaid Bill Precharge Failure Negative RPM Parameter CRC Error Setting CRC Error Lead Screw CRC Error Offset CRC Error Programs CRC Error Internal Program Error Queue Advance Error Queue Allocation
222. contacts the drawbar and the shim is held in place For the VF 0 wedge a large flat tip screwdriver under the cooling fins of the motor and push the piston down IMPORTANT Use extreme care when performing this procedure on TSC equipped machines or the pipe fitting will break off the top of the TRP shaft gt If machine is equipped with the macros option set macro variable 1120 to 1 This will energize the pre charge solenoid bringing the TRP in contact with the drawbar no prying is necessary Press RESET to de energize the solenoid 8 While the tool release piston is down move the switch bracket all the way in and check for Tool Unclmp status on the CRT DB OPN 0 DB CLS 0 and tighten the bracket bolts If not move the switch out until Tool status appears on the CRT and then tighten the bolts 7 968100 January 1998 V f MECHANICAL SERVICE SERVICE MANUAL MANUAL 9 Check the switch several times This is done by by moving the piston up and down to ensure that the Tool Unclmp status appears when the piston makes contact with the shim and drawbar and does not appear when it is in the retracted position Tool Unclmp status appears on the CRT display as DB OPN 0 CLS 0 Figure 5 5 Push piston down to hold shim in place
223. d point toward the rear of the machine Note The drain line must run straight through the cable clamp guide on the transmis sion and must not interfere with the pulley or belts On VF O OE machines the drain line must go straight down through the cable clamp on the bracket 58 968100 January 1998 V eS MECHANICAL SERVICE SERVICE MANUAL MANUAL 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 10 Replace the head covers 2 3 SETTING PRE CHARGE Note This procedure does not apply to machines equipped with a 50 taper spindle 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 Adjust ment section section 16 1 and perform those adjustments 1 Remove the cover panels in accordance with Head Covers Removal and Installation It will not be necessary to remove the rear or left side panels for this operation 2 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 pre charge regulator the adjustment knob is out as far as it will turn Figure 2 3 Air pr
224. 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 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 Inserta TSC type tool holder with a small TSC drill or restrictor in the spindle CAUTION Changing 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
225. e 8000000 x 0 0375 300000 steps second For an 8192 line encoder and 6 mm screw this would be 60 x 300000 138718 130 inches minute SERVO AMPLIFIERS The brushless servo amplifier is PWM based current source The PWM outputs control the current three phase brushless motor The PWM frequency is 16 KHz The amplifiers are current limited to 30 amps peak 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 and over temperature and over heat protection There is a 10 amp supply fuse for failure protection This fuse is relatively slow therefore it can handle the 30 amp peak Actual continues current limit to the motor is controlled by software Commands to the amplifier are 5 volts current in two legs of the motor and a digital enable signal A signal from the amplifier indicates drive fault or sustained high current in stalled motor The connectors on the amplifiers are H V 320 volts DC H V 320 volts return A motor lead phase A B motor lead phase B C motor lead phase J1 Three pin Molex connector used for 12 and GND J2 Eight pin Molex connector used for input signals 96 8100 ffi5s5 ell cc 173 TECHNICAL REFERENCE SERVICE MANUAL
226. e 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 22 96 8100 1998 se 0 Jes TROUBLESHOOTING SERVICE MANUAL MANUAL Pause until spindle is at speed Command high or low gear solenoid active Pause until in new gear or reversal time If not in new gear reverse spindle direction 4 5 6 7 Alarm and stop if max gear change time elapsed 8 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 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 Alarm 179 Low Pressure Transmission has been triggered Check for low oil supply in reservoir Check see that pump motor is running Check for an air leak in the suction side of the pump Check for bad pressure sensor Check broken or damaged cable Check for a worn pump head 1 6 THROUG
227. e It is in units of 1 50 seconds SPINDLE REV TIME Time in milliseconds to reverse spindle motor SPINDLE DECEL DELAY Time in milliseconds to decelerate spindle motor SPINDLE ACC DECEL Accel decel time constant in steps ms ms for spindle motor X PHASE OFFSET The motor phase offset for X motor This is arbitrary units Y PHASE OFFSET See Parameter 121 for description Z PHASE OFFSET See Parameter 121 for description A PHASE OFFSET See Parameter 121 for description 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 Y GRID OFFSET See Parameter 125 for description SAS 203 WM f _ SERVICE MANUAL IVIANUAL 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 THERMAL
228. e 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 AAAS 43 veoussesnoorne V 727 gt ms 96 8100 se June 1998 L n ssP gt TROUBLESHOOTING SERVICE MANUAL MANUAL 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 powered 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 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 Q 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 e Check the orientation of the machine ATC will not run
229. e 3 37 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 90 9 96 8100 1998 erles MECHANICAL SERVICE SERVICE MANUAL MANUAL INSTALLATION 1 Slide motor into motor housing inserting the end of the lead screw in the motor coupling Coupling Halves Front View Flex Plates Figure 3 38 Motor coupling components 2 Reinstall and tighten down the four SHCS that hold the motor to the housing 3 Visually inspect the coupler flex plates to ensure they are parallel to the coupling halves 96 8100 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 the leadscrew or motor shaft Tighten the SHCS on the motor coupling atthe lead screw Place a drop of blue Loctite on the screw before inserting 4 Replace the cover plate and fasten with the f
230. e 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 14 20 x 1 14 20 x 34 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 v v v v v Tighten the clamp nut hand tight on the motor end Install and tighten clamp nut on bearing support Ensure the nut 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 tigh
231. e 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 2 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 ATA 5 968100 1998 er 125 TECHNICAL REFERENCE SERVICE MANUAL MANUAL 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
232. e all programs to floppy disk delete all then reload Possible corrupted program Save all programs to floppy disk delete all then reload Check for a low battery and low battery alarm AAS 41 m ALARMS cI 42 213 214 215 217 218 219 220 221 222 223 224 225 226 227 228 229 231 232 233 234 235 236 237 240 241 242 Program RAM CRC Error No of Programs Changed Free Memory PTR Changed X Axis Phasing Error Y Axis Phasing Error Z Axis Phasing Error A Axis Phasing Error B Axis Phasing Error Axis Phasing Error Door Lock Failure X Transition Fault Y Transition Fault Z Transition Fault A Transition Fault B Transition Fault Transition Fault Jog Handle Transition Fault Spindle Transition Fault Jog Handle Cable Fault Spindle Enc Cable Fault Spindle Z Fault Spindle Motor Overload Spindle Following Error Empty Prog Invalid Code No End eres SERVICE MANUAL MANUAL June 1998 Electronics fault Call your dealer Indicates that the number of programs disagrees with the internal variable that keeps count of the loaded programs Call your dealer Indicates the amount of memory used by the programs counted in the system disagrees with the variable that points to free memory Call your dealer Error occurred in phasing initialization of brushless motor This can be caused by
233. e 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 72 SHCS and remove the clamp nut the lead screw in the motor housing 11 For 32 mm lead screws gt Loosen the six 4 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 gt Loosen the SHCS that mount the bearing support to the saddle and remove Remove the pull pins from the bearing support gt Loosen the five SHCS in the ball nut and remove the lead screw by pulling from the bearing support end 98 9 96 8100 1998 125 MECHANICAL SERVICE SERVICE MANUAL MANUAL 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 ar
234. e 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 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 REV ENCODER Used to reverse the direction of encoder data REV POWER Used to reverse direction of power to motor REV PHASING Used to reverse motor phasing DISABLED Used to disable any axis Z CH ONLY With A only indicates that no home switch AIR BRAKE With A only indicates that air brake is used DISABLEZ T Disables encoder Z test for testing only SERVO HIST Graph of servo error for diagnostics only INV HOME SW Inverted home switch N C switch INV Z CH Inverted Z channel normally high CIRC WRAP Future Option Not Yet Implemented With A only causes 360 wrap to return to 0 NO I IN BRAK With A only removes I feedback when brake is active LOW PASS 1X Adds 1 term to low pass filter LOW PASS 2 Adds two terms to low pass filter OVER TEMP NC Sel
235. e 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 10 3 taking not to make contact with the screw threads which will cause possible damage Motor Housing Nut Housing Ball Nut Lead Screw Support Casting Figure 3 46 Install lead screw from right side 4 1140 or 50 mm lead screw gt 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 gt Insertthe 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 gt Skip to Step 8 5 Place the bearing sleeve in the motor housing as shown It may be necessary to align the bearings in the sleeve to facilitate mounting on the lead screw 9 810 gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt 5 99 MECHANICAL SERVICE Mi r 125 une 1998 SERVICE MANUAL MANUAL Bearing Sleeve Figure 3 47 Bearing sleeve mounting location 6 Insert the six 14 20 x 1 SHCS attaching the bearing sleeve to the motor housing Plac
236. e 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 96 8100 June 1998 fg 7 TROUBLESHOOTING SERVICE MANUAL IMIANUAL 96 8100 1 9 LINEAR SCALES Perform the Linear Scale Alignment Check if any of the linear scale alarms 279 290 are received LINEAR SCALE ALIGNMENT CHECK Note This procedure is only accurate if the machine is square 1 Remove the right side way cover for the X axis to gain access to it s linear scale Remove the front way cover for the Y axis to gain access to it s linear scale 2 Access to the Z axis linear scale is from the top of the machine Removal of the head cover may be necessary 3 Tap the encoder head lightly and note any position change indicated by the control If there is any change ensure that the encoder head encoder bracket fasteners are tight 4 f problems persist check for correct gaps at each end of travel by inserting tools T 1548 and T 1549 into their respective gaps as shown in Figure 1 4 These tools must fit without having to force them If
237. e 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 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 7 0 96 8100 January 1998 eS MECHANICAL SERVICE SERVICE MANUAL MANUAL 96 8100 4 3 REPLACEMENT REMOVAL 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 5 Reinstall the tool release piston 6 Remove the tool holder from the spindle 7 Remove the spindle as described earlier in this section 8 Remove the drawbar from the spindle assembly INSTALLATION 9 Thoroughly coat the replacement drawbar with grease including the end of the shaft where the four holding balls are located 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
238. e machine vibrates excessively in a cut e 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 Accuracy Before you complain of an accuracy problem please make sure you follow these simple do s and don ts e 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 e Don t ever use a wiggler test indicator for linear dimensions They measure in an arc and have sine cosine errors over larger distances e Don t use magnetic bases as accurate test stops The high accel decel of the axis can cause them to move Don t attach magnetic base to the shee
239. e main processor receiving servo commands and closing the servo loop around the servo motors 610 620 KE aS wa wa 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 1 Buss 2 X amplifier control and fault sensing 610 P3 Y amplifier control and fault sensing 620 P4 Z amplifier control and fault sensing 630 P5 A amplifier control and fault sensing 640 P32 Bamplifier control and fault sensing 6408 P33 Camplifier control and fault sensing 640C P6 X encoder input 660 96 8100 6 179 TECHNICAL REFERENCE V er 125 SERVICE MANUAL IVIANUAL P7 Y encoder input 670 P8 Z encoder input 680 P9 A encoder input 690 P30 Bencoder input 6908 P31 encoder input 6900 P18 Jog encoder input 750 P20 Spindle encoder input 1000 P10 Inputs from 1 0 board 550 P11 1 0 relays K1 8 510 P12 1 0 relays 9 16 520 P13 1 0 relays K17 24 530 P14 1 0 relays K25 32 540 P15 Low Voltage Power 860 P16 Spindle command output 720 P19 Address bus P24 Axis home switches 990 June 1998 5 10 SPINDLE D
240. e 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 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 72 968100 January 1998 V eS MECHANICAL SERVICE SERVICE MANUAL MANUAL 5 TOOL CLAMP UNCLAMP SWITCH ADJUSTMENT Please read this section in its entirety before adjusting clamp unclamp switches or setting drawbar height TOOLS REQUIRED v Machined aluminum block 2 x 4 x 4 v 6 flexible ruler or 020 shim v 1 diameter pipe approx 1 long Note If machine is equipped with a 50 Taper spindle skip to Section 5 5 5 1 CLAMP UNCLAMP SWITCH ApJUSTMENT INITIAL PREPARATION 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 appr
241. e 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 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 itinto 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 Priorto 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 performed the travel limits will operate unless an axis hits the limit switch When the limit switch is hit the zero returned condition is reset and an AUTO ALL AXES must be don
242. ebolts 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 7 Position the receiver back onto the table 8 Install the six mounting bolts 140 968100 1998 eri 125 MECHANICAL SERVICE SERVICE MANUAL MANUAL 9 Reconnect the air to the machine 10 Postion a pallet onto thte 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 was been removed from the VMC any tooling on the pallets must be re aligned Drive REPLACEMENT Note Ifthe 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 loosene in order to remove the entire drive pin assembly 1 Power off the machine 2 Remove the drive pin retaining clip Figure 3 73 Drive Pin Assembly 3 Remove 1 4 washer 4 The cam follower is lightly pressed onto the pin The spacer should slide off easily LOOSENING THE
243. ection Tool holders spin at all pockets of the ATC when the ATC shuttle retracts e 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 Tool holders spin only at certain pockets of the ATC when the ATC shuttle retracts e 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 of the ATC is usually a result of operator error 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 e 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 the ATC 18 96 8100 se
244. ections 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 atthe 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 and remove the cover plate 13 Loosen the SHCS on the motor coupling at the lead screw 14 On the motor housing loosen the SHCS and remove the motor from the housing aaa 96 8100 1998 eri 125 MECHANICAL SERVICE SERVICE MANUAL MANUAL 3 8 16 x 3 4 SHCS 2 Hose Barb Shop Air Air Filter Regulator Bijur Lubricator Figure 3 40 Lube Air Panel 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 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
245. ects a normally closed overheat sensor in motor CABLE TEST Enables test of encoder signals and cabling Z TEST HIST History plot of Z channel test data 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 X HI INVIS AXIS Used to create an invisible axis ROT ALM LMSW Rotary alarms at the limit switch ROT TRVL LIM Rotary travel limits are used UNDEFINED UNDEFINED UNDEFINED TORQUE ONLY For HAAS only 3 EREV MREV For HAAS only 2 EREV MREV For HAAS only NON MUX PHAS Not currently used 96 8100 _ 195 MP SERVICE MANUAL IVIANUAL BRUSH MOTOR Enables the brushless motor option LINEAR DISPL This bit changes the display from degrees to inches or millimeters on the A and B axes SCALE X LO With SCALE X HI bit determines the scale factor used in bit SCALE FACT X 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 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 Parameter 6
246. ed 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 1 0 assembly the drawbar assembly or in the wiring 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 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 AAS 37 m ALARMS cI 133 134 135 136 137 138 139 140 141 142 143 144 145 146 147 148 149 150 38 M Spindle Locked Tool Clamp Fault X Motor Over Heat Y Motor Over Heat Z Motor Over Heat A Motor Over Heat X Motor Z Fault Y Motor Z Fault Z Motor Z Fault A Motor Z Fault Spindle Not Locked Time out Call Your Dealer X Limit Switch Y Limit Switch Z Limit Switch A Limit Switch Spindle Turning Z and Tool Interlocked eres SERVICE MANUAL Shot pin did not release This is detected when spindle motion is commanded Check the solenoid that controls the air to the lock relay 2 8 the wiring to the sense switch and the switch When UNCLAMPING the tool did not release from
247. ed 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 C LIN SCALE EN Used to enable linear scales for the C axis C INVRT LN SCL Used to invert the C axis linear scale C DSBL LS ZTST Used to disable the linear scale Z test C ZERO AXIS TC Used to return axis to zero prior to tool change C 2ND HOME BTN Used to move axis to coordinate specified in Work Offset 0129 C DELAY AXIS 0 Used with an APL to ensure C axis is zeroed before A axis of APL AAG 968100 1998 96 8100 M Parameter 272 Parameter 273 Parameter 274 Parameter 278 INVERT G B DPR SERIAL CK PALLET IN CK HIDN VAR DISPLAY ACT TSC PRG ENBL RESERVED SPND DRV LCK RESERVED CNCR SPINDLE RESERVED HAAS VECT DR I JEES PARAMETERS GS X THERM 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 Y THERM 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 Z THERM 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 COMMON SWITCH 3 Parameter 278 is a collection of general purpose single bit flags used to turn some functions on and off This bit w
248. edicated 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 software is version 9 xx 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 HAAS 96 8100 1998 er 125 TECHNICAL REFERENCE SERVICE MANUAL MANUAL SERVO CHARACTERISTICS Servo characterstics are explained in detail in the previous chapter The following is an example of how to achieve 130 inches minute The exponential accel decel time constant is set by Parameters 113 114 115 116 and 168 It has units of 0 0001 seconds The speed limit at which exponential accel decel is not available is defined by the relationship between Parameters 7 and 113 for the X axis Thus if Parameter 7 is 8000000 steps sec sec and Parameter 113 is 375 0 0375 seconds the maximum velocity for accurate interpolation should b
249. el 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 1 Reconnect all cables to the Serial KBIF board at their proper locations 4 6 SPINDLE ENCODER REPLACEMENT 96 8100 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 Mechanical Service 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 replaceme
250. elerations 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 66 96 8100 January 1998 V eS MECHANICAL SERVICE SERVICE MANUAL MANUAL Outer Tube 2 7 Belt Tension Tool Figure 3 3 Belt tension tool 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 Mount it to the head casting by inserting 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 see Figure 3 3 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 stil
251. em PARAMETERS N 202 Parameter Parameter Parameter Parameter Parameter Parameter Parameter Parameter Parameter Parameter Parameter Parameter Parameter Parameter Parameter Parameter Parameter Parameter Parameter Parameter Parameter Parameter Parameter Parameter Parameter Parameter Parameter Parameter Parameter 102 103 104 105 106 107 108 109 V Cries SERVICE MANUAL MANUAL M MACRO CALL 09000 M code that will call 09000 Zero causes no call M MACRO CALL 09001 same as 81 M MACRO CALL 09002 same as 81 M MACRO CALL 09003 same as 81 M MACRO CALL 09004 same as 81 M MACRO CALL 09005 same as 81 M MACRO CALL 09006 same as 81 M MACRO CALL 09007 same as 81 M MACRO CALL 09008 same as 81 M MACRO CALL 09009 same as 81 G MACRO CALL 09010 G code that will call 09010 Zero causes no call G MACRO CALL 09011 same as 91 G MACRO CALL 09012 same as 91 G MACRO CALL 09013 same as 91 G MACRO CALL 09014 same as 91 G MACRO CALL 09015 same as 91 G MACRO CALL 09016 same as 91 G MACRO CALL 09017 same as 91 G MACRO CALL 09018 same as 91 G MACRO CALL 09019 same as 91 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 IN POSITION LIMIT Y Same definition as Parameter 101 IN POSITION LIMIT Z Same definition as Parameter 101 IN POSITION LIMIT A Same definition as
252. emove 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 6 Push the help button twice This will put the machine in the calculator mode 96 8100 January 1998 7 7 0 eS MECHANICAL SERVICE SERVICE MANUAL MANUAL HELP JOG 00001 100000 k NO SOLUTION YET 0 0000 205 ANGLE3 ANGLE1 MACHINE ANGLE2 X 0 0000 in ANGLE3 SIDE 2 SIDE 1 if 7 0 0000 in SIDE1 2 1 0 000 deg SIDE2 ANGLE 1 ANGLE 2 U 0 000 deg SIDE3 F3 COPIES CALCULATOR VALUE TO HIGHLIGHTED ENTRY IN OTHER DISPLAYS F3 COPIES CALCULATOR VALUE TO DATA ENTRY LINE F4 COPIES OR OPERATES HIGHLIGHTED DATA TO CALCULATOR WRITE ENTERS DATA TO HIGHLIGHTED DISPLAY JOGGING Z AXIS HANDLE 01 2 Figure 7 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 f
253. enoids 4th axis brake and the oiler Itis never expected to trip If it does trip itis likely caused by a short circuit in the wiring on the 1 0 assembly or the wiring to the solenoids on the spindle head 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 Power Up Low CoNTRoL TRANSFORMER 5 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 5 13 POWER TRANSFORMER ASSEMBLY T1 The power transformer assembly is used to convert three phase 354 488V to three phase 230V and 115V and is primarily used by the servo drives The video monitor solenoids fans and oiler also use 115V AC This transformer s maximum input voltage is 440V 60 Hertz and 240V Q 50 Hertz Itis located in the main cabinet in the lower right corner It is rated at 12KVA and its primary is protected to the figures listed in the preceding table This transformer has five high voltage connections that allow for a range of inputs from 354V to 488V The transformer has a 230 volt secondary to supply three phase to the spindle drives HIGH VOLT LOW VOLT 78 7 r INPUT TERMINALS FROM CONTACTOR K1 r INPUT TERMINALS FROM CONT
254. ent 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 Accuracy BACKLASH Accuracy complaints are usually related to tooling programming or fixturing problems Eliminate these possibilities before working on the machine lt Poor mill table positioning accuracy Check for loose encoder 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 Check parameters for that axis Check for backlash in the lead screw as outlined below 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 12 Set up a dial indicator and base on the mill table as shown in Fig 1 1 AAAS June 1998 96 8100 se June 1998 n T U 125 TROUBLESHOOTING SERVICE MANUAL MANUAL
255. ent pins are out of the receiver body check the depth of the hole Depth should be 510 to 550 Sticking Pallet e Check for chips around the alignment pins or pallet clamp rail bushings e 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 lt responding to controller commands e fthe APC does not run but the mill does check the APC control cable e Make sure the E Stop jumper is removed and that the APC control cable is plugged into the 5th axis port tightly 28 96 8100 SERVICE MANUAL MANU SERVICE MANUAL June 1988 Recovery from E Stop initiated during pallet change Trouble Shooting an E Stop or Power Outage Condition with a Pallet in transition between the Receiver and the APC Is Power on Was power off after E Stop Power up NO YES Do not Zero Return auto axes Do not Zero single axis Do not Jog or otherwise move the X and Y axes Is the receiver Unclamped T T YES NO With power and air supply on have an assistant manually actuate the solenoids move ioa known location Run M17 to o
256. er Carousel Assembly CT 96 8100 AMAG 30 ASSEMBLY DRAWINGS MI eri eS luune 1998 SERVICE MANUAL MANUAL IN 0 N 6X7 BALLSCREW SEE TABLE 50 0018 BALLSCREW ASS Y 40mm PART NO TITLE iR 1 20 0146 SNAP LOCK RING BMPR 2 1 20 0148 SNAP LOCK RING BMPR 43 1 20 0151 MOTOR MOUNT 40 50mm BS MACH 4 1 20 0152 BEARING HOUSING 40 50mm BS MACH 5 1 20 9213 SPACER RING 40mm BALL SCREW 6 1 40 1222 BALL SCREW SUPPORT BEARING ASSY 6 40 1715 SHCS 5 16 18 x t 1 2 8 4 51 0007 BEARING DEEP GROOVE 9 2 51 0008 BEARING LOCKNUT 06 BALL SCREW ASS Y BALL SCREW A APPLICATION 30 0018A BS ASS Y 40mm 1 57 X 71 935 24 9961 8 BALLSCR 40mm 1 57 x 71 935 VF 6 8 X 30 0053 BS ASS Y 40mm 1 57 X 57 897 24 0003 BALLSCR 40mm 1 57 X 57 897 HL 5 6 Z 30 1212A BS ASS Y 40mm 1 57 X 47 711 24 99608 BALLSCR 40mm 1 57 X 47 711 W l Y 7 30 1211 BS ASS Y 40mm 1 57 X 90 859 24 9970B BALLSCR 40mm 1 57 90 859 VF 7 9 X 30 0303 BS ASS Y 40mm 1 57 X 57 897 24 0003 BALLSCR 40mm 1 57 X 5
257. er speeds and in low gear If there is no gear box in your machine VF 0 E OE 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 ORIENTATION 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 On machines equipped with a Haas vector drive 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 LUBRICATION The spindle orientation mechanism does not require regular lubrication SPINDLE ORIENTATION SOLENOID WITH SHOT A solenoid controls the air valve supplying pressure to the
258. eroed before A axis of APL 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 ALIN SCALE EN Used to enable linear scales for the A axis AINVRT LN SCL Used to invert the A axis linear scale A DSBL LS ZTST Used to disable the linear scale Z test A ZERO AXIS TC Used to return axis to zero prior to tool change A 2ND HOME BTN Used to move axis to coordinate specified in Work OPffset 6129 A DELAY AXIS 0 Used with an APL to ensure axis is zeroed before A axis of APL 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 B LIN SCALE EN Used to enable linear scales for the B axis INVRT LN SCL Used to invert the B axis linear scale B DSBL LS ZTST Used to disable the linear scale Z test B ZERO AXIS TC Used to return axis to zero prior to tool change 2ND HOME BTN Used to move axis to coordinate specified in Work Offset 0129 B DELAY AXIS 0 Used with an APL to ensure B axis is zeroed before A axis of APL 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 equipp
259. erpendicular to spindle PaALLET CLAMP REPLACEMENT TOOLS REQUIRED v Strapsor Chains v Eyeholts 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 72 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 968100 fy ff nT P 139 MECHANICAL SERVICE E 125 P No _ June 1998 SERVICE MANUAL MANUAL ALIGNMENT Pin REPLACEMENT TOOLS REQUIRED v Hoist v Chains v Eyebolts 2 CAUTION Be careful when changing out pallets each weighs approx 300lbs Note The receiver must 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 Alignment Bushing Alignment Pin Figure 18 3 Alignment Pin Removal 3 Remove the six 6 receiver mounting bolts 4 Use a hoist and the two ey
260. es CNC Mill same as 333 same as 333 An attempt was made to program the A axis while it was disabled DISABLED bit in Parameter 43 set to 1 Subprogram is not in memory or P code is incorrect There is a problem with circle definition check your geometry Only one M X Y Z A Q etc allowed in any block or two G codes in the same group Select cutter compensation earlier Cutter comp must begin on a linear move Disable cutter comp later Geometry not possible Check your geometry A block exists that is too long for displaying queue Shorten title block Cutter comp only allowed in XY plane G17 Parameters 5 and 19 must be same value Parameters 5 and 33 must be same value 5 96 8100 1998 96 8100 347 348 349 350 352 353 354 355 356 357 358 359 360 362 363 364 367 368 Diff Step Ratio On G19 Plane Motion Not Allowed In 693 Mode Prog Stop W 0 Cancel Cutter Comp Cutter Comp Look Ahead Error Invalid P Code Aux Axis Power Aux Axis No Home Aux Axis Disconnected Aux Axis Position Mismatch Aux Axis Travel Limit Aux Axis Disabled Multiple Aux Axis Invalid 1 4 or K In 612 613 Tool Changer Disabled Gear Change Disabled Tool Usage Alarm Coolant Locked Off No Circ Interp Aux Axis Cutter Comp Interference Groove Too Small erles SERVICE MANUAL MANUAL Parameters 19 and 33 must s
261. es 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 The compensation time constant is on the order of 20 to 50 minutes to lose half of the heat in the screw 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 Thus a real time clock is required for this compensation to work if the machine is turned off for less than 2 hours AHAS June 1998 96 8100 1998 96 8100 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 WEEKLY MONTHLY SIX MONTHS ANNUALLY gt gt Check coolant level every eight hour shift especially during heavy TSC usage Check way lube lubri
262. ess 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 direction one increment atatime 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 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 Shim Washers section 1 To add or subtract shim washers remove tool release piston assembly Tool Release Piston section from head casting 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 Mounting Bolt Locations Tool Releas Coolant Tip Shim Washers Figure 5 2 Tool release piston assembly TSC shown 7434 968100 January 1998 V eS MECHANICAL SERVICE SERVICE MANUAL MANUAL 2 Remove tool release bolt If machine is
263. essure regulator adjustment knob 3 Ensure Parameter 149 PRE CHARGE DELAY is set to 300 If not set it at this time 4 Execute a tool change A banging noise will be heard as the tool release piston contacts the drawbar 5 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 96 8100 ff l O F DA T 0 0 gt 59 MECHANICAL SERVICE 125 1998 SERVICE MANUAL MANUAL CAUTION Only increase the pressure to the point where tool changes become obviously quiet Any further pressure increases are not beneficial Excessive pressure to the pre charge system will cause damage to the tool changer and tooling in the machine 2 4 TRP Remova 50 TAPER 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 proceeding 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
264. eter Parameter Parameter Parameter Parameter Parameter Parameter Parameter Parameter Parameter Parameter Parameter Parameter Parameter 144 145 146 147 148 149 150 151 152 153 154 155 156 157 158 159 160 161 162 SERVICE MANUAL MANUAL Wi a2eries RIG FINISH DIST This parameter sets the finish tolerance for determining the end point of a rigid tapping operation Units are encoder counts X ACCEL FEED FORWARD Y ACCEL FEED FORWARD Z ACCEL FEED FORWARD A ACCEL FEED FORWARD These parameters set the feed forward gain for the axis servo They have no units PRE CHARGE DELAY This parameter sets the delay time from pre charge to tool release Units are milliseconds MAX SP RPM LOW GEAR Max spindle RPM in low gear B SWITCHES See Parameter 1 for description B P GAIN See Parameter 2 for description B D GAIN See Parameter 3 for description GAIN See Parameter 4 for description RATIO STEPS UNIT See Parameter 5 for description BMAX TRAVEL STEPS See Parameter 6 for description B ACCELERATION See Parameter 7 for description B MAX SPEED See Parameter 8 for description MAX ERROR See Parameter 9 for description B FUSE LEVEL See Parameter 10 for description B BACK EMF See Parameter 11 for description B STEPS REVOLUTION See Parameter 12 for description SAAS
265. fitting can help 96 8100 6 17 43 V 727 gt ms SERVICE MANUAL MANUAL During a tool change appears to be pulled up no popping noises e Check the adjustment of the Z offset Setting Parameter 64 section Note If the offset is incorrect a tool changer crash has occurred and a thorough inspection of the ATC is necessary at this time e Ensure the roller bolts on the shuttle of the are tight against the V guides on the holding the lower right roller bolt is loose against the V guide the upper right bolt is probably bent See the following section Crashing or Roller Bolt Replacement for roller bolt replacement Note Bent roller bolts are a symptom of another problem with the ATC Repair the bent roller bolt and then isolate the ATC problem e Check Parameter 71 against the values that are in the documentation sent with the machine e 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 lt Tool holders twist against extractor fork during a tool change e Check the alignment of the ATC in the X and Y axes Automatic Tool Changer Alignment s
266. flection During tool change appears to down e Check to see if pull studs on the tool holder are correct and tight e Check the adjustment of the Z offset Setting Parameter 64 Note the offset is incorrect tool changer crash has occured and a thorough inspection of the ATC is necessary at this time e 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 e Ensure the tool holders are held firmly in place by the extractor forks e 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 a 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 e Check Drawbar height adjustment e f 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 If sticking occurs only during these circumstances n
267. g Arm Slip Clutch Assembly Extactor Key Figure 3 57 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 Puta 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 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 carousel and slide the spring into position in the slot in the ATC carousel 4 Put the replacement slidi
268. g marked SPARE Low Air Pressure Air Solenoid H K Y e CU Sensor Assembly BN Disconnect all Air Lines Disconnect all AirLlines Figure 4 1 Air solenoid assembly 7 Remove the SHCS holding the assembly to the bracket and remove the assembly 96 8100 143 ELECTRICAL SERVICE eri eS 1998 SERVICE MANUAL MANUAL 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 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 Mechanical Service 3 Remove air supply from machine 4 Remove the tool release piston assembly Mechanical Service 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 3
269. gram Between and 96 there was no program found Check Your Program An ASCII EOF code was found in the input data before program receive was complete This is a decimal code 26 AAS 49 m ALARMS 50 413 414 415 416 417 418 419 420 429 430 431 432 433 434 435 436 501 502 VI RS 232 Load Insufficient Memory RS 232 Buffer Overflow RS 232 Overrun RS 232 Parity Error RS 232 Framing Error RS 232 Break Invalid Function For DNC Program Number Mismatch Flpy Dir Insufficient Memory Floppy Unexpected End of Input Floppy No Prog Name Floppy Illegal Prog Name Floppy Empty Prog Name Floppy Load Insufficient Memory Floppy Abort Floppy File Not Found Too Many Assignments In One Block Or Not First Term In Expressn Cries SERVICE MANUAL MANUAL Program received doesn t fit Check the space available in the LIST PROG mode and possibly delete some programs Data sent too fast to CNC This alarm is not normally possible as this control can keep up with even 38400 bits per second Data sent too fast to CNC This alarm is not normally possible as this control can keep up with as much as 38400 bits per second Data received by CNC has bad parity Check parity settings number of data bits and speed Also check your wiring Data received was garbled and proper framing bits were not found One or more characters of the
270. h S1 1 must be ON to auto start the CNC operational program If 51 1 is OFF the PGM light will remain off Switch 52 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 Serial port 1 for upload download DNC 850 J5 Serial port 2 for auxiliary 5th axis 850A J3 Power connector 46 Battery Memory RETENTION BATTERY The memory retention battery is initially soldered into the processor PCB This is 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 VipEo 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 this board There is a single jumper on this board used to select inverse video The video PCB connectors are 1 LOW VOLTAGE POWER SUPPLY 860 p3 KEYBOARD INFO 700 P4 ADDRESS BUSS P5 DATA BUSS P10 FLOPPY DR POWER ATA 5 F M 9658100 1998 er j _____ TECHNICAL REFERENCE SERVICE MANUA
271. hard stop by hand Pallet Number Conflict Receiver and Pallet Changer The incorrect pallet number is entered in macro variable 510 M50 to reset this variable Pallet 1 did not return from the receiver to the APC in the allowable amount of time This can be caused by the chain switch block missing the limit switch or from another mechanical problem such as clutch slippage Pallet Z2 did not return from the receiver to the APC in the allowable amount of time This can be caused by the chain switch block missing the limit switch or another mechanical problem such as clutch slip page The automatic door did not open in the allowable time when necessary to perform an APC function This can be caused by a bad air solenoid a blocked or kinked air line or a mechanical problem 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 HAAS 53 2 12 SERVICE MANUAL MANUAL 1010 Missing Pallet Receiver Pallet change sequence was halted because receiver switch was not activated Pallet is either unclamped or not on the receiver Ensure the pallet is correctly located on receiver against hardstop then run M18 to clamp the pallet 1011 Unknown Chain Location Neither Chain Location switch is tripped so the control cannot locate the chain
272. he AUTOFEED feature can use and should initially be set to 1 LEAD SCREW COMPENSATION Separate lead screw compensation is provided for each of the X Y and Z axes The operator entered compensation values are spaced at 0 5 inch intervals within the machine coordinate system The compen sation 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 T HERMAL 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 Haas new 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 do
273. he 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 SETTING THE OFFSET 1 Set the grid offsetto zero Parameter 125 126 127 128 170 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 968100 ff 6 123 MECHANICAL SERVICE 125 n Y Y June 1998 SERVICE MANUAL IVIANUAL 3 14 ENCLOSURE REPLACEMENT Please read this section in its entirety before attempting to replace the doors or windows TOOLS REQUIRED v 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
274. he nylon washer goes on top of the shims 2 Installation is the reverse order of removal 3 Setthe main air regulator to 85 psi Note The following two steps must be completed 2 6 Our ADJUSTMENT 1 Put tool holder in spindle 2 Place machined aluminim block onto machine table Place a clean sheet of paper under the block to protect the table Sheet of paper Aluminum Block Figure 2 5 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 96 8100 9 6 MECHANICAL SERVICE MI 0 125 1998 SERVICE MANUAL MANUAL 62 Tool Unclamped 4 Switch Fork Shims 1 0 010 Shim Washer 7 0 018 Shim Washer Spindle Endcap Figure 2 6 Fork shim location The Tool Push out adjustment is 0 060 0 010 Add or remove shims from 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 alumi num block If the block is tight when the button is pressed shims
275. he 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 s connections at the carriage casting 7 Remove the four SHCS attaching the turret motor and mounting plate to the tool carriage casting ffig 119 erles 120 Carriage Casting Figure 3 60 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 INSTALLATION 1 Grease the locking element and drive pin on the Geneva driver Also grease the teeth on the Geneva star on the ATC 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 AAS June 1998 96 8100 1998 VY 7 7 125 MECHANICAL SERVICE SERVICE MANUAL MANUAL Mounting Plate Turret Motor
276. head casting lightly stone if necessary 9 810 9 gt 69 MECHANICAL SERVICE _ WnIU 55 90n January 1998 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 Figure 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 4 f 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 the six SHCS and tighten down completely 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 th
277. hen 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 96 8100 151 ELECTRICAL SERVICE o n O Ls 0 eS 1998 SERVICE MANUAL MANUAL 4 the POWER SUPPLY board there are three fuses located in 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 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 gt 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 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 The Operator s Lamp Fuse is located at the lower left of the Power Supply Board An orange light will be on to indicate the blown fuse TO LVPS P20 FROM LVPS P16 230VACITS Overvoltage Fuses
278. his 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 SWITCH HYSTERESIS UNIT Hz This defines the hysteresis band around parameter 197 For example if par 197 is 85 Hz and par 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 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 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 XTHERMAL COMP COEF This is the coefficient of heating of the lead screw and is used to shorten the screw length X AIR BRAKE DELAY This parameter is not used Y AIR BRAKE DELAY This parameter is not used Z AIR BRAKE DELAY This parameter is not used A SPINDLE TEMP COEF This parameter controls the amount of correction to the A axis in response to heating of the spindle head It is 10 times the number of encoder steps per degree F SPIGOT POSITIONS Maximum number of spigot positions SPIGOT TIMEOUT MS Maximum timeout allowed for spigot to traverse one spigot location SPIN FAN OFF DELAY Delay for turning the spindle fan off after the spindle has been turned off AAG OI n 968100
279. i CS TECHNICAL REFERENCE SERVICE MANUAL MANUAL 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 front of the spindle head The two manual buttons only operate in MDI or JOG modes CLANP UNcLANP Air SOLENOIDS A single solenoid controls the air pressure to release the tool clamp This corresponds to relay K15 When the relay is activated 115V AC is applied to the solenoid This applies air pressure to release the tool Relay K15 is on the 1 0 PCB Circuit breaker CB4 will interrupt power to this solenoid CLANP UNcLANP 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
280. if equipped then replace front cover from the bottom and attach with eight SHCS 4 Replace rear cover and attach to side covers with six SHCS 5 Replace top cover and attach to side covers with four SHCS 5 968100 January 1998 V eri eS MECHANICAL SERVICE SERVICE MANUAL MANUAL 2 TOOL RELEASE PISTON TRP ASSEMBLY Please read this section in its entirety before attempting to replace tool release piston assembly 2 1 TRP Note This procedure applies to machines with 40 taper spindles only Refer to the following sections for 50 taper TRP replacement instructions 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 in accordance with Head Covers Removal and Installation 3 Remove the four 3 8 16 x 134 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 2 1 If machine is equipped with TSC also remove the coolant hose wrench required 7 Remove entire tool release piston assembly Note Steps 8 and 9 apply only to machines with TSC 8 Remove the drain and purge l
281. ight 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 machine 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 7 14 M99 50 Rapid 15 If Z axis overcurrents alarm during travel verify and correct system pressure Note gt If Z axis overcurrent alarm at top or bottom of travel call HAAS Automation Service Department immediately for assistance gt If fluid leaks from hydraulic fittings check that fittings are tight gt 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 132 96 8100 1998
282. ightening 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 1 Attach the mast support to the support base using the four 3 8 16 x 114 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 72 13 x 4 HHB three 72 split washers three 9 13 hex nuts and the three spacers Modification Plate Spacer b lt gt 4 5 1 2 13 x 41 2 HHB Figure 3 27 Support base mast support assembly 96 8100 af 1 5 C TTF 83 MECHANICAL SERVICE Mi r 125 une 1998 SERVICE MANUAL MANUAL Mast Support 3 8 16 x 1 1 4 SHCS 4 E Support Base Flat Washers 4 Split Washers 4 3 8 Hex Nuts 4 Figure 3 28 Exploded view of boom modification plate components 3 Assemble the boom assembly as follows A Lubricate the components of the assembly 1 Using a grease brush apply g
283. ill 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 setto 1 On all other mills it must be setto 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 This bit allows an alternate gearbox configuration It inverts the sense of the gearbox inputs Used for 50 taper option Causes the main serial inputs outputs to go through the floppy video board This bit is used on horizontal mills only This bit is used on horizontal mills only When set to 1 displays the actual spindle speed on the Current Commands display page Enables purge output on TSC option Reserved for later use This bit must be set to 1 if machine is equipped with a non Haas vector spindle drive This bit will must be set to 1 if the machine has a 50 taper spindle or a non Haas vector drive Reserved for later use 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 feed G1 X 1 F1 57500 M3 Reserved for later use Haas Vector Drive This bit must be setto 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 HAAT 215 iin
284. ines from the seal housing 9 Remove the seal housing from the TRP 3 8 16 X 1 3 4 SHCS 1 4 Air Hose Fitting 3 8 Air Hose TSC Fitting switch Unclamp switch Figure 2 1 Tool Release Piston with Optional TSC fitting 96 8100 5 gt 51 MECHANICAL SERVICE 0 125 1998 SERVICE MANUAL MANUAL 1 4 Air Hose Fitting ool Release Piston Assembly Transmission Except VF 0 3 8 Air Hose Fitting Drive Belt Spindle Pulley Head Casting Figure 2 2 Mounting location for tool release piston assembly 2 2 TRP INSTALLATION 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 to the sides of the solenoid bracket Note Steps 7 and 8 apply only to machines with TSC 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 shoul
285. ion section NOTE It will not be necessary at this time to completely remove the motor Do not disconnect the electrical components 2 Completely loosen the 10 32 x 72 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 the motor coupling at the lead screw Place a drop of blue Loctite on the screw before inserting 5 Reinstall the axis motor Coupling Halves Front View Flex Plates Figure 3 43 Motor coupling 6 96 8100 1998 2711 125 MECHANICAL SERVICE SERVICE MANUAL MANUAL 3 10 LEAD SCREW REMOVAL AND INSTALLATION Please read this section in its entirety before attempting to remove or replace the lead screws TOOLS REQUIRED v Spanner wrench 32 mm or 40 50 mm Y 2 x 4 wood block 21 23 long v Shaft lock 32 mm or 40 50 mm Y Torque tester vx Z Axis Cylinder shaft stop P N 99 7562 VF 0 through 4 P N 93 9962 VF 6 through 10 NOTE Certain steps in the following procedures app
286. ion one increment at a time Press the TOOL RELEASE button and check for movement between increments until block is tight gt If the block is tight at 0 070 or less the Coolant Tip Figure 4 must be replaced Replace coolant tip and seal housing at the same time TSC Service Kit 93 9000 222 8 4 241 96 8100 1998 M Cries SERVICE MANUAL MANUAL CABLE LOCATIONS e 96 8100 8 PCB S CABLE LOCATIONS AND BOARD DIAGRAMS AAAS 223 CABLE LOCATIONS r 125 61998 SERVICE MANUAL MANUAL P7 as 850A P4 BUM IC95 IC96 IC97 IC98 SERIAL OOOO PORT 2 D D D D gt 14 lll oe 9 0 920 s dg 5 D D D D ooo OOOO Oaa 850 SERIAL 1 o ooo H RUN H q IC10 PAL2 2B 93 1083 1084 q B 1 tb MSG IC30 1 B IC32 PAL2 1A HALT 1 B q D Co q 51
287. ional gain used in the position control loop when performing a spindle orientation C BASE FREQ This is the rated frequency of the motor C HI SP CURR LIM At speeds higher than the base frequency the maximum current that is applied to the motor must be reduced C MAX CURRENT Same definition as Parameter 105 C MAG CURRENT This is the magnetization component of the current in the motor also called the flux or field current 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 SAS 207 em PARAMETERS N 208 Parameter Parameter Parameter Parameter Parameter Parameter Parameter Parameter Parameter Parameter Parameter Parameter Parameter Parameter Parameter 194 195 196 197 198 199 200 201 202 203 204 205 206 207 208 June 1998 V erfes SERVICE MANUAL SPINDLE STOP The spindle is considered to be stopped discrete input SP ST 0 when the speed drops below this value Units encoder steps millisecond START STOP DELAY This delay is used at the start of motion to magnetize the rotor before accelera tion starts C ACCEL LIMIT LOAD This is the load limit during acceleration SWITCH FREQUENCY Unit Hz T
288. is allowed in any WHILE or IF THEN block A conditional expression was found outside of an IF THEN WHILE or M99 block A macro expression cannot be concatenated to N or O Do not declare 0 1 etc An alpha address with expression such as A 1 2 evaluated incorrectly Same as 517 In the evaluation of a macro expression an operand was expected and not found In the evaluation of a macro expression an operator was expected and not found An illegal value was passed to a function such as SQRT or ASIN AAS 51 m ALARMS 52 522 523 524 525 526 527 528 529 530 531 532 533 534 535 536 537 538 539 M Illegal Assignment Var Or Value Conditional Prior To THEN END Found With No Matching DO Var Ref Illegal During Movement Command Found On DO END Line Not Expected Or THEN Required Parameter Precedes G65 Illegal G65 Parameter Too Many J or In G65 Macro Nesting Too Deep Unknown Code In Pocket Pattern Macro Variable Undefined DO Or END Already In Use Illegal DPRNT Statement Command Found On DPRNT Line RS 232 Abort DPRNT Matching END Found Illegal Goto Cries SERVICE MANUAL MANUAL June 1998 A variable was referenced for writing The variable referenced is read only THEN was encountered and a condi
289. is connection from the control panel 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 114 SHCS that hold the motor to the housing 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 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 Ifthe 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 96 8100 af fy fff G T TR 95 MECHANICAL SERVICE V eri 125 une 1998 SERVICE MANUAL MANUAL 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 CouPLER REPLACEMENT 1 Remove the axis motor in accordance with Axis Motor Removal Installat
290. 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 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 Circuit breaker CB4 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 Between gears both switches are closed indicating a between gear condition The diagnostic display shows the status of these switches and the CURNT 5 display shows which gear is selected If the switches indicate that the gear box is between gears the display will indicate No Gear 96 8100 mn ANG P 175 TECHNICAL REFERENCE Cri 125 SERVICE MANUAL IVIANUAL When a gear change is performed the following sequence of events o
291. 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 Refer to appropriate section and install the spindle cartridge 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 snap ring on the spindle shaft 16 Reinstall the tool release piston 17 Finish installation of the spindle beginning with Spindle sweep adjustment 18 Set the drawbar height and clamp and unclamp switches as described in the following section CAUTION Step 19 must be followed or damage to the ATC will result 19 Refer to Spindle Orientation and set the spindle orientation ffig T 11 MECHANICAL SERVICE E 125 _ January 1998 SERVICE MANUAL MANUAL 20 Reinstall the head covers 21 Test run the machine and perform the necessary ATC adjustments in the Automatic Tool Changer section 4 4 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 plac
292. is within 0 030 2 Threaded Holes Orientation m Detent Figure 6 1 Top view of spindle orientation components 78 5 968100 January 1998 125 MECHANICAL SERVICE SERVICE MANUAL MANUAL Shot pin 2 N NI 5 Orientatio ring NA Figure 6 2 VF 0 motor with orient ring location 7 There is 0 015 0 030 backlash the spindle system when it is oriented Be certain to compensate 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 11 Tighten the orient screws evenly to 15 ft Ibs Verify that spindle alignment has not changed Note It is vital that the orient screws be tightened evenly If not the top of the orienta tion ring will run out and the ring will slip Note Ensure the orientation ring has an adequate layer of grease around the circumfer ence before starting operation 12 Make at least 50 tool changes to test the spindle orientation 6 2 ORIENTATION DRIVE 1 Place the machine in low gear 2 Adjust Parameter 257 SPINDL ORIENT OFSET until the
293. ith 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 100 C 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 ORIENTATION lt Spindle loses correct orientation Non Vector Drive e Check alarm history looking for spindle overload and axis overcurrent alarms These alarms mean the machine is not being properly operated e Check the orientation ring for tightness Ensure the shaft on which the ring mounts is clean and is free of grease and oil e Check the orientation ring for cracks near the bolt holes or near the balancing holes gt If there are cracks replace the ring e Check the shot pin on the gearbox for binding damage and proper operation Replace it if it is damaged e Check the switch on the shot pin against the Diagnostic display Replace the switch if it is found to be faulty Vector Drive e Check alarm history
294. l 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 96 8100 5 AuU DJS V 67 MECHANICAL SERVICE E 125 January 1998 SERVICE MANUAL MANUAL 68 4 SPINDLE ASSEMBLY Please read this section in its entirety before attempting to replace spindle IMPORTANT The current pulley is shrink fitted onto the spindle and is not field serviceable It is identified by two threaded 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 service on the transmission or spindle of the machine 4 1 SPINDLE CARTRIDGE REMOVAL 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 Remove cover panels from head stock area as described in Head Covers Removal section 3 Remove the tool release piston assembly in accordance with appropriate section 4 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 5 First disconnect the oil line from the fitting at the oil injection cover then remove the brass fitting Note When replacing a new design
295. lace in accordance with Axis Motor Removal Installation ERRORS FOLLOWING ERROR only SERVO ERROR TOO LARGE alarms 103 106 187 occur on one or more axes sporadically e Check DC bus voltage on diagnostics page 72 VF E 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 Replace driver card Electrical Service Replace servo motor Axis Motor Removal Installation Replace encoder VF E only Z axis motor overcurrent Brake won t release leadscrew won t rotate Alarm not cleared Low counterbalance pressure Check Z axis parameters Check the lead screw for binding Check motor and cable for shorts Replace amplifier drive card on a VF E VF 6 with Z axis brake only e Brake power fuse blown e Brake power transformer blown e Brake power rectifier blown e Cabling pinched e Brake failed AAAS June 1998 96 8100 June 1998 7 TROUBLESHOOTING SERVICE MANUAL 1 4 AUTOMATIC TOOL CHANGER 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 de
296. liseconds Control problem call your dealer Put a Pn n for seconds or a Pn for milliseconds AAS 45 m ALARMS cI 46 327 328 329 330 331 332 333 334 335 336 337 338 339 340 341 342 343 344 345 346 M No Loop For M Code Except M97 M98 Invalid Tool Number Undefined M Code Undefined Macro Call Range Error H and T Not Matched X Axis Disabled Y Axis Disabled Z Axis Disabled A Axis Disabled Line Referenced By P Not Found Invalid IJK and XYZ 602 603 Multiple Codes Cutter Comp Begin With 602 003 Cutter Comp End With G02 or G03 Cutter Comp Path Too Small Display Queue Record Full Cutter Comp With G18 and G19 Diff Step Ratio On G17 Plane Diff Step Ratio On G18 Plane Cries SERVICE MANUAL MANUAL L code not used here Remove L Code Tool number must be between 1 and the value in Parameter 65 That M code is not defined and is not a macro call Macro name 090nn not in memory A macro call definition is in parameters and was accessed by user program but that macro was not loaded into memory Number too large 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 Parameters have disabled this axis Not normally possible in VF Seri
297. lt ATA 5 968100 lt EF IET Note REPLACE ONLY ONE BOLT A TIME inspect 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 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 Spindle Dog Spindle Figure 3 55 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 968100
298. lt 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 No problems will occur and noise should eventually go away Noise is caused by bearings Rolling grinding sound is heard coming from the motor ENSURE NOISE 15 NOT COMING FROM THE BRUSHES If bearings are making a consistently loud sound replace the bearing sleeve Q 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 1150 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 gt Ifthe 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 Check the lead screw for misalignment If incorrect perform alignment procedure Misalignm
299. ly only to 40 and 50 mm lead Screws 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 Motor Housing Nut Housing Ball Nut Lead Screw Support Casting Figure 3 44 X axis lead screw and components 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 9 8100 gt gt gt gt gt gt gt gt gt gt gt gt gt 5 gt 552 97 MECHANICAL SERVICE Mi r 125 une 1998 SERVICE MANUAL MANUAL Bearing Sleeve Motor Housing ar A I Lead Screw Ball Nut Figure 3 45 Lead screw assembly 9 Remove th
300. machine power off 2 Slide the doors to the full open position Remove the tension springs 2 connecting the two swivel roller brackets at 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 gt 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 124 968100 1998 V 2711 125 MECHANICAL SERVICE SERVICE MANUAL IVIANUAL Roller Wheel Roller Guide Tension Spring Swivel roller Bracket Figure 3 62 Roller roller guide assembly DOOR ADJUSTMENTS 10 Close both doors and check
301. me XZ CH YZCH ZZ AZCH BZ CH Z B HOME The following inputs and outputs pertain to the Haas Vector Drive Otherwise it will display a 1 or 0 value 192 M erles June 1998 SERVICE MANUAL MANUAL Note If the machine is equipped with an APC the following inputs and outputs will change 1009 Pallet Clamped SW 1021 Door SW 1022 Pin 1 CLR 1023 Pin 2 CLR 1121 PAL Clamp 1122 Door 1125 APC Motor 1126 Beeper 1026 PAL 2 Home 1027 PAL 1 Home The second page of diagnostic data is displayed using the PAGE UP and PAGE DOWN keys It contains INPUTS 2 Description Name Description Name Description X axis Z Channel X OVRH X Motor Overheat X CABL Broken cable to X encoder Y axis Z Channel Y OVRH Y Motor Overheat Y CABL Broken cable to Y encoder Z axis Z Channel 7 Z Motor Overheat 7 CABL Broken cable to Z encoder A axis Z Channel AOVRH A Motor Overheat ACABL Broken cable to A encoder B axis Z Channel B Motor Overheat B CABL Broken cable to B encoder X axis Home Lim Switch XDRVF X axis drive fault SZ CH Spindle Z Channel Y axis Home Y DRVF Y axis drive fault Z axis Home Z DRVF Z axis drive fault A axis Home ADRVF A axis drive fault B axis Home DRVF B axis drive fault of HAAS VECT SP FWD SP REV SPLOK AT SPD SP STP SP FLT SPLKD SP OHT 5 CABL Haas Vector Drive Enabled Spindle Forward Spindle Reverse Spindle
302. ment 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 Transmission section 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 bo
303. mmanded axis position and the actual position becomes larger the 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 lt Axis Z Fault or Z Channel Missing e 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 96 8100 V V 31 43 veoussesnoorne V 727 gt eoe SERVICE MANUAL IVIANUAL Axis Cable Fault e 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 e During a self test of communications between the MOCON and main processor the main processor does not respond and is suspected to be de
304. 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 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 Lower the spindle head to its lowest position 5 If the machine is equipped with a hydraulic counterbalance install cylinder shaft stop See Fig 9 6 HANDLE JOG Z axis up until shaft stop blocks axis 6 Disconnect the electrical power 7 On the motor housing loosen the four BHCS and remove the cover plate Motor Motor Housing Nut Housing Lead Screw Support Bearing Way Figure 3 41 Z axis motor and components __ _ 96 8100 1998 125 MECHANICAL SERVICE SERVICE MANUAL MANUAL Hydraulic Cylinder Cylinder Bracket Cylinder Rod Bracket attached to head casting Figure 3 42 Z axis motor and components for machines equipped with hydraulic counterbalance 8 Loosen the SHCS on the motor coupling at the lead screw 9 On the motor housing loosen the four SHCS and remove the motor from the housing 10 Disconnect the Z ax
305. mportant to ensure proper installation of the lead screw Tighten the clamp nut hand tight on the motor end gt Install and tighten clamp nut on bearing support Ensure the nut does not touch the support bearing gt 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 v v 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 v v v v 9 Move the milltable 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 gt Move the table all the way forward Tighten down completely the SHCS that mount the bearing support to the base gt 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 atorque screwdriver torque the clamp nut to 4 in Ibs 11 Reinstall the motor according to Axis Motor Removal and Installation If applicable
306. n 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 100 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 subsequently occur because of an overvoltage condition inside the spindle drive HAAS 96 8100 1998 Nn _ c V er 7i TECHNICAL REFERENCE SERVICE MANUAL MANUAL 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 100 C At thattemperature 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 SENSE There 15 over temperature sense switch mounted near the above mentioned resistors This sensor is anormally closed switch that opens at about 100 C It will generate an alarm and all motion will stop After thirty seconds of an overheat condition a
307. n automatic shutdown will occur in the control 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 CIRCUIT BREAKER CB1 AMP RATING HP RATING 195 260 VAC 354 488 VAC 20 15 40 20 40 30 80 40 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
308. n labeled 860A on the board should be used for the cable marked 860B Some boards the connection for cable 920 has been incorrectly 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 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 Replace the SDIST board attaching it with the eight screws previously removed using one of the screws as a grounding connection Reconnect all leads previously removed to their proper connection SERVO DRIVER BOARDS Note Refer to Cable Locations for a diagram of this board 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
309. n the SHCS that mount the bearing support to the saddle and remove Remove the pull pins from the bearing support gt Loosen the five SHCS in the ball nut and remove the lead screw by pulling from the bearing support end Nut Housing Lead Screw Support Bearing Lead Screw Figure 3 49 Pull lead screw forward around bearing support 102 96 8100 1998 eri 125 MECHANICAL SERVICE SERVICE MANUAL MANUAL Nut Housing Lead Screw Support Bearing Lead Screw 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 1140 or 50 mm lead
310. n the lube panel to open the APC door and unclamp ese are either on the receiver or on ihe and engaging associated switch open fne amp oor and 5 4 Verify alignment of pin and bushing unclamp the receiver Manually move pallet to known location These ore either the receiver Rotate the chain to a known location that and engaging the associated switch Verify alignment of pin and bushing to move the chain Rotate the chain to a known location that compliments the pallet locations Run M18 to Use the sprocket rotation tool close the door and to move the chain clamp the receiver Release the solenoid actuators Run M50 to complete a pallet cycle The completed 50 Zero the Axes will reset 709 to 0 There are 5 switches involved in the location of the pallets and chain 1 pallet switch on the receiver 2 pallet switches on the APC 2 chain switches on the APC See attached APC electrical notes nder the control panel If the power to has been shut down either intentionally or by power outage damage may occur to the APC pallet or receiver if the X or Y axes are moved in the VMC at power up At power up should investigate the condition of the pallet and chain location and alarm if either an unknown chain location or unknown pallet location are detected 96 8100
311. ng 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 ALAS 117 MECHANICAL SERVICE 125 1998 SERVICE MANUAL MANUAL SHUTTLE REMOVAL 1 2 7 8 Turn the VMC off Remove the cover from the tool carriage casting Remove the hex bolt that attaches the cam follower to the slip clutch see Fig 3 56 Push the tool changer in as far as it will go Loosen the set screw that secures the slip clutch assembly to the shuttle motor see Fig 3 57 Using a small two jaw puller pull the slip clutch assembly see Fig 3 57 off the shuttle motor shaft Remove the 5 5 attaching the cover to the holding arm casting on the tool changer Remove the cover from the wire channel inside the holding arm casting and unplug the shuttle motor from the wiring harness Wiring Harness Unplug Shuttle Motor Figure 3 58 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 HHB s holding the shuttle motor gear box together SHUTTLE MOTOR NSTALLATION 1 Install the new motor on the tool changer holdi
312. ng plate using the four 10 32 x 34 FHCS Before inserting the FHCS place a drop of blue Loctite on each screw 2 3 118 Reattach the shuttle motor connection to the wiring harness in the holding arm casting Replace the cover on the holding arm casting 5 968100 1998 96 8100 EX PETS service SERVICE MANUAL MANUAL 10 32 x 3 4 FHCS 4 Figure 3 59 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 VMC and go through a performance check consisting of at least 30 tool changes assuring correct operation 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 t
313. nned cycle must be greater than zero I J and Q in a canned cycle must be greater than zero Subprogram nesting is limited to nine levels Simplify your program Use a lower feed rate G code not defined and is not a macro call Possible corruption of memory by low battery Call your dealer Program End of subroutine reached before M99 Need an M99 to return from sub No P Code In M97 M98 or G65 Subprogram or Macro Not In Memory Invalid P Code In M97 M98 or M99 X Over Travel Range Y Over Travel Range Z Over Travel Range A Over Travel Range No Feed Rate Specified Auto Off Alarm Sub Prog Without M99 Delay Time Range Error Queue Full G04 Without P Code routine Must put subprogram number in P code Check that a subroutine is in memory or that a macro is defined 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 X axis will exceed stored stroke limits This is a parameter in negative direction and is machine zero in the positive direction This will only occur during the operation of a user s program same as 316 same as 316 Not normally possible with A axis Must have a valid F code for interpolation functions A fault turned off the servos automatically occurs in debug mode only Add an M99 code to the end of program called as a subroutine P code in G04 is greater than or equal to 1000 seconds over 999999 mil
314. nt skip to step 13 ALAA 163 ELECTRICAL SERVICE eri eS 21998 SERVICE MANUAL MANUAL Please note the differences in installation between the VF 0 VF 1 VF 2 and the VF 3 VF 4 5 10 11 12 164 For the 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 Screw the standoffs into the four holes located at the rear of the transmission s top plate For the VF 0 place the mounting bracket in place Fasten to the top plate with the four screws and four lock washers Place the 18 tooth pulley onto the pulley bushing and tighten down Place the SHCS through the center axis of the pulley Screw this assembly into the spindle orientation ring Solenoid Assembly Transmission Tool Release Piston Figure 4 20 Spindle encoder installation VF 1 VF 2 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 Unscrew the four screws and remove the cover panel on the box at the base of the flexible tube Feed the encoder cable through the flexible tube and connect at the plug in the box on top of the electrical cabinet 5 re 9658100 7
315. nt Main Transformer 65 Coolant Pum P21 5 69 22 5 5 CB4 CB3 CB2 D P17 P31 P23 24 P8 P7 P30 P14 P6 15 TB2 HAAS June 1998 P4 P2 P3 TB1 96 8100 Cries SERVICE MANUAL MANUAL n CABLE LOCATIONS June 1998 U POWER PCB 32 5010 CABLE CONNECTIONS POWER 96 8100 740 POWER AAAS ON OFF SWITCH PLUG CABLE SIGNAL NAME c TO gt LOCATION PLUG P1 190 260VAC INPUT CB1 P3 K1 K1 CONTACTOR 170 AUTO OFF 1 0 PCB P8 P5 PRI SEC 5 5 6 930 230VAC COOLANT 1 0 PCB 6 P7 910 115VAC CB SOLENOID 1 0 PCB P28 P8 90 115VAC T1 I O PCB P36 P9 860 LOW VOLTAGE POWER P10 860 LOW VOLTAGE POWER P11 860 LOW VOLTAGE POWER 12 860 LOW VOLTAGE POWER 1 860 LOW VOLTAGE POWER P14 800A P15 70 230VAC K1 CONTACTORS K1 CONTACTOR P17 860 12VDC 19 290 230VAC T4 T4 P21 PORT 1 amp 2 12VDC PORT 182 PROCESSORPCB P22 12VDC P24 SPARE SPARE SPARE N A P26 860 LOW VOLTAGE POWER P27 860 LOW VOLTAGE POWER P30 800 1 860A 12VDC POWER 1 115VAC IN T1 SECONDARY TB2 115VAC OUT 229 GND FAULT TC MOTORS rr 9 SPIN LOCK P11 ee OVO P43 P30 9 1060 8104 810 AT TC STAT P13 820 i 2 P33 90 LO TSC P14 900 Te P34 90A 46 7
316. nt tank prime the Through the Spindle Coolant TSC system according to the following procedure This procedure should also be performed whenever the pump has sucked in air e g low coolant 50 Taper TSC old system With no tool in the spindle switch to MDI mode Close the programmable coolant p Cool and lock line shut off valves Press the COOLNT key to turn on the main coolant pump this will prime the TSC pump Wait 20 30 seconds for the TSC pump to fill Press the AUX CLNT key to turn on the TSC Wait for coolant to flow from the spindle at full force Press the reset key to shut off the system The TSC system will continue to hold it s prime after this 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 Note If the coolant pressure with no tool in the spindle is 60 psi or less replace the pump assembly 30 3281 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 133 MECHANICAL SERVICE Z 125 1998 SERVICE MANUAL MANUAL 2 With no tool in the spindle prime the TSC system as
317. 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 overwound 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 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 Lift Fixture Figure 3 30 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 transmission 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
318. o be caused by anything that causes a very high load on the motors 96 8100 35 m ALARMS cI 36 109 110 111 112 113 114 115 116 117 118 119 120 M Y Servo Overload Z Servo Overload A Servo Overload No Interrupt Shuttle In Fault Shuttle Out Fault Turret Rotate Fault Spindle Orientation Fault Spindle High Gear Fault Spindle Low Gear Fault Over Voltage Low Air Pressure eres SERVICE MANUAL MANUAL June 1998 same as 108 same as 108 same as 108 Electronics fault Call your dealer Tool changer 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 so check CB4 relays K9 K12 and fuse F1 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 so check 4 relays
319. o service is necessary 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 e Check the condition of the customer s 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 e 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 e 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 or tool release piston See the Spindle Assembly section in Mechanical Sevice for spindle cartridge replacement e 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
320. oks 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 88 96 8100 1998 eri 125 MECHANICAL SERVICE SERVICE MANUAL MANUAL 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 gt Place one cable tie around the limit switch cable gt Place the second cable tie through the first one forming a loop gt 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 y
321. om 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 HAAS m ALARMS cI 40 166 167 168 169 170 171 172 173 174 175 176 177 178 179 180 182 183 184 185 186 187 VI Y Zero Ret Margin Too Small Z Zero Ret Margin Too Small A Zero Ret Margin Too Small Spindle Direction Fault Phase Loss UNUSED UNUSED Spindle Ref Signal Missing Tool Load Exceeded Ground Fault Detected Over Heat Shutdown Over Voltage Shutdown Divide by Zero Low Pressure Transmission 01 Pallet Not Clamped X Cable Fault Y Cable Fault Z Cable Fault A Cable Fault Spindle Not Turning B Servo Error Too Large erles SERVICE MANUAL MANUAL Same as 165 Same as 165 Not normally enabled for A axis Problem with rigid tapping hardware The spindle started turning in the wrong direction Problem with incoming line voltage between legs L1 and L2 This usually indicates that there was a transient loss of input power to the machine The Z channel pulse from the spindle encoder is missing for hard tapping synchronization 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 ma
322. ooling or into the ATC itself during a tool change e Program the machine to move the part out of the way of the ATC Inspect the pocket involved in the crash for damage and replace parts as necessary The part or fixture on the mill table crashes into long tooling or into the ATC itself when machining e 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 atten tion 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 BREAKAGE Breakage of the ATC is caused by either very hard and repeated crashes or excessive TSC coolant tip wear lt shuttle is broken off of the holding plate e 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 Q extractor forks are damaged after breakage e Check the condition of the mounting holes in the carousel If the threads are damaged they m
323. oose 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 BELT ASSEMBLY Please read this section in its entirety before attempting to replace the drive belt 3 1 REMOVAL 1 Note FOR EASIER REMOVAL PLACE TRANSMISSION IN HIGH GEAR BEGINNING Remove cover panels from headstock area in accordance with Head Covers Removal and Installation Inspection Cover Figure 3 1 Spindle head casting disconnect points 2 Remove tool release piston assembly in accordance with Tool Release Piston Assembly Removal 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 34 max to allow the drive belt to be pulled upward over the spindle pulley 96 8100 January 1998 V eas MECHANICAL SERVICE SERVICE MANUAL MANUAL 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 Transmission N Except VF 0 idi Head Casting Figure 3 2 Head casting area showing belt location 5 Remove the inspection cover from the bottom of the spindle head casting
324. or s lamp switch 800A not used P15 230V AC from main transformer to CB3 70 P16 Low voltage power from power supply not used P17 12V DC option connector to MCD relay board 860A P18 Not used P19 Primary and Secondary connections to worklight transformer 4 290 not used P20 115V AC to low voltage power supply P21 12V DC option connector P22 12V DC option connector to MOTIF P23 230 VAC from main transformer to CB5 70A P24 230 VAC from CB3 to TSC coolant pump 930A P26 5 12 12 GND from low volt supply to logic boards to processor 860 P27 5 12 12 GND from low volt supply to logic boards 860 P28 5 12 12 GND low volt power from power supply P29 5 5 GND low volt power from power supply P30 12V AC to operator s light 800 not used P31 12V option connector to stack fan 860A TB1 115VAC 3 phase from main transformer 94 95 96 TB2 115 VAC 3 phase to IOPCB 91 92 93 Three more circuit breakers are 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 ATA 5 F M 9658100 1998 er 7i TECHNICAL REFERENCE SERVICE MANUAL MANUAL CB4 controls the 115V AC to the air sol
325. or Operand Stack Error Too Few Operands Stack Division By Zero Illegal Macro Variable Use Illegal Operator or Function Use Unbalanced Right Brackets Illegal Assignment Use Var Ref Not Allowed With N Or O Illegal Macro Address Reference Too Many Conditionals In a Block Illegal Conditional Or No Then Exprsn Not Allowed With N Or O Illegal Macro Exprsn Reference Term Expected Operator Expected Illegal Functional Parameter erles SERVICE MANUAL MANUAL macro variable number was used that is supported this control use another variable Unbalanced brackets delete a bracket were found in an expression Add or The macro expression value stack pointer is in error Call your dealer The macro expression operand stack pointer is in error Call your dealer An expression operand found too few operands on the expression stack Call your dealer A division in a macro expression attempted to divide by zero Re configure expression See Macros section for valid variables See 5 section for valid operators Number of right brackets not equal to the number of left brackets Attempted to write to a read only macro variable Alphabetic addresses N and O cannot be combined with macro variables Do not declare etc A macro variable was used incorrectly with an alpha address Same as 513 Only one conditional expression
326. or lock this bit must be set to 1 AHAS June 1998 96 8100 V JEES _ PARAMETERS 5 N Parameter 279 X MAX 3rd DERIV This parameter supports S curve It is initialized to 250000000 and be altered as needed In order to ensure the desired effect the minimum value that the control will use is 11700 ACCELERATION ACC DEC T CONST If the parameter is set to a lower value the control will instead use the value computed using the above formula Parameter 280 Y 3rd DERIV See parameter 279 for description Parameter 281 Z MAX 3rd DERIV See parameter 279 for description Parameter 282 A 3rd DERIV See parameter 279 for description Parameter 283 B MAX 3rd DERIV See parameter 279 for description Parameter 284 C 3rd DERIV See parameter 279 for description Parameter 294 MIN BUSS VOLTAGE This parameter specifies the minimum Haas Vector Drive buss voltage When a Haas Vector Drive is installed it should be set to 200 volts Otherwise it should be set to zero Alarm 160 will be generated if the voltage falls below this value Parameter 295 SHTL SETTLE TIME This is for the air driven shuttle used on the VR series mills 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 all mills with the Air Driven Shuttle This may very All other mills can
327. or s electrical connections do not need to be removed for this operation After removing motor from the housing set it to one side Loosen the 10 32 SHCS and remove the clamp nut on the lead screw in the motor housing 10 For 32 mm lead screws gt Loosen the six 4 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 DONOT 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 USE EXTREME CAUTION DO NOT DAMAGE THE THREADS ON THE LEAD SCREW For 40 and 50 mm lead screws gt Loosen the SHCS that mount the bearing support to the column and remove Remove the pull pins from the bearing support gt Loosen the five SHCS in the ball nut and remove the lead screw by pulling from the bearing support end 105 MECHANICAL SERVICE Mi r 125 une 1998 SERVICE MANUAL MANUAL Lead Screw EN Bearing Figure 3 50 Z axis lead screw and components INSTALLATION WARNING ALWAYS BLOCK THE HYDRAULIC CYLINDER WITH SHAFT STOP BLOCK
328. other possible headings If the problem is still not found contact Haas Automation for further details BEFORE YOU BEGIN USE COMMON SENSE Many problems are easily overcome by correctly evaluating the situation All machine operations are composed of a program tools and tooling You must look at all three before blaming one as the fault area If a bored hole is chattering because of an overextended boring bar don t expect the machine to correct the fault Don t suspect machine accuracy if the vise bends the part Don t claim hole mis positioning if you don t first center drill the hole FIND THE PROBLEM FIRST Many mechanics tear into things before they understand the problem hoping that it will appear as they go We know this from the fact that more than half of all warranty returned parts are in good working order If the spindle doesn t turn remember that the spindle is connected to the gear box which is connected to the spindle motor which is driven by the spindle drive which is connected to the 1 0 BOARD which is driven by the MOCON which is driven by the processor The moral here is don t replace the spindle drive if the belt is broken Find the problem first don t just replace the easiest part to get to DON T TINKER WITH THE MACHINE There are hundreds of parameters wires switches etc that you can change in this machine Don t start randomly changing parts and parameters Remember there is a good chance that if you
329. ou 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 Gearbox Isolators Figure 3 36 Gearbox isolators Adjust the drive belt tension as noted in Belt Assembly section before tightening screws down completely 8 Reattach the cable carrier to the solenoid bracket and reconnect all electrical and fluid lines Replace any leaking lines at this time if necessary 96 8100 041 gg MECHANICAL SERVICE Mi r 125 une 1998 SERVICE MANUAL IVIANUAL 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 circumfer ence before starting operation 3 9 AXIS MOTOR REMOVAL INSTALLATION Please read this section in its entirety before attempting to remove or replace the motors v Z Axis Cylinder shaft stop P N 99 7562 VF 0 through 4 P N 93 9962 VF 6 through 10 X Axis Motor REMOVAL 1 Turn the VMC ON ZERO RETURN all axes and put the machine in HANDLE JOG mode Motor Housing Nut Housing Lead Screw Support Casting Figur
330. our 5 5 Move the table to the far right position Replace the left way cover with the 5 5 6 Move the table to the far left position Replace the right way cover with the SHCS 7 Reinstall the side enclosures 8 Check for backlash in the X axis lead screw Troubleshooting section or noisy operation 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 machine Remove the two roller brackets from the base the cover forward and off of the base AAS V T 91 MECHANICAL SERVICE V r 125 HV U une 1998 SERVICE MANUAL MANUAL 92 4 Ifthe 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 Plate Motor Housing Lead Screw Support Bearing Figure 3 39 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 8 Disconnect the two air lines from the panel quick disconnect fittings by hand 9 Disconnect the three conn
331. ousing which could result in backlash Tighten the six 4 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 968100 9 113 MECHANICAL SERVICE 125 noUNasTVv June 1998 SERVICE MANUAL IVIANUAL 114 3 12 AUTOMATIC TOOL CHANGER TOOLS REQUIRED Y Two jaw puller v Hydraulic jack v 1 2 3 Block v Cardboard CARRIAGE CAsTING REPLACEMENT Note If the carriage casting is damaged in a crash it must be replaced Look specifi cally 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 replace
332. ower 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 6 0 The Microprocessor PCB contains the 68ECO30 processor running at 40 MHz 128K EPROM between 256K and 8MB of CMOS RAM and between 512K and 1MB of FAST STATIC RAM It also contains a dual serial port a five year battery to backup RAM buffering to the system buss and eight system status LED s Two ports on this board are used to set the point at which an NMI is generated during power down and the point at which RESET is generated during power down The eight LED s are used to diagnose internal processor problems As the system completes power up testing the lights are turned on sequentially to indicate the completion of a step The lights and meanings are 51 5V logic power supply is present Normally 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 i
333. oximately 2 x 4 x 4 on the paper Sheet of paper Aluminum Block Figure 5 1 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 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 9 810 9 73 MECHANICAL SERVICE 125 1998 SERVICE MANUAL MANUAL 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 overcurrent in the Z axis 5 2 SETTING DRAwBAR HEIGHT 1 Press MDI and turn hand wheel to zero 0 2 Press HANDLE JOG button and set increments to 01 the Z axis in the positive direction 0 100 3 Pr
334. pads on the bottom of the mounting base are in place and in good condition or damage to the mill table may result 86 n TP P 0q T fffl P Ss Q gt TD 96 8100 1998 V 125 MECHANICAL SERVICE SERVICE MANUAL MANUAL Figure 3 32 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 Modification Plates AN Cotter Pins Clevis Pins Figure 3 33 Mounting boom assembly to mast 11 Place the hoist directly over the transmission and attach the hook to the cradle s eye bolt 96 8100 aJ 4 9 87 MECHANICAL SERVICE r 125 une 1998 SERVICE MANUAL MANUAL Figure 3 34 Fully assembled hoist in position 12 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 Lift Fixture Figure 3 35 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 ho
335. properly labeled for reconnecting later The following illustration shows all cable numbers and the locations on the LVPS board 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 Replace the LVPS board attaching it to the cabinet with the two screws and two standoffs previously removed Replace the POWER board as described in Steps 6 7 AAAS 157 ELECTRICAL SERVICE T eri eS 1998 SERVICE MANUAL MANUAL Note Refer to Cable Locations for a diagram of this board 1 Follow all precautions noted previously before working in the electrical cabinet See warning at beginning of Servo Driver amp SDIST section 2 Turn the main switch upper right of electrical cabinet to the off position 3 Using a large flat tip screwdriver loosen the three screws on the cabinet door and then open the door enough to safely work on the electrical panel Note It is suggested to make use of a step ladder high enough to allow you to work from the top of the electrical cabinet It will be necessary when replacing the RS 232 board to work from the inside and outside of the cabinet at the same time 4 Onthe leftside of the cabinet at the top of the side panel are two serial port connections labeled SERIAL PORT 1
336. ption Tool Changer In Tool Changer Out At Tool One Low Coolant T C Geneva Mark Spindle In High Spindle In Low Emergency Stop Door Open Switch Not M Func Finish Not Over Voltage Low Air Pressure Low Lube Oil Not Over Heat Tool Unclamped Tool Clamped L 1016 1017 1018 1019 1020 1021 1022 1023 1024 1025 1026 1027 1028 1029 1030 1031 DISCRETE OUTPUTS Description Servo Power On 4th Axis Brk Rel Coolant Pump Auto Turn Off Spind Motor Fan Tool Changer In Tool Changer Out Tool Changer CW Tool Changer CCW Spindle High Gear Spindle Low Gear Tool Unclamped L 1116 1117 1118 1119 1120 1121 1122 1123 1124 1125 1126 1127 1128 1129 1130 1131 HAAS Name spare spare spare spare LO OIL spare1 spare2 spare3 UNCLA LOPHSE spare4 spared GR FLT SKIP SPIGOT CNVEYR Name SPGCW SPGCCW spare PURGE PRE CH HTC SH 5TH BK DOORL M21 M22 M23 AUXCLT GRNBCN REDBCN CNVENA CNVREV Description Spindle GB coolant low Remote tool unclamp Low voltage in phase 1 Ground fault Skip Signal Conveyor overload Description Spigot clockwise Spigot counter clockwise TSC Purge Pre charge Horizontal T C shuttle 5th Axis Brake Door Lock Auxiliary Coolant Red beacon worklight Red beacon worklight Conveyor enabled Conveyor reverse 191 TECHNICAL REFERENCE The inputs are numbered the same as the connections on the inputs printed circuit board Na
337. r is disabled the coolant pump is off and the spindle motor is stopped Caused by EMER GENCY STOP motor faults tool changer problems or power fail 103 XServo Error Too much load or speed on X axis motor The difference between the Too Large motor position and the commanded position has exceeded 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 YServo Error same as 103 Too Large 105 Z Servo Error same as 103 Too Large 106 A Servo Error same as 103 Too Large 107 Emergency Off EMERGENCY STOP button was pressed Servos are also turned off After the E STOP is released the RESET button must be pressed at least twice to correct this once to clear the E STOP alarm and once to clear the Servo Off alarm This alarm will also be generated if there is a low pressure condition in the hydraulic counterbalance system In this case the alarm will not reset until the condition has been corrected 108 X Servo Overload Excessive load on X axis motor This can occur if the load on the motor over a period of several seconds or even minutes is large enough to exceed the continuous rating of the motor The servos will be turned off when this occurs This can be caused by running into the mechanical stops but not much past them It can als
338. r is free of obstruction e Check that Parameters are at Default settings e 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 board 96 8100 Yj ST 25 43 727 gt ms 26 SERVICE MANUAL IVIANUAL 1 8 HYDRAULIC COUNTERBALANCE 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 ther
339. racy Backlash section Check the condition of the tooling and the spindle Check for spindle failure Check the condition of the servo motors Check that the is machine level 96 8100 se June 1998 n nC qs Q D s O gt TROUBLESHOOTING SERVICE MANUAL MANUAL 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 inaccurate boring depths This is especially critical in jobs that require high accuracy machining multiple parts in one setup or machining one part with multiple setups Note 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 the table example X 15 0 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 Cur
340. rameter 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 BACKEMF 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 96 8100 197 Qiu f SERVICE MANUAL IVIANUAL Parameter 31 Z D GAIN See Parameter 3 for description Parameter 32 Z GAIN See Parameter 4 for description Parameter 33 Z RATIO STEPS UNIT See Parameter 5 for description Parameter 34 Z MAXTRAVEL 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 Parameter 37 Z MAX ERROR See Parameter 9 for description Parameter 38 Z FUSE LEVEL See Parameter 10 for description Parameter 39 Z BACKEMF 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 set to
341. rease 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 16 1 SHCS two 3 8 lock washers and the two 3 8 hex nuts See owner s manual for mounting for 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 Hole is toward top edge Pulley Wheel Cable guide must rotate freely Boom Rounded side on outer edge Figure 3 29 Mounting cable guide and pulley wheel to boom 84 2 4 NA QmT v x3 gt gt a a 96 8100 1998 125 MECHANICAL SERVICE SERVICE MANUAL MANUAL 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
342. rew 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 aaa 96 8100 1998 V 125 MECHANICAL SERVICE SERVICE MANUAL MANUAL 3 11 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 v Pre load fixture v Wood block 16 long vx 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 Cover Plate Motor Motor Housing Lead Screw Support Bearing and Casting Figure 3 52 X axis lead screw and components 2 Loosen the SHCS and remove the chip tray from the mill table 3 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 4 Loosen the 10 32 x SHCS and remove the clamp nut on the lead screw in the motor housing 5 Loosen the six 4 20 1 SHCS and remove
343. rive 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 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 o 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 machine s drive belt tension Tension Adjustment section gt 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 gt 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
344. rom 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 in spindle taper and initiate a tool change Note When the Parameter 64 is changed the tool offsets must be reset 96 8100 if fff 81 MECHANICAL SERVICE Mi SERVICE MANUAL IVIANUAL 82 3 8 SPINDLE MOTOR amp TRANSMISSION Please read this section in its entirety before attempting to remove or replace transmission NOTE The drive belt s tension should be adjusted after every service on the transmission or spindle Remova 0 1 Ensure the is ON You will need to raise and lower the head stock to remove the transmission 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
345. rtical mills this parameter is not used ATOOL CHANGE OFFSET This parameter is not used B TOOL CHANGE OFFSET This parameter is not used D Y CURRENT RATIO UNIT 96 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 CAROUSEL OFFSET Parameter used to align tool 1 of tool changing carousel precisely Units are encoder steps CNVYR RELAY DELAY Delay time in 1 50 seconds required on conveyor relays before another action can be commanded Default is 5 AAG F_m 96 8100 1998 96 8100 Parameter Parameter Parameter Parameter Parameter Parameter Parameter Parameter Parameter Parameter Parameter Parameter Parameter 217 218 219 220 221 222 223 224 225 226 227 228 229 SERVICE MANUAL MANUAL 7 CNVYRIGNORE Amount of time in 1 50 seconds before overcurrent is checked after motor is turned on Default is 50 CONVYR RETRY REV Amount of time that the conveyor is reversed 1 50 seconds after overcurrent is sensed Default is 200 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
346. s counterclockwise to remove Replace the blown fuse s with ones having the same type and rating FU2 amp type AGC 250V FU3 5 amp type ABC 250V 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 D R2 RIS 2 Figure 4 13 Servo Drive Assembly fuse locations TH f YH 153 ELECTRICAL SERVICE T eri eS 1998 SERVICE MANUAL MANUAL 4 4 PCB REPLACEMENT 154 Please read this section in its entirety before attempting to replace any PCBs Microprocessor MOTIF amp Vipzo 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
347. s power or alarms 1 Raise spindle head by HANDLE JOG up to 14 5 abovetable 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 Shrader fi CGA 580 fitting Charge Discharge Kit i P N 35 4050A Figure 3 66 Hydraulic counterbalance charge discharge kit shown in place to discharge system 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 66 128 968100 1998 96 8100 SERVICE MANUAL MANUAL 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
348. s 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 590 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 is broken power to the servos will be removed instantly This will also shut off the tool changer spindle drive and coolant pump The EMERGENCY 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 HAAS 96 8100 1998 er 7i TECHNICAL REFERENCE SERVICE MANUAL MANUAL 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 ZE
349. s a serious problem with the processor PCB Check that the EPROM is plugged in Test the card with the buss connectors off 96 8100 n ANG 177 TECHNICAL REFERENCE er 7 June 1998 SERVICE MANUAL IVIANUAL 178 510 MSG CRT Serial 1 0 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 Power on serial 1 0 message output complete Normally On If this light does not come on there is a problem with serial 1 0 or interrupts Disconnect anything on the external RS 232 and test again 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 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 51 1 is on and the EPROM is plugged in Program Running Without Fault Exception Normally On If this light does not come on or goes out after coming on there is a problem with the microprocessor or the software running in it Check all of the buss connectors to the other two PCB s and ensure all three cards are getting power There 1 two position DIP switch on the processor PCB labeled S1 Switc
350. screw gt 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 gt Insertthe 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 gt Skip to Step 8 5 Place the bearing sleeve in the motor housing as shown It may be necessary to align the bearings in the sleeve to facilitate mounting on the lead screw 96 8109 103 MECHANICAL SERVICE V 125 une 1998 SERVICE MANUAL 104 6 Insert the six 4 20 1 SHCS attaching the bearing sleeve to the motor housing Place drop of blue Loctite amp on each of the SHCS before inserting Tighten to torque specifications CAUTION Do not use more than one drop of Loctite amp 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 i
351. se Error Number Range Error Prog Data Begins Odd Program Data Error Prog Data Struct Error Memory Overflow Electronics Overheat Spindle Overheat Program Data Error Invalid DPRNT Format Bad Language Version Bad Language CRC Rotary CRC Error Parameter CRC Missing Lead Screw CRC Missing Rotary CRC Missing Macro Variable File CRC Error Door open M95 Start C Servo Error Too Large erles SERVICE MANUAL MANUAL Data entered is not a number Comment must end witha Check input line or data from RS 232 This alarm can occur while editing data into a program or loading from RS 232 Input line is too long The data entry line must be shortened Software Error Call your dealer Number entry is out of range Possible corrupted program Save all programs to floppy disk delete all then reload Same as 249 Same as 249 Same as 249 The control box temperature has exceeded 145 degrees F This can be caused by an electronics problem high room temperature or clogged air filter This alarm is only generated in machines equipped with a Haas vector drive The spindle temperature sensor sensed a high temperature for greater than 1 5 seconds Same as 249 Macro DPRNT statement not structured properly Call your dealer Indicates FLASH memory has been corrupted or damaged Rotary table saved parameters used by Settings 30 78 have a CRC error Indicates a loss of memory call your dealer
352. se limits turn off the power and recheck the incoming power and the transformer wiring repeat steps 2 and 3 If the voltage is still incorrect turn off the power and call the factory 7 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 screw the screws into place and turn the power back on 4 3 FUSE REPLACEMENT Please read this section in its entirety before attempting to replace any fuses OVERVOLTAGE FUSES 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 11 Unscrew the three screws to open the cabinet door Control cabinets may require a key 3 Using a large flat screwdriver loosen the three screws on the cabinet door and t
353. small orifice tooling The minimum default value is 2500 millisec onds TSC SPINDLE RPM When TSC is enabled and in use this parameter limits the maximum spindle speed Default value is 7500 RPM On 50 taper machines TSC can be run at the maximum speed of 5000 RPM SPNDL ENC STEPS REV This parameter sets the number of encoder steps per revolution of the spindle encoder C AXIS MAX TRAVEL This parameter sets the C axis maximum travel in the positive direction U AXIS MAX TRAVEL This parameter sets the U axis maximum travel in the positive direction V AXIS MAX TRAVEL This parameter sets the V axis maximum travel in the positive direction W AXIS MAX TRAVEL This parameter sets the W axis maximum travel in the positive direction AHAS June 1998 96 8100 1998 96 8100 Parameter Parameter Parameter Parameter Parameter Parameter Parameter Parameter Parameter Parameter Parameter 244 245 246 247 255 256 257 258 259 266 267 SERVICE MANUAL MANUAL ______ AXIS MIN TRAVEL This parameter sets the C axis minimum travel in the negative direction U AXIS MIN TRAVEL This parameter sets the U axis minimum travel in the negative direction V AXIS MIN TRAVEL This parameter sets the V axis minimum travel in the negative direction W AXIS MIN TRAVEL This parameter sets the W axis minimum travel in the negative direction
354. sor to X and press PART ZERO SET twice This will set X0 YO at this position 4 Enter the following program It will start at the new zero position rapid 10 inches in the X direction feed the final 25 inches at 10 inches min and then repeat the X movement 600 G90 6110 YO X10 0 001 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 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
355. spindle dogs are parallel to the X axis Ensure that the dogs are within 0 030 using a dial indicator 3 If the machine is equipped with a 50 taper spindle add 5 degrees of offset 111 encoder steps to Parameter 257 to match the tool changer arm offset 96 8100 fy fff 79 MECHANICAL SERVICE 125 1998 SERVICE MANUAL MANUAL 80 7 SETTING 64 TOOL CHANGE 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 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 Tool Holder Spindle Table Figure 7 1 Checking tool offset reference 3 Carefully so as not to disturb relative position move the indicator to one side R
356. 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 6 Ensure oil plug is inserted into oil injection port of spindle before removing spindle or oil may spill into the spindle cartridge 7 With the 5 16 hex wrench loosen approximately two turns the six SHCS holding the spindle to the underside of the head casting 8 Place the block of wood minimum 6 thick on the table directly under the spindle 96 8100 January 1998 7 7 125 MECHANICAL SERVICE SERVICE MANUAL MANUAL Wood Block Covered Table Min Figure 4 1 Position wood block under spindle 9 At the panel 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 10 Z axis in the positive direction until spindle is half way out of the head casting 11 Grasp spindle with one hand and continue to jog in Z in the positive direction until it is completely free of the casting 4 2 SPINDLE CARTRIDGE INSTALLATION Tool Drawbar Housing Figure 4 2 Spindle cartridge 1 Thoroughly clean all mating surfaces of both the cartridge and the
357. ssembly from the T fitting Figure 4 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 4 2 LINE VOLTAGE ADJUSTMENTS Please read this section in its entirety before attempting to adjust the line voltage TOOLS REQUIRED v Large flat tip screwdriver v Digital voltmeter ADJUSTING VOLTAGE Note The machine must have air pressure at the air gauge or an interlock will prevent it from powering 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 146 gt n H Hs n n O M WS R IY AAAS 968100 7 SERVICE MANUAL MANUAL WARNING The electrical panel should be closed and the
358. st put the bezel spacer in place and fasten temporarily with screws in the top corners 5 114445 BEERS Eam gu 508 Figure 4 19 installation AAS June 1998 96 8100 1998 JE SERVICE IVIANUAL 8 Insert the ribbon cable through the opening in the control panel and place the keypad in the upper right corner of the lower opening and 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 9 While holding the bezel spacer in place remove the two screws holding the spacer put the front cover panel in place and fasten with all screws previously removed 10 Reinstall all switches spindle load meter and the jog handle as described in the previous sections 11 Replace the rear cover panel and fasten with the screws that were previously removed SERIAL 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 four screws the back of the control box then remove the cover panel Take care to hold the pan
359. t Place a spanner wrench on the clamp nut at the motor end of the assembly Torque the clamp nut to 15 FT LBS v v 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 8 Tighten down completely the five SHCS attaching the ball nut to the nut housing v v v v 96 8109 107 MECHANICAL SERVICE 125 une 1998 SERVICE MANUAL MANUAL 108 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 electrical power 11 Jog the spindle down and remove the cylinder shaft stop 12 For 40 and 50 mm lead screws only gt the spindle head towards the bearing support end gt Tighten down completely the SHCS that mount the bearing support to the column gt 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 Ibs 13 Check lead screw torque at bearing support end with torque tester Jog the the spindle head to it s highest position Check the lead sc
360. t metal of the spindle head or table Don t mount the magnetic base on the spindle dogs Don t check for accuracy repeatability using an indicator with a long extension Ensure that test indicators and stops are absolutely rigid and mounted to machined casting surfaces e g spindle head casting spindle nose or the table Don t rapid to position when checking accuracy The indicator may get bumped and give an inaccurate reading For best results feed to position at 5 10 inches per minute Check a suspected error with another indicator or method for verification Ensure that the indicator is parallel to the axis being checked to avoid tangential reading errors Center drill holes before using jobber length drills if accuracy is questioned Once machining practices have been eliminated as the source of the problem determine specifically what the machine is doing wrong 96 8100 F N P lt qRQ k 5 43 Mi 727 ms SERVICE MANUAL MANUAL Machine will not interpolate a round hole e Check that the machine is level see Installation section e Check for backlash Servo Motors Leadscrews section Bored holes do not go straight through the workpiece e Check that the machine is level see Installation section e Check for squareness in the Z axis Machine bores holes out of round e Check that the machine is
361. t was made to use a control feature not enabled by a parameter bit Set the parameter bit to 1 Same as 336 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 15 the minus direction Same as 316 A rotary axis must be specified in order to perform cylindrical mapping G107 The rotary axis specified is not a valid axis or has been disabled This alarm is generated if a G code block specifies 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 Aux axis servo shut off due to a fault Cannot have more than 200 programs in memory Need name in programs when receiving ALL otherwise has no way to store them Check files being loaded Program name must be Onnnn and must be at beginning of a block A receive found bad data Check your program The program will be stored but the bad data is turned into a comment Check your program The program will be stored but the bad data is turned into a comment Check your program The program will be stored but the bad data is turned into a comment Bad Parameter or Setting data User was loading settings or parameters and something was wrong with the data Bad parameter or setting data User was loading settings or parameters and something was wrong with the data Check your pro
362. take deflection for backlash in the system Figure 1 3 Dial indicator in position to check Z axis If backlash is found in the system check for the following possible causes e Loose SHCS attaching the ball nut to the nut housing Tighten the SHCS as described in Mechanical Service e 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 e Loose clamp nut on the bearing sleeve Tighten the SHCS on the clamp nut e Loose motor coupling Tighten as described in Mechanical Service e 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 e Loose SHCS attaching the bearing sleeve to the motor housing Tighten as described in Lead Screw Removal and Installation e Defective thrust bearings in the bearing sleeve Replace the bearing sleeve as outlined in Bearing Sleeve Removal and Installation e 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 e Incorrect backlash compensation number in the parameter in the machine Check Parameters
363. ten to 4 IN LBS against the bearing Retighten the clamp screw 9 For 40 and 50 mm lead screws only 100 ALLA O m 96 8100 1998 eri 125 MECHANICAL SERVICE SERVICE MANUAL MANUAL gt Move the table all the way to the right Tighten down completely the SHCS that mount the bearing support to the saddle gt 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 atorque screwdriver torque the clamp nut to 4 in Ibs 10 Reinstall the motor according to Axis Motor Removal and Installation 11 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 12 Reinstall the way covers and chip tray If applicable replace the hard stop 13 Check for backlash in the lead screw Accuracy Backlash section or noisy operation Y Axis Leap 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 gt SHCS and remove the clamp nut on the lead screw bearing support Y Axis Motor Cover Plate Motor Housing Lead Screw Support Bearing
364. ter every installation 3 3 TENSION ADJUSTMENT Note The drive belt s tension should be adjusted after every service on the transmission 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 Mount it to the head casting by inserting 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 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 see Figure 3 3 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 acc
365. that the vertical gap between them is uniform If it is not Determine which door must be adjusted gt Loosenthe door s outer lower roller attachment and pivot the door on the inner lower roller wheel gt When the dooris in the desired position the vertical gap is uniform tighten the lower outer roller fastener Outer Lower Roller Attachments Figure 3 63 View of vertical gap between front doors 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 968100 aJ 019 125 MECHANICAL SERVICE V E 125 t r _ June 1998 SERVICE MANUAL gt Loosenthe 000175 upper roller fasteners and the door forward or back as necessary to adjust door position Figure 3 64 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 5 reads 0 Move the door to the open position and ensure DOOR 5 reads 1 If either reading is incorrect gt 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 gt Move the bracket in its slot to the proper position and tighten the SHCS WiNpow REPLAC
366. the tool can be moved more than 0 003 the fit is too loose Use this Here Encoder bracket scale Scale mount Encoder head Use this Tool Here Figure 1 4 Linear scale alignment check tools If the tools can be inserted in accordance with the above instructions the linear scale is correctly aligned 5 Check for flatness and parallelism of the linear scale s with respect to the linear guide path with a magnetic base and indicator setup It should be possible to insert the tools correctly at both ends of travel Runout specifications are Flatness 0 005 along full travel Parallel 0 005 along full travel 6 Note results and contact Haas Automation for further instruction DO NOT attempt to align the linear scales HAT 27 43 727 gt ms SERVICE MANUAL IVIANUAL 1 40 AUTOMATIC PALLET CHANGER Checking pallet repeatability to the receiver e Maximum tolerance is 0005 e Pallets are not considered repeatable from one to the other Pallets should use seperate offsets e f 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 e 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 e the alignm
367. the SHCS on the motor coupling atthe lead screw Place a drop of blue Loctite on the screw before inserting 4 Replace the cover plate and fasten with the four 5 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 96 8100 s P Q Y T JTn Q 93 MECHANICAL SERVICE V E 125 June 1998 SERVICE MANUAL MANUAL 94 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 Z Ax s REMOVAL 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
368. 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 e 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 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 the current program is the cause change the program the axis hits a hard stop the travel limits may be set wrong Q Phasing Error e 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 gt Servo Error Too Large e This alarms occurs when the difference between the co
369. the bearing sleeve from the motor housing Push on the mill table or the opposite end of the lead screw to loosen 9658200 x af fff 109 MECHANICAL SERVICE E 125 1998 SERVICE MANUAL MANUAL 110 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 bearings in the sleeve to facilitate mounting Bearing Sleeve Motor Housing Mill Table mm Lead Screw Ball Nut Figure 3 53 Lead screw assembly 4 Insert the six 14 20 x 1 SHCS attaching the bearing sleeve to the motor housing Place a
370. the top right FU2 FU3 Ifthe 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 The two fuses FU4 and FU6 are not used FUSE NAME TYPE RATING VOLTAGE LOCATION amps FU1 AGC 250V POWER pcb upper right FU2 AGC 250V i FU3 AGC 250V not used Lamp AGC 250V lower left FU1 5 250V 0 PCB FU2 ABC 5 250V 0 PCB FU3 ABC 5 250V 0 PCB FU4 ABC 5 250V 0 PCB F1 ABC 15 250V Amplifier X Y Z A B 5 15 SPARE USER M CODE INTERFACE The M code interface uses outputs M21 23 and one discrete input circuit M codes M21 through M23 will activate relays labelled M21 23 These relay contacts are isolated from all other circuits and may switch up to 120V AC atone amp The relays are SPDT WARNING Power circuits and inductive loads must have snubber protection Note If the optional M code relay board is installed relays M21 28 become available on the secondary board These relays will be controlled by outputs M21 28 The M FIN circuit isa normally open circuit that is made active by bringing itto ground The one M FIN applies to all eight 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 pL M FIN 1 1 1 1 CNC RUNNING I WAITING 05 SEC WAITING RUNNING The Diagnostic Data displa
371. this time POWER BOARD 7 Note Refer to Cable Locations for diagram of this board Follow all precautions noted previously before working in the electrical cabinet See warning at beginning of Servo Driver 50151 section Turn the main switch upper right of electrical cabinet to the off position 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 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 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 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 Reconnect all cables to the POWER board at their proper location LOW VOLTAGE POWER SUPPLY 8 9 10 11 12 Remove the Power Distribution POWER board as described in Steps 1 5 Disconnect all leads to the Low Voltage Power Supply LVPS board Ensure all cables are
372. ting 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 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 control cabinet below all of the motor connectors Door OPEN SENSE SWITCH
373. tion 96 8100 147 244 to 260 left 5 ELECTRICAL SERVICE eri eS June41998 SERVICE MANUAL MANUAL Main Switch Figure 4 7 Power lines hookup location 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 overloads To check simply pull on the wires after the screws are tightened 2 After the line voltage is connected to the machine make sure that main circuit breaker at top right of rear cabinet is off rotate the shaft that connects to the breaker counterclockwise until it snaps off Turn on the power at the source Using an accurate digital voltmeter and appropriate safety procedures measure the voltage between all three pair phases at the main circuit breaker and write down the readings The voltage must be between 195 and 260 volts 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 yo
374. tional statement was not processed in the same block An END was encountered without encountering a previous matching DO DO END numbers must agree Variable cannot be read during axis movement A G code command was found on a WHILE DO or END macro block Move the G code to a separate block Only one Assignment is allowed per block or a THEN statement is missing On G65 lines all parameters must follow the G65 G code Place parameters after G65 The addresses G L N O and P cannot be used to pass parameters Only 10 occurrences of J or K can occur in G65 subroutine call Reduce the 1 J or K count Only four levels of macro nesting can occur Reduce the amount of nested G65 calls Macro syntax is not allowed in a pocket pattern subroutine A conditional expression evaluated to an UNDEFINED value i e 0 Return True or False Multiple use of a DO that has not been closed by and END in the same subroutine Use another DO number A DPRNT statement has been formatted improperly or DPRNT does not begin block A G code was included on a DPRNT block Make two separate blocks While a DPRNT statement was executing the RS 232 communications failed WHILE DO statement does not contain a matching END statement Add the proper END statement Expression after GOTO not valid AHAS 96 8100 1998 96 8100 540 613 1002 1003 1004 1005 1006 1007 1008 1009 Macro S
375. 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 Lifting Points Figure 3 26 VF 0 with lifting eyeholes HAAS June 1998 96 8100 1998 7 7 125 MECHANICAL SERVICE SERVICE MANUAL MANUAL 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 Itis recommended that the HAAS Transmission Hoist be used in this operation Refer to Hoist Pre Assembly later in this 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 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 t
376. tor in position to check Y axis 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 0 2 0 Set the rate of travel to 001 on the control panel and the machine 010 in the positive Y direction back to zero 0 on the display The dial indicator should read zero 0 0001 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 14 Set up a dial indicator and base on the mill table as shown in Fig 1 3 96 8100 se June 1998 Q lt vr gt f 125 TROUBLESHOOTING SERVICE MANUAL MANUAL 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 mis
377. u 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 148 MH AAAS 96 8100 EXF ETMS execreicar service SERVICE MANUAL MANUAL TER aT 27 r uv Figure 4 8 Transformer connections 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 to this transformer The input voltage range for each terminal block is as follows 96 8100 149 ELECTRICAL SERVICE eri eS ymne 1998 SERVICE MANUAL MANUAL HIGH VOLT LOW VOLT r INPUT TERMINALS FROM CONTACTOR K1 34 r INPUT TERMINALS FROM CONTACTOR K1 488 448V 447 429V 428 403V 402 377V 260 244V 243 227V 226 211V 210 195V
378. une 1998 96 8100 1998 n T P V moO oUV gt P 7 ELECTRICAL DIAGRAMS MANUAL 4 PIN 1 PIN 1 7 PN K25 MeL 12VDC 1 PIN 2 E i PIN2 Le e PIN 3 PIN 3 as 7 1 bog aA K26 Mee 12VDC 1 PIN 4 4 4 PIN 5 I PIN 5 57 K27 M23 12VDC PIN PIN 6 LE 27 2 1 4 PIN 7 7 7 aA 28 M24 OR TSC 12VDC 1 PNB PIN 8 2 28 1 4 9 PIN 9 i 65 Z i K29 GREEN STROBE 12VDC PIN 10 PIN 10 LE e i 4 PN 10 PIN 11 i OVDC V K30 RED STROBE 12VDC PIN 12 N PIN 12 LE i 4 PIN 13 i PIN 13 i 5 5 K31 CHIP CONVEYOR ON 12VDC PIN 14 PIN 14 LE 31 2 J PIN 15 a 15 V7 213 K32 CHIP CONVEYOR REVERSE 12VDC 1 PIN 16 PIN 16 LE e 14 CABLE Hm PCB __ 540 __ vO NOTE ANY RELAY K55 CAN BE REPLACED WITH SOLID STATE EQUIVALEN COI
379. urn purge on and off optional Pre charge is on 40 taper spindle only Shuttle moves in to release tool Tool unclamps Zaxis moves up 0 Tool Changer rotates 1 Z axis moves down 2 Tool clamps 3 Pre charge off 40 taper spindle only 4 1 2 3 4 5 6 7 8 9 1 1 1 1 1 Shuttle moves out 96 8100 mn ANG 167 2 erie 168 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 characterized by a long shaft and a 45 shoulder under the head Do not use the short shaft or pull studs with a sharp right angle 90 head as they will not work and will cause serious damage If the machine is equipped with the optional BT tool changer use BT tooling only Pull studs are available through HAAS USE ONLY CORRECT PULLSTUDS 1 USE ONLY CORRECT PULLSTUDS CT TOOLING DIN ISO TOOLING BT TOOLING L pum 1 104 0 990 0 990 THREAD 5 8 11 MIB X 27 THREAD _ T _ THREAD T i HAAS P N 20 7165 HAAS P N 20 7164 HAAS P N 20 7164A TSC 20 7595 TSC 20 7594 TSC 20 7556 1 AVOID EXCESSIVE TOOL
380. ust be repaired or the carousel replaced See appropriate section for extractor fork replacement 96 8100 6 19 SERVICE MANUAL MANUAL Noisy OPERATION To isolate noise s in the ATC carefully observe the ATC in operation and look for the following lt ATC makes noise as the shuttle moves 20 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 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 ATC makes noise during carousel rotation Check to ensure the Geneva driver on the turret motor is tight and properly adj
381. usted 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 Replacement section Check the adjustment of the Geneva driver in relation to the Geneva star Geneva Star Replacement 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 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 nois
382. val 3 Remove the hard stop from the bearing housing on the lead screw 4 Loosen the 10 32 x gt SHCS and remove the clamp nut from the bearing support end of the lead screw 5 Loosen the six 4 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 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 14 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 amp 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 4 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 f iG
383. while a tool change operation is going on Changer not at home and either the Z or A or B axis or any combination is not atzero 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 HAAS June 1998 96 8100 1998 96 8100 151 152 153 154 155 156 157 158 159 160 161 162 163 164 165 Low Thru Spindle Coolant Self Test Fail X axis Z Ch Missing Y axis Z Ch Missing Z axis Z Ch Missing A axis Z Ch Missing M0C0N Watchdog Fault Video Keyboard Failure Keyboard Failure Low Voltage X Axis Drive Fault Y Axis Drive Fault Z Axis Drive Fault A Axis Drive Fault X Zero Ret Margin Too Small erles SERVICE MANUAL MANUAL For machines with Through the Spindle Coolant only This alarm will shut off the spindle feed and pump all at once It will turn on purge wait for the amount of time specified in parameter 237 for the coolant to purge and then turn off the purge Check for low coolant tank level any filter or intake strainer clogging or for any kinked or clogged coolant lines If no problems are found with any of these and none of the coolant lines are clogged or kinked call your dealer
384. 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 AAS 23 43 veoussesnoorne Mi 727 o ms SERVICE MANUAL MANUAL Low CooLANT Alarm 151 Low Thru Spindle Coolant e Check coolant tank level e Check for slow coolant drainage from machine enclosure e 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 e f received at start up check that the breaker hasn t tripped and that the pump is turning Check the electrical continuity of cables e 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 e Forold 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 e Check for pressure switch failure refer to Testing the Coolant Pressure
385. witch Figure 5 3 Tool release piston assembly 4 While activating tool release tap unclamp switch assembly towards spring retainer until it just trips Switch must trip at 060 010 THIS ADJUSTMENT IS VERY IMPORTANT FOR PROPER TOOL CHANGER OPERATION AND MUST BE PROPERLY SET 96 8100 15 MECHANICAL SERVICE V 125 January 1998 SERVICE MANUAL 5 Check the adjustment by setting the jog handle at 06 and activating the tool release The DB signal should be a 1 If the adjustment is not correct adjust until it is within specifications You may have to readjust the switch several times UPPER CLAMP SWITCH CAUTION Remove the tool holder from the spindle before performing the upper CLAMP switch adjustment Failure to remove it could result in damage to the tool holder the mill table or cause severe personal injury 6 Place a shim approximately 020 thick or the flexible ruler between the tool release piston adjustment bolt and the drawbar Tool Release Piston Spindle Cartridge Assembly Figure 5 4 Placement of shim before checking switch adjustment 7 Move the tool release piston down so the shim is pressed against the drawbar This can be done in one of the two following ways Using the pipe as a lever push down on the piston until it
386. wn 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 Replace IOPCB see Electrical Service Check Parameter 57 for Power Off at E STOP Replace MOTIF or MOCON PCB see Electrical Service Machine turns on keyboard beeps but no CRT display e Check for green POWER LED at front of CRT Check for power connections to CRT from IOPCB Close doors and Zero Return machine possible bad monitor Check video cable 760 from VIDEO PCB to CRT Check for lights on the processor Replace CRT see Electrical Service Machine turns on CRT works but no keyboard keys work e Check keyboard cable 700B from VIDEO to SKBIF PCB e Replace keypad see Electrical Service e Replace SKBIF PCB see Electrical Service lt Constant E Stop Condition will not reset e Check Hydraulic counterbalance pressure low pressure switches and cabling 4 968100 se June 1998 TROUBLESHOOTING SERVICE MANUAL MANUAL 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
387. xpected G37 may only specify Z axis and must have tool offset defined Auto work offset probing must be done without tool offset A Dnn code is required in G35 in order to store the measured tool diameter G20 was specified but settings have selected metric input G21 was specified but settings have selected inches G10 was used to changes offsets but L P or R code is missing or invalid An address A Z was used improperly If block buffering has been limited Cutter comp cannot be used Coordinates cannot be altered while cutter comp is active Move G10 outside of cutter comp enablement Planes of rotation cannot be changed while rotation is enabled HAAS 96 8100 1998 96 8100 390 391 392 393 394 395 396 397 398 403 404 405 406 407 408 409 410 411 412 Spindle Speed Feature Disabled B Axis Disabled Invalid Motion In 074 G84 B Over Travel Range No G107 Rotary Axis Specified Invalid 6107 Rotary Axis Specified Aux Axis In G93 Block Aux Axis Servo RS 232 Too Many Progs RS 232 No Program Name RS 232 Prog Name RS 232 Missing Code RS 232 Invalid Code RS 232 Number Range Error RS 232 Invalid N Code RS 232 Invalid V Code RS 232 Empty Program RS 232 Unexpected End of Input erles SERVICE MANUAL MANUAL S code has been encountered 5 code An attemp
388. y page may be used to observe the state of these signals RELAYS The IOPCB contains three relays 21 23 and the optional M code relay board contains eight M21 M28 either one of these groups of relays 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 If the optional M code relay board is installed the relays on the IOPCB are to be left unused 96 8100 _ J C ec HN 3 Oo OLOS 185 TECHNICAL REFERENCE er 7 1998 SERVICE MANUAL 186 1 Input Signal M Code Output Relay Normally 2 Input GND Discrete discrete input is 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 Inputs PCB on the Input Output Assembly 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 TunNiNc M Functions Orr The M code relays can also
389. yntax Not Allowed Command Not Allowed In Cutter Comp section of code was interpreted by the control where macro statement syntax is not permitted A command M96 for example in the highlighted block cannot be executed while cutter comp is invoked End Of List Note Alarms 1000 1999 are user defined by macro programs Unclamp Error Clamp Error Mislocated Pallet Pal No Conflict Rec amp Ch Switch Missed Pal 1 Switch Missed Pal 2 Door Not Open Door Not Closed The palletdid not unclamp in the amountoftime allowed This can be caused by air solenoid a blocked or cinked air line or a mechanical problem The pallet did not clamp in the amount of time allowed by the M50 macro This alarm is most likely caused by the VMC table not being in the correct position This can be adjusted using the macro variables for the X position 7500 504 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 an 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 an air solenoid is bad or an air line is blocked or kinked A pallet is not in the proper place on the APC The pallet must be pushed back against the

HAAS SERVICE AND OPERATOR MANUAL ARCHIVE VF

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