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    Haas Technical PublicationsManual_Archive_Cover_Page Rev A June 6, 2013•This content is for illustrative purposes.•Historic machine Service Manuals are posted here to provide information for Haas machine owners.•Publications are intended for use only with machines built at the time of origi...

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    Troubleshooting196-0189 rev L June 2005BackCOMMON ABBREVIATIONSACAlternating CurrentAMPAmpereAPCAutomatic Pallet ChangerAPLAutomatic Parts LoaderASCIIAmerican Standard Code for Information InterchangeATCAutomatic Tool ChangerATC FWDAutomatic Tool Changer ForwardATC REVAutomatic Tool Changer Rever...

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    2Troubleshooting96-0189 rev L June 2005LO CLNTLow CoolantLOW AIR PRLow Air PressureLVPSLow Voltage Power SupplyMBMegabyte (1 million)MCD RLY BRDM -Code Relay BoardMDIManual Data InputMEMMemoryM-FINM -code FinishedMMMilliMeterMOCONMotor ControlMOTIFMotor InterfaceMSGMessageMSHCPMetric Socket Head ...

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    Troubleshooting396-0189 rev L June 20051. TROUBLESHOOTINGThis section is intended for use in determining the solution to a known problem. Solutions given are intended togive the individual servicing the CNC a pattern to follow in, first, determining the problem’s source and, second,solving the ...

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    4Troubleshooting96-0189 rev L June 20051.1 GENERAL MACHINE OPERATIONMACHINE NOT RUNNINGMachine cannot be powered on• Check input voltage to machine (see "Electrical Service").• Check main circuit breaker at top right of electrical cabinet; switch must be at the on position.• Check...

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    Troubleshooting596-0189 rev L June 2005VIBRATIONVibration is a subjective evaluation with perceptions varying among individuals, making it difficult to determine inmild cases if there is an actual problem. In obvious cases, it is a matter of determining the source - which isnot easy, since all pa...

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    6Troubleshooting96-0189 rev L June 2005• Once machining practices have been eliminated as the source of the problem, determine specificallywhat the machine is doing wrong.Machine will not interpolate a round hole.• Check that the machine is level (see "Installation" section of the R...

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    Troubleshooting796-0189 rev L June 20052.Jog to an offset location on the table (example: X-15.0" Y-8.0" ). Select the X axis and press theORIGIN key to zero it. Select the Y axis and zero it.3.Press the OFSET key, then scroll down to G110 (or any unused offset). Cursor to X and pressPA...

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    8Troubleshooting96-0189 rev L June 20051.2 SPINDLENOT TURNINGSpindle not turning•If there are any alarms, refer to "Alarms" section.•Check that the spindle turns freely when machine is off.•Command spindle to turn at 1800 RPM and check spindle drive display. If display blinks “b...

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    Troubleshooting996-0189 rev L June 2005•Ensure that the correct oil is being used (refer to "Maintenance Schedule").STALLING / LOW TORQUEGenerally, complaints of stalling or low torque relate to incorrect tooling or machining practices. A spindle thatis tending to seize will yield a p...

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    10Troubleshooting96-0189 rev L June 2005If the fault occurs upon acceleration -or- the spindle accelerates slowly -or- the spindlemakes noise, do the following:7.Disconnect the output cables to the spindle motor. Turn on the machine and press <RESET>. Donot command the spindle to turn. With...

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    Troubleshooting1196-0189 rev L June 2005•Check the condition of the tooling, verifying the taper on the tooling is ground and not turned. Lookfor damage to the taper caused by chips in the taper or rough handling. If the tooling is suspected,try to duplicate the symptoms with known-to-be-good t...

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    12Troubleshooting96-0189 rev L June 20051.3 SERVO MOTORS / BALL SCREWSNOT OPERATINGAll problems that are caused by servo motor failures should register an alarm. Check the alarm history todetermine thecause of the problem before any action is taken.Servo motor is not functioning•Check the power...

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    Troubleshooting1396-0189 rev L June 2005•Check the ball screw for misalignment. If incorrect, perform alignment procedure in "Ball Screw"section.•Misalignment in the ball screw itself will tend to cause the ball screw to tighten up and make excessivenoise at both ends of the travel....

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    14Troubleshooting96-0189 rev L June 2005The “Distance to go” display in the lower right hand corner of the screen should read: X=0 Y=0 Z=03.Set the rate of travel to .001 on the control panel and jog the machine .010 in the positive (+) Xdirection. Jog back to zero (0) on the display. The ...

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    Troubleshooting1596-0189 rev L June 2005TOTAL DEVIATION BETWEEN THE DIAL INDICATOR AND THE CONTROL PANEL DISPLAYSHOULD NOT EXCEED .0002.An alternate method for checking backlash is to place the dial indicator as shown in Fig. 1.3-2 and manuallypush up and down on the spindle head while listening ...

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    16Troubleshooting96-0189 rev L June 2005•Loose SHCS attaching the ball nut to the nut housing. Tighten the SHCS as described in "MechanicalService" section.•Loose SHCS attaching the nut housing to the column, head, or saddle, depending on the axis. Tightenthe SHCS as described in &q...

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    Troubleshooting1796-0189 rev L June 2005A-axis backlash adjustment for optional 1° indexer:The facegear must be disengaged before checking backlash. First raise the platter by applying air to the liftpiston with Haas tool number T-2150. Disconnect the A-axis and connect tool T-2150 as shown on d...

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    18Troubleshooting96-0189 rev L June 2005BALL SCREWS - VISUAL INSPECTIONThe three main causes of Ball Screw failure are:Loss of LubricationContaminationMachine CrashWear of the nut balls and the screw threads is generally a non-issue under proper operating conditions.Each type of suspect cause wil...

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    Troubleshooting1996-0189 rev L June 2005BALL SCREW CLEANINGIn most cases, a thorough cleaning of the suspect Ball Screw will resolve “bad screw” issues, including noisecomplaints.1.Manually jog the ball nut to one end of the screw.2.Visually inspect the screw threads. Look for metal flakes, d...

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    20Troubleshooting96-0189 rev L June 20051.4 PALLET CHANGEREC-400 PALLET CHANGER OVERVIEWWhen the automatic pallet changer (APC) is at rest, the pallet is clamped, the pallet at the load station is athome position, and the APC door is closed. The H-frame “Down” solenoid is on, the safety sole...

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    Troubleshooting2196-0189 rev L June 200522. The servomotor rotates the H-frame and pallets 180 deg., by driving through the gearbox, torque tube, &hub, while the apc shaft, cycloid hub, and part of the gearbox remain stationary.The servomotor rotates with the assembly.23. The H-frame down swi...

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    22Troubleshooting96-0189 rev L June 2005EC-300 PALLET CHANGERIntroductionUnclampedSprings andair clampAir Unclamp ExhaustSwitch NormallyOpenClamp PlateTable ClampSpringsClamp PistonClampedAir Clamp PressureOperationNote: Pallet is pulled down by clamp plate.The table trips the clamp switch, not t...

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    Troubleshooting2396-0189 rev L June 2005Table ClampA. Condition is clamped when machine is normally powered off or when first powered on or when table index iscompleted.P13524SolEx231BlockedSolSafety ValvePressurePowerOnPower OnExB. Condition when machine is unclamped• Note: Same condition appl...

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    24Troubleshooting96-0189 rev L June 2005Result The clamp plate unclamps, raising the pallet. The machine is ready to rotate the pallet, but the controldoes not receive a signal that the table has raised. Without the signal the control thinks the pallet is clamped.After a period of time an alarm ...

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    Troubleshooting2596-0189 rev L June 20051.5 AUTOMATIC TOOL CHANGER (ATC)Refer to the alarm description when problems arise with the ATCSee “Spindle” section for additional trouble shooting information.CRASHINGCrashing of the ATC is usually a result of operator error. The most common ATC cras...

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    26Troubleshooting96-0189 rev L June 20051.6 THROUGH THE SPINDLE COOLANTNOTE:Abrasive swarf from grinding or ceramic machining operations will causeheavy wear of TSC coolant pump, coolant tip and drawbar. This is not coveredby warranty on new machines. Notify HAAS Service Department if machine is...

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    Troubleshooting2796-0189 rev L June 2005PRE-CHARGE FAILUREAlarm 198, "Precharge Failure"NOTE:This alarm only applies to the TSC system.•Check for broken or disconnected pre-charge air line, and replace if necessary.•Check if the "Tool Clamped" limit switch is sticking; rep...

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    28Troubleshooting96-0189 rev L June 20051.7 ELECTRICAL TROUBLESHOOTINGCAUTION! Before working on any electrical components, power off the machine andwait approximately 10 minutes. This will allow the high voltage power onthe brushless amplifiers to be discharged.ELECTRICAL ALARMSAxis Drive Fault...

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    Troubleshooting2996-0189 rev L June 2005Alarm 101, "MOCON Comm. Failure"•During a self-test of communications between the MOCON and main processor, the main proces-sor does not respond, and is suspected to be dead. This alarm is generated and the servos arestopped. Check all ribbon ca...

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    30Alarms96-0189 rev L June 20052. ALARMSAny time an alarm is present, the lower right hand corner of the screen will have a blinking "ALARM". Push theALARM display key to view the current alarm. All alarms are displayed with a reference number and a completedescription. If the RESET key...

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    31Alarms96-0189 rev L June 2005109 Y SERVO OVERLOAD Excessive load on Y-axis motor. This can occur if the load on the motor over a period ofseveral seconds or even minutes is large enough to exceed the continuous rating of the motor. The servos will beturned off when this occurs. This can be cau...

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    32Alarms96-0189 rev L June 2005123 SPINDLE DRIVE FAULT Failure of spindle drive, motor or regen load. This can be caused by a shorted motor,overvoltage, overcurrent, undervoltage, failure of drive or shorted or open regen load. Undervoltage and overvoltageof DC bus are also reported as alarms 160...

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    33Alarms96-0189 rev L June 2005139 X MOTOR Z FAULT Encoder marker pulse count failure. This alarm usually indicates that the encoder has beendamaged and encoder position data is unreliable. This can also be caused by loose encoder connectors.140 Y MOTOR Z FAULT Encoder marker pulse count failure...

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    34Alarms96-0189 rev L June 2005157 MOCON WATCHDOG FAULT The self-test of the MOCON has failed. Call your dealer.158 VIDEO/KEYBOARD PCB FAILURE During power-on tests, the control has detected a problem in either thekeyboard or the video memory. Call your dealer.159 KEYBOARD FAILURE Keyboard shorte...

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    35Alarms96-0189 rev L June 2005172 APC-PALLET UNCLAMP TIMEOUT The pallet in the mill did not unclamp in the time allowed. Check forforeign objects between the pallet and the clamp plate. Verify there is an adequate supply of air pressure andair volume. Check air solenoids for sticking and air re...

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    36Alarms96-0189 rev L June 2005192 B AXIS Z CH MISSING Z reference signal from encoder was not received as expected. Can be caused by looseconnections, encoder contamination, or parameter error.193 B AXIS DRIVE FAULT Current in B servo motor beyond limit. Possibly caused by a stalled or overloade...

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    37Alarms96-0189 rev L June 2005216 EPROM SPEED FAILURE Possible processor board problem217 X PHASING ERROR Error occurred in phasing initialization of brushless motor. This can be caused by a badencoder, or a cabling error.218 Y PHASING ERROR Error occurred in phasing initialization of brushless...

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    38Alarms96-0189 rev L June 2005236 SPINDLE MOTOR OVERLOAD The spindle motor is overloaded.237 SPINDLE FOLLOWING ERROR The error between the commanded spindle speed and the actual speed hasexceeded the maximum allowable (as set in Parameter 184).238 AUTOMATIC DOOR FAULT The automatic door was comm...

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    39Alarms96-0189 rev L June 2005258 INVALID DPRNT FORMAT Macro DPRNT statement not structured properly.259 LANGUAGE VERSION Problem with language files. Please reload foreign language files.260 LANGUAGE CRC Indicates FLASH memory has been corrupted or damaged.261 ROTARY CRC ERROR Rotary table sav...

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    40Alarms96-0189 rev L June 2005279 X AXIS LINEAR SCALE Z FAULT Encoder marker pulse count failure. This alarm usually indicates that the Z Faultencoder has been damaged and encoder position data is unreliable. This can also be caused by loose scaleconnectors.280 Y AXIS LINEAR SCALE Z FAULT Encode...

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    41Alarms96-0189 rev L June 2005299 ATC SHUTTLE OUT OF POSITION The ATC shuttle mark switch is in an incorrect state. Check for a sticking,misaligned, or damaged switch, mechanism binding, damaged motor, or debris build up. Use Tool Changer Restoreto recover the ATC, then resume normal operation....

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    42Alarms96-0189 rev L June 2005326 G04 WITHOUT P CODE Put a Pn.n for seconds or a Pn for milliseconds.327 NO LOOP FOR M CODE EXCEPT M97, 98 L code not used here. Remove L Code.328 INVALID TOOL NUMBER Tool number must be between 1 and the value in Parameter 65.329 UNDEFINED M CODE That M code is n...

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    43Alarms96-0189 rev L June 2005352 AUX AXIS POWER OFF Aux C, U, V, or W axis indicate servo off. Check auxiliary axes. Status from control wasOFF.353 AUX AXIS NO HOME A ZERO RET has not been done yet on the aux axes. Check auxiliary axes.354 AUX AXIS DISCONNECTED Aux axes not responding. Check a...

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    44Alarms96-0189 rev L June 2005381 G43, G44 NOT ALLOWED IN G36 OR G136 Auto work offset probing must be done without tool offset.382 D CODE REQUIRED IN G35 A Dnn code is required in G35 in order to store the measured tool diameter.383 INCH IS NOT SELECTED G20 was specified but settings have selec...

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    45Alarms96-0189 rev L June 2005406 RS-232 MISSING CODE Bad data was received. Check your program. The program will be stored but the baddata is turned into a comment.407 RS-232 INVALID CODE Check your program. The program will be stored but the bad data is turned into acomment.408 RS-232 NUMBER ...

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    46Alarms96-0189 rev L June 2005431 FILE NO PROG NAME Need name in programs when receiving ALL; otherwise has no way to store them.432 FILE ILLEGAL PROG NAME Check files being loaded. Program must be Onnnn and must be at the beginning of ablock.433 FILE EMPTY PROG Check your program. Between % and...

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    47Alarms96-0189 rev L June 2005515 TOO MANY CONDITIONALS IN A BLOCK Only one conditional expression is allowed in any WHILE or IF-THENblock.516 ILLEGAL CONDITIONAL OR NO THEN A conditional expression was found outside of an IF-THEN, WHILE, or M99block.517 EXPRSN. NOT ALLOWED WITH N OR O A macro ...

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    48Alarms96-0189 rev L June 2005539 ILLEGAL GOTO Expression after GOTO not valid.540 MACRO SYNTAX NOT ALLOWED A section of code was interpreted by the control where macro statement syntaxis not permitted.541 MACRO ALARM This alarm was generated by a macro command in a program.542 OPERATION NOT AVA...

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    49Alarms96-0189 rev L June 2005613 COMMAND NOT ALLOWED IN CUTTER COMP At least one command in the highlighted block cannot be executedwhile cutter compensation is active. Block Delete characters (‘/’) and M codes such as M06, M46, M50 and M96 arenot allowed. Your program must have a G40 and ...

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    50Alarms96-0189 rev L June 2005630 APC-DOOR SW FAULT-SWITCH NOT EQUAL TO SOLENOID The APC Door Switch indicates the door is open butthe solenoid shows the door has been commanded to close. Either the door failed to close and is stuck or the switchitself is broken or stuck. Also, the door switch w...

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    51Alarms96-0189 rev L June 2005642 642 APC-PIN CLEAR SWITCH FAULT – One of the pallet changer pin clear switches was contacted unexpectedly.The most likely cause is debris on a switch. Also check the pin clear switches for damage and their electrical wiringfor damage. After correcting the cond...

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    52Alarms96-0189 rev L June 2005653 V ZERO RET MARGIN TOO SMALL This alarm will occur if the home/limit switches move or are misadjusted. Thisalarm indicates that the zero return position may not be consistent from one zero return to the next. The encoder Zchannel signal must occur between 1/8 and...

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    53Alarms96-0189 rev L June 2005673 TT or B SERVO ERROR TOO LARGE Too much load or speed on TT or B-axis motor. The difference between themotor position and the commanded position has exceeded Parameter 470. The motor may also be stalled, discon-nected, or the driver failed. The servos will be tu...

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    54Alarms96-0189 rev L June 2005691 U AXIS DRIVE FAULT Current in U servo motor beyond limit. Possibly caused by a stalled or overloaded motor.The servos are turned off. This can be caused by running the axis into a mechanical stop. A short in the motor or ashort of one motor lead to ground can al...

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    55Alarms96-0189 rev L June 2005905 NO P CODE IN M14, M15, M36 In M14, M15, M36 must put pallet number in a P code.906 INVALID P CODE IN M14, M15, M36 OR M50 The P code must be the pallet number of a valid pallet without adecimal point, and must be a valid integer number.907 APC UNLOAD-SWITCH MIS...

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    56Alarms96-0189 rev L June 2005921 APC LOAD-SWITCH MISSED PAL 4 Pallet #4 did not complete its move from the APC to the receiver in theallowable time. Pallet change sequence was halted because receiver switch was not activated. Pallet is eitherunclamped or not on the receiver. Ensure the pallet i...

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    57Alarms96-0189 rev L June 2005946 APC-PALLET CLAMP TIMEOUT The pallet in the mill did not clamp in the time allowed. Check for foreign objectsunder the pallet and between the pallet and the clamp plate. Verify there is an adequate supply of air pressure and airvolume. Check air solenoids for st...

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    58Alarms96-0189 rev L June 2005957 APC-SWITCH FAULT An illegal switch condition was detected. The pallet clamp switch did not function correctly.Use M17 and M18 commands to verify the input switch (input relay 26) changes state when the pallet clamps andunclamps. Check switch adjustment and check...

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    59Mechanical Service96-0189 rev L June 20053. MECHANICAL SERVICERECOMMENDED TORQUE VALUES FOR MACHINE FASTENERSThe following chart should be used as a reference guide for torquing machine fasteners where specified.DIAMETERTORQUE8-3230 in. lb.1/4 - 2015 ft. lb.5/16 - 1830 ft. lb.3/8 - 1650 ft. lb...

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    Mechanical Service6096-0189 rev L June 20054.Remove the seven (7) BHCS on each side that fasten the vertical guides to the column.5.Remove the lower waycover.Install the way cover in the reverse order above however make sure that all necessary gaskets, and sealantsare replaced and repaired as ne...

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    61Mechanical Service96-0189 rev L June 2005Shades1Clamp the shaft at the flat with clamping pliers or other such clamping device to hold the shaftwhen adjusting of the spring tension.2.Loosen the set screw so that the spring tension may be adjusted.3.Rotate the shaft one complete revolution agai...

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    Mechanical Service6296-0189 rev L June 2005Installation1.Install the four SHCS at the top of the way cover. Slide the way cover up and down to ensure that itmoves freely.2.Slide the way cover down until the bottom flange goes under the spindle head cover and fasten itwith four (4) BHCS.3.Fasten ...

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    63Mechanical Service96-0189 rev L June 20053.2 SPINDLE MOTOR REPLACEMENTRemoval1.Remove the rear enclosure panel.2.Disconnect the electrical cable to the fan.3.At the rear of the spindle and motor shroud, remove the four (4) SHCS that hold the fan mountingbracket in place. Remove the electrical ...

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    Mechanical Service6496-0189 rev L June 2005Installation1.Sweep the spindle before the motor installation is started.2.Check the condition of the coupler hub on top of the spindle, and the condition of the couplerspider. Lift the motor up and position it just above the TRP using a forklift or hoi...

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    65Mechanical Service96-0189 rev L June 200550 TAPER TRANSMISSION AND MOTOR REPLACEMENTRemoval1.Lower the Z-axis travel to its full negative value (full down). Position the mill table so that it iscentered on the X-axis and as close to the doors as possible (full -Y). This will allow the bestwork...

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    Mechanical Service6696-0189 rev L June 2005CAUTION! Measure the distance between the bottom of the Z-axis motor and theballscrew anchor mount. Cut a wood block to the proper length and put inplace. This is necessary to counteract the Hydraulic Counterbalancemechanism when the transmission/motor ...

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    67Mechanical Service96-0189 rev L June 200514. Replace sheetmetal.15. Set spindle orientation. Refer to the “Spindle Orientation” section.16. Check Toolchanger function.TOOL RELEASE PISTON REPLACEMENTRemoval1.Remove the rear enclosure panel.2.Jog the Y-axis all the way to the top. Insert a s...

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    Mechanical Service6896-0189 rev L June 2005TRP Assembly3/8 “ AirHose FittingClampSwitch4X SHCS4XLockwasherSpindle Motor andShroud AssemblyUnclampSwitch1/4” AirHose F 1/4” Air HoseFitting3/8” Air Hose FittingView Rotated for ClarityUnclamp SwitchClampSwitchEC-Series TRP assembly7.Remov...

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    69Mechanical Service96-0189 rev L June 20053.3 SPINDLESPINDLE CARTRIDGEREMOVAL-1.Remove the six SHCS that mount the spindle to head casting.2.Slide the spindle out from the front side of machine.INSTALLATION-1.Inspect the mating surface for high spots on the spindle and spindle head casting befo...

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    Mechanical Service7096-0189 rev L June 20053.4 DRAWBAR REPLACEMENTDRAWBAR REPLACEMENT - IN-LINE DRIVEThe drawbar is only replaceable on the 8000 RPM spindle. The 12000 RPM spindle has a non-serviceable draw-bar.Note:12000 spindles only: Should a spindle fail, both the spindle and drawbar areto ...

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    71Mechanical Service96-0189 rev L June 2005Verify the operation of the spindle by running it. If there is excessive vibration, loosen the bolts to the spindlecartridge and spindle head. Run the spindle at 1000 rpm and snug the bolts. Stop the spindle and tighten thebolts.DRAWBAR REPLACEMENT - 50...

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    Mechanical Service7296-0189 rev L June 20054.POWER ON the machine.5.Insert an empty tool holder into the spindle taper.6.Go to HANDLE JOG mode. Choose Z-axis and set the jog increments to .01.7.Jog the Z-axis in the negative (-) direction until the tool holder is approximately .03" from the...

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    73Mechanical Service96-0189 rev L June 2005NOTE:Shims may need to be added or removed when spindle cartridge, tool releasepiston assembly, or drawbar is replaced. If none have been replaced, skip thissection.1.Check the condition of the tool release bolt and the draw bar. Repair or replace these...

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    Mechanical Service7496-0189 rev L June 20057.Check the adjustment. Jog the Z-axis down until the tool is .050 above the block and confirm thatDB OPN=0 when the tool release button is pressed. The switch must trip (DB OPN =1) at 0.06"above the block and not trip (DB OPN =0) at 0.05" abo...

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    7596-0189 rev L June 2005Mechanical Service3.6 40 TAPER CAROUSEL SIDE MOUNT TOOL CHANGER40 TAPER CAROUSEL REMOVAL AND INSTALLATION11312 1110 9 87654322322212019181716151424CarouselNumber DiscTool PocketsCarouselCarouselCoverCarousel HousingAssemblyATC AssemblyBaseEC-300 Side Mount Tool Changer ...

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    Mechanical Service7696-0189 rev L June 2005Removal:1.Power Off machine.2.Unscrew the BHCS from the carousel number disc and remove.3.Using a spanner wrench, remove nut on the center shaft of the carousel.4.Carefully pull carousel assembly from the ATC center shaft. Lift carousel away from the ma...

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    7796-0189 rev L June 2005Mechanical ServiceCarouselMotorCarouselPulleyPulley locations and ATC movement4.Re-attach the carousel number disc with the BHCS. Apply blue loctite to the BHCS and tighten.50 TAPER CAROUSEL REMOVAL AND INSTALLATIONCAUTION! Do not attempt to remove the carousel with the ...

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    Mechanical Service7896-0189 rev L June 2005TOOL CHANGER ASSEMBLY REMOVAL / INSTALLATIONRemoval:1.Power off machine.2.Remove all ATC assembly sheet metal covers and fasteners.3.Remove the tool changer amphenol connection at the control box and tool pocket air line at the topof the carousel. Wrap ...

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    7996-0189 rev L June 2005Mechanical ServiceAUTOMATIC TOOL CHANGER ALIGNMENTUse Split Tool P/NT-2086 for 40 taper, CT typeT-2088 for 50 taper, BT typeT-2087 for 40 taper, BT typeT-2089 for 50 taper, CT typeThis procedure is for a newly mounted ATC assembly without the double-arm installed.Perform...

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    Mechanical Service8096-0189 rev L June 2005Radial Alignment of Double Arm to Carousel:1.Rotate the cam box pulley counter-clockwise to raise the double-arm into the split tool. Visuallycheck the centerline alignment of the split tool to the centerline of the tool pocket.2.In order to adjust the ...

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    8196-0189 rev L June 2005Mechanical ServiceSetting the Double-arm Extension:20. Press the DOWN ARROW to command the tool pocket out. Place the split tool with the pull studinto the tool pocket. In TCR mode, rotate the double arm near the tool pocket.21. Visually check the alignment of the double...

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    Mechanical Service8296-0189 rev L June 20051234567891011121314151617181920222324252627282930313233343536 3738394021CarouselNumber Disc8X BHCSSpindleAssemblyDouble-ArmAssemblyATC CoversCarouselAssemblyATCMountingBracketATC AssemblyPocketStop ATC Assembly Alignment.6.Use a mallet to align the ATC...

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    8396-0189 rev L June 2005Mechanical ServiceTC Door (Open)View Rotated 90CCW8Spring DamperTC Door (Closed)Hose ClampTool ChangerDoor OpenSwitch4.Mark the spot where the bit changes to 1 and secure the switch with a hose clamp.5.Reconnect the main air supply, and take the machine off of E-stop.6.R...

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    Mechanical Service8496-0189 rev L June 20053.Push air cylinder towards linear guide rail while tightening bolts.4.Thread & tighten onto cylinder rod end.Tool Changer Doors5.Grease main panel face where the door guide will be mounted. Mount door guide to main panel,with the guide spacer betwe...

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    8596-0189 rev L June 2005Mechanical Service7.Retract air cylinder rod. Place a 7/16 washer over rod aligner thread. Move top door bracket downto air cylinder rod aligner. The hole in bracket should line up with rod aligner without forcing it overrod end. If not loosen air cylinder mounting bolts...

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    Mechanical Service8696-0189 rev L June 20053.Enter DEBUG mode. Record the encoder value under “spindle orientation position”. Refer to Figure3.12-13.4.Return to Parameter 257. Enter the spindle orientation value from DEBUG and lock parameters.5.In TCR mode, press the ATC REVERSE button until...

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    8796-0189 rev L June 2005Mechanical Service4X Double-ArmJack SHCS8X Lock RingSHCSLock RingDouble-ArmRemoval of the Double ArmInstallation1.Place the double-arm onto output shaft. Align the double-arm to the home position, then slide thelock ring onto the shaft.2.Reattach the lock ring to the dou...

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    Mechanical Service8896-0189 rev L June 2005To adjust the clearance, remove the slide and the cover by removing the cover plate and lifting the slide outat an angle. Be careful not to lose the spring. Loosen the adjuster and correct the clearance by adding orremoving shims. Apply blue Locktite an...

  • Page 90

    8996-0189 rev L June 2005Mechanical ServiceTool Pocket(Load Position)Tool PocketMountingFHCSCarouselSliderPositionPocketOrientationTabsPocketStop5.Remove the tool changer pocket by carefully maneuvering the pocket out of the carousel, takingcare not to drop the pocket slide.NOTE:If the carousel ...

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    Mechanical Service9096-0189 rev L June 20052.Visually check for misalignment (tool pockets should move smoothly).3.If necessary, loosen the setscrew nut. Adjust the setscrew in or out until the tool pocket is alignedwith the circular path on the carousel housing. Advance the tool pocket and obse...

  • Page 92

    9196-0189 rev L June 2005Mechanical ServiceTool Clamp SensorOriginSensorMotor StopSensorOil Fill LevelTriggerGroovesCam Box Pulley4X Cam BoxMounting SHCS3X ProximitySensorsOil Fill/BreatherProximity Sensor Switch LocationInstallationThe proximity trigger disk inside the cam box determines the se...

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    Mechanical Service9296-0189 rev L June 20054.Screw the proximity sensor into the cam box an additional 1/8 turn after the L.E.D light comes on.Loosen both nuts then re-tighten the inner nut against the cam box housing. Tighten the outer nutagainst the inner nut.5.Repeat this procedure for each p...

  • Page 94

    9396-0189 rev L June 2005Mechanical Service6.Enter DEBUG. Jog handle the Z-axis up or down until the end of the tool is at the same height asthe measured value found when the tool was placed in the tool pocket. Record the Z-axis spindleheight value.7.Take the difference in the spindle height val...

  • Page 95

    Mechanical Service9496-0189 rev L June 2005Setting the Tool Change Offset1. Set the Tool changer axis to “Visible”. This is done by setting bit 18 of Parameter 462 to zero.2. Make sure the spindle head is up out of the way3. Go to the Discrete Inputs page and look at the cambox origin displa...

  • Page 96

    9596-0189 rev L June 2005Mechanical Service3.7 AXIS MOTORSPlease read this section in its entirety before attempting to remove or replace the axismotors.X-AXIS MOTORX-Axis MotorKey4X SHCS4X BHCSCouplingCouplingHousingCoverX-Axis Motor and Ball Screw Assembly EC-300CouplingX-Axis MotorCover Plate...

  • Page 97

    Mechanical Service9696-0189 rev L June 20058.Remove the SHCS motor mounting bolts and remove the motor from the coupling housing.Installation1.Inspect the motor coupling and replace it if required. Visually inspect the flex plates to ensure theyare parallel to the coupling halves. Slide the new ...

  • Page 98

    9796-0189 rev L June 2005Mechanical Service3.Jog the X-axis until the Y-axis motor can be easily accessed from the rear.4.Install the column shipping bolts if available, or place a block of wood on the column castingbeneath the spindle head casting. Lower the spindle head (Y-axis) until it rests...

  • Page 99

    Mechanical Service9896-0189 rev L June 20053.Align the key on the motor shaft. Slide the motor into the motor housing, inserting the end of theball screw into the motor coupling.4.Reinstall and tighten down the SHCS that hold the motor to the coupling housing.5.Tighten the SHCS on the motor coup...

  • Page 100

    9996-0189 rev L June 2005Mechanical Service2.EC-300 – Jog the Y-axis to the bottom of its travel. Jog the Z-axis to the back of the machine.EC-400 – Jog the Z-axis away from the spindle.3.POWER OFF the machine.4.EC-400 – Unbolt the Z-axis way cover from the receiver and pull it away from t...

  • Page 101

    Mechanical Service10096-0189 rev L June 2005Motor Ccoupling Ccomponents.INSTALLATION-1.Slide the new coupling onto the motor shaft until the coupling half is flush to the end of the shaft.NOTE:The slot in the locking collar must be positioned 45 degrees between the bolthole pattern of the couple...

  • Page 102

    10196-0189 rev L June 2005Mechanical Service3.8 BEARING SLEEVEPlease read this section in its entirety before attempting to remove or replace the bearingsleeve.Removal1.POWER ON the machine. Zero return all axes and put the machine in HANDLE JOG mode.2.Remove the rear enclosure panel.3.Jog the a...

  • Page 103

    Mechanical Service10296-0189 rev L June 2005Installation1.Ensure all mating surfaces on the bearing sleeve, motor housing, nut housing, and ball nut are freeof dirt, burrs, grease, or other contaminants.CAUTION! Mating surfaces must be clean or misalignment may occur, seriouslyaffecting the prop...

  • Page 104

    10396-0189 rev L June 2005Mechanical Service3.9 BALL SCREWPlease read this section in its entirety before attempting to remove or replace the ballscrews.TOOLS REQUIRED:• Torque wrench• Spanner nutX-AXIS BALL SCREW4X BHCS2XSHCS2XSHCS6XSHCS4XSHCSCouplingHousing CoverCouplingMotorBumperSupportB...

  • Page 105

    Mechanical Service10496-0189 rev L June 20055.Remove the hardstop and locknut from the bearing support.6.Remove the SHCS that secure the nut housing to the ball screw nut.7.Remove the oil line from the ball screw nut.8.Rotate the nut on the ball screw, in order to move the nut near the bearing s...

  • Page 106

    10596-0189 rev L June 2005Mechanical Service10. The following sequence is important to ensure proper installation of the ball screw:• Tighten the locknut, hand tight, on the motor end.• Install and tighten locknut on bearing support. Ensure the nut does not touch thebearing support.• Insta...

  • Page 107

    Mechanical Service10696-0189 rev L June 2005BumperBumperBracket4X BHCSBearing Locknut4X SHCSSupportBearingHousing2X Dowel PinBearing LocknutY-AxisBallscrewCouplingHousingCoverCoupling5X SHCSBumperBall ScrewNut HousingPlane5Plane6Plane5 BumperBearingLocknutCouplingMotorHousingCoverBumper6X SHCSB...

  • Page 108

    10796-0189 rev L June 2005Mechanical Service11. Remove the upper bearing pack.12. Remove the ball screw out the topY-Axis MotorSpindle AssemblyHydraulicCounterbalanceBumperBearingLocknutCouplingBumperBearingLocknutY-Axis leadBallscrew2X SHCS2X SHCSBallscrewNut6xSHCSBearingSupport Bearing Housing...

  • Page 109

    Mechanical Service10896-0189 rev L June 20058.Hand-turn the ball screw to move the spindle motor up and down, to assure free movement of theball screw.9.Torque the SHCS that hold the ball nut to the nut housing to 30 ft-lb.10 The following sequence is important to ensure proper installation of t...

  • Page 110

    10996-0189 rev L June 2005Mechanical ServiceZ-AxisWay CoverReceiverZ-AxisBall ScrewCouplingCouplingHousing CoverBumperBearingLocknutSupport BearingHousing6X SHCS4X SHCSBearingLocknutBumper4XBHCS5XSHCSOil Line FittingBall Screw NutHousingEC-400 Z-Axis Ball Screw removal1.Turn the machine ON. ZERO...

  • Page 111

    Mechanical Service11096-0189 rev L June 200514. EC-300: Carefully push the ball screw towards the front of the machine and above the supportbearing.EC-400: Carefully push the ballscrew to the side of the bearing support and then remove by pullingthe ballscrew towards the spindle.EC-1600: Carefu...

  • Page 112

    11196-0189 rev L June 2005Mechanical Service14. Tighten the ball screw against the locknut as follows. The sequence is important to ensure properinstallation of the ball screw:•Tighten the locknut, hand tight, on the motor end.• Install and tighten locknut on bearing support. Ensure the nut ...

  • Page 113

    Mechanical Service11296-0189 rev L June 20053.10 EC-300 PALLET CHANGERPALLET CHANGER DISASSEMBLYPallet Changer Disassembly can be done from the “Load Station” of the EC 300 without removing anyenclosure parts.1.Enter “M-17” in MDI mode and press “Cycle Start” to un-clamp the pallet (...

  • Page 114

    113Mechanical Service96-0189 rev L June 2005NOTE:There are 2 power lines and 2 air lines: one pair connected to each table. Thereis also an oil line that splits to each table.Remove the cable cover on the rotating door and pull the cables through. Disconnect the power cables fromthe J-box, remo...

  • Page 115

    Mechanical Service11496-0189 rev L June 20059.Remove the pallet changer tables by unbolting the (4) 5/8" shoulder bolts between the pallet changer andthe frame support. After removing the shoulder bolts, the pallet is loose on the pallet support springs and canbe lifted off using 2 “eye...

  • Page 116

    115Mechanical Service96-0189 rev L June 20054.Bolt-in lifting tools and lift out. Disconnect the “un-clamp” air fitting on the bottom side of thePiston Cover Plate. Remove the Piston Cover, the Pallet Clamp Piston and P.C.Shaft to service theassembly.To service the “Thrust Bearing” asse...

  • Page 117

    Mechanical Service11696-0189 rev L June 2005Squaring The Pallet 1. Loosen all bolts from Pallet Changer to the base and align front-machined surface of pallet parallel toX-axis (NTE 0.002" overall). Perform a pallet change and verify other side.2. Level the pallet along the X-axis by indi...

  • Page 118

    117Mechanical Service96-0189 rev L June 20056. Indicate across rotary table surfaces along the X and the Z axes. The indications should be parallelto within 0.0005"/10".7. Rotate the pallet changer, and indicate the other rotary table as described in step 5 above.Pallet Changer Grid Of...

  • Page 119

    Mechanical Service11896-0189 rev L June 20053.11 EC-400 PALLET CHANGERMake sure the machine is turned off and the air pressure is discharged before attempting to work on thismachine. Refer to the assembly drawing of the APC in the back of this manual.The drive mechanism for the APC is located in...

  • Page 120

    119Mechanical Service96-0189 rev L June 2005Tapered RollerBearingBearing LocknutShaft CoverAir VentTaperedRoller BearingO Ring 2-358HubO Ring Inside 2-377Seal HousingCam3X Ball BearingsCageCamShaft ClampBridgeCylinder LeverShaft Mount(Wired in series withLoad Station door switch)OperatorStation ...

  • Page 121

    Mechanical Service12096-0189 rev L June 2005PALLET CHANGER DISASSEMBLY AND REPLACEMENTDisassembly1.Remove the rotating door and the servo motor sheet metal cover.2.Unplug the electrical wires to the servo motor. Dismount the servo motor held to the umbrellamount plate with four (4) SHCS.3.Remove...

  • Page 122

    121Mechanical Service96-0189 rev L June 2005H-FRAME REPLACEMENT1.Remove the rotating door.2.Remove the two (2) hardstops from the H-frame.3.Remove the SHCS that fasten the H-frame to the hub.4.Raise the H-frame with an appropriate lifting device until the H-frame is above the dowel pins.5.Carefu...

  • Page 123

    Mechanical Service12296-0189 rev L June 20057.Press the key to raise the pallet. Turn up the air pressure (at the air regulator) slowly and verifythat the H-frame and pallet are aligned. To lower the H-frame and pallet raise the air pressure andpress the button for pallet down.8.If the alignment...

  • Page 124

    123Mechanical Service96-0189 rev L June 2005H-FRAME SWITCH ADJUSTMENTH-frame up sensor1.Remove the APC cylinder shield to access the up switch.2.Loosen the switch clamp.3.Find the correct position for the switch: Go to the APC diagnostics page. The status of “H-FrameUp” should be “0” for...

  • Page 125

    Mechanical Service12496-0189 rev L June 2005EC-400 ROTARY INDEXER AIR DIAGRAMTop ViewFront ViewAir InSafety SolenoidAssemblyLift/PurgeSolenoidAssemblyAir in FromAir Doubler(140 PSI)ClampSolenoidAssembly Platter AirPurgeClamp SolenoidAssemblyLiftClampAir in FromAir Doubler(140 PSI)LiftSol...

  • Page 126

    125Mechanical Service96-0189 rev L June 2005Receiver Geometry Verification:Note: The receiver is never adjusted to correct pallet flatness. It is adjusted for runout and concentric-ity. Both need to be confirmed before the pallet is installed.Indicate the receiver concentricity by first rotating...

  • Page 127

    Mechanical Service12696-0189 rev L June 20057. Remove the 8 bolts securing the receiver to the rotary platter.The receiver is now ready to be removed from the machine.8. Working through the operator door, use lifting equipment to remove the receiver. The receiver clamp plate has1/2-13 tapped hol...

  • Page 128

    127Mechanical Service96-0189 rev L June 2005Indicating the pallet1. Install the new pallet on the receiver and indicate across the 45 degree angles on the receiver locating keysuntil they are parallel with the X-axis. The keys must be parallel to the x-axis within .0005,” if the keys are notpa...

  • Page 129

    Mechanical Service12896-0189 rev L June 20053.Connect the test air regulator Haas P/N T-2150 to the shop air supply. Connect the outlet to the rotarytable at the platter lift, air in connection (Air In). (Be sure that the regulator adjustment knob is fully open.)Air InSolenoidPlungerPlatter UpPl...

  • Page 130

    129Mechanical Service96-0189 rev L June 2005Oil Bleed ValveRing GearHydraulicBrake AssyBrake BoosterOil LineAir LinesSETTING PARAMETERS 212 AND 128 (INDEXER A AXIS OFFSET)1.In Debug mode, go to parameter 212 and enter “0” then press the “Write” key. Repeat for parameter 128.2.Toggle air ...

  • Page 131

    Mechanical Service13096-0189 rev L June 20053.13 THROUGH THE SPINDLE COOLANT SYSTEM - ADJUSTMENTSTOOLS REQUIREDTool holder with small through coolant drill or small orifice tool (#T-1461).TSCHP Gauge Kit (P/N 93-9011), includes:Ball valve0-600 PSI coolant gaugePRIMING THE TSC SYSTEMNOTE:When mac...

  • Page 132

    131Mechanical Service96-0189 rev L June 2005TESTING THE COOLANT PRESSURE SWITCH1.Insert the ball valve and pressure gauge into the coolant line between the machine enclosure andthe TSC pump hose. The ball valve must be between the pump and pressure gauge. Tighten thefittings snugly with wrenches...

  • Page 133

    Mechanical Service13296-0189 rev L June 20053.14 GRID OFFSET CALCULATIONPlease 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 isreleased. If DISTANCE TO GO is...

  • Page 134

    133Mechanical Service96-0189 rev L June 20053.15 THROUGH THE SPINDLE COOLANT SYSTEM FLOW DIAGRAMIn-Line DriveAIR PRESSURE SWITCH, 70 PSI2 POSITION, 3 WAY, SP. RET.SOLENOID VALVE (PRE-CHARGE)METERING ORIFICE .040SHUTTLE VALVE (TOOL RELEASE)TOOL RELEASE SOLENOID ASSEMBLYCHECK VALVE ASSEMBLYINTAK...

  • Page 135

    Mechanical Service13496-0189 rev L June 20053.16 HS3-7R AIR VALVE ASSEMBLY (S/N 51003 AND BEFORE)The Air Valve Assembly has three main components:3-Way Air ValveHigh-Pressure RegulatorLow-Pressure RegulatorTHEORY OF OPERATIONThe Air Valve Assembly actuates the Rotary Table brake. Supplied air...

  • Page 136

    135Mechanical Service96-0189 rev L June 20054.Cut the tubing to fit once installed in the table. Insert one end of one piece of tubing into the elbowon the air side of the hydraulic cylinder.5.Thread one of the two remaining elbows into the low-pressure port of the pressure booster, locatedin th...

  • Page 137

    Mechanical Service13696-0189 rev L June 2005INSTALLATION - HYDRAULIC CYLINDER1.Lift the hydraulic cylinder into its area beneath the table. See the following figure for the approxi-mate location. The hose connections should face the left of the table (away from the pressurebooster) to prevent ki...

  • Page 138

    137Mechanical Service96-0189 rev L June 20053.17 HS-3/4/6/7 MOTOR AND TRANSMISSIONRemovalNote:The motor and transmission are removed as a unit.Caution:The motor/transmission assembly is very heavy; lifting equipment will beneeded to safely remove and instal this assembly.1. Remove the wire cover...

  • Page 139

    Mechanical Service13896-0189 rev L June 20056. Connect the cables to the motor and transmission, and then replace the cover.BELTS REPLACEMENTThe motor and transmission assembly must be removed to replace the spindle drive and spindle encoder belt.See the motor and transmission section for instru...

  • Page 140

    139Mechanical Service96-0189 rev L June 20053.18 50 TAPER SPINDLE TRP REMOVAL1.For TSC equipped machines, place a tool holder in the spindle.2.Remove the screws that hold the lower Y-axis way cover from the head and lower the way cover.3.For TSC equipped machines the coolant union and extension ...

  • Page 141

    Mechanical Service14096-0189 rev L June 2005Rear ViewTRPLifting StrapTRP in PositionMotor andTransmissionTRP shown in position and as it is lowered8.Remove the four shoulder screws holding the tool release piston assembly to the head casting.9.Lower the TRP to remove it from the machine.TRP DISA...

  • Page 142

    141Mechanical Service96-0189 rev L June 2005O' Ring Replacement1.Remove and replace the 4 O'rings (57-0027) on the TRP 50T shaft2.Remove and replace the 2 O'rings (57-0092) on the TRP 50T piston, 1 O'ring per piston.3.Remove and replace the 3 O'rings (57-0095). 2 in the center of the TRP 50T hou...

  • Page 143

    Mechanical Service14296-0189 rev L June 2005Figure 3-10. Shim and spacer location diagram.1.Use the lifting straps to position the TRP. The TRP is heavy, use an overhead lifting device.2.Install the 4 bolts, with the shim stock and spacers under the TRP.Part No.Description30-0013A (NEW) 30-0013 ...

  • Page 144

    143Mechanical Service96-0189 rev L June 2005TRP(45-0019)0.093 Nylon Washer 1 ea.1 ea.Spacers:(45-0017)0.010 Shim Washer 2 ea.2 ea.(45-0018)0.015 Shim Washer 3 ea.2 ea.(NOTE: TRP Spacers: the nylon washer goes on top of the shims.)3.If the machine is equipped with TSC, re-install the Extension Tu...

  • Page 145

    Mechanical Service14496-0189 rev L June 2005h)Block Spindle rotation with a bolt, bar or socket inserted into one of the Pulley holes. It will stopagainst the TRP Fork.i)Tighten the Extension Tube to 15-20 ft-lb. Remove the bolt from the Spindle Pulley.j)Install the Rotating Union. Lightly greas...

  • Page 146

    145Mechanical Service96-0189 rev L June 2005Figure 3.2-10 Fork shim location.6.The Tool Push-out adjustment is 0.060” +/-0.010. Add or remove shims from the tool releasefork to make adjustments. The shims come in 0.010” and 0.018” thicknesses.Jog away from the plate 0.060”. Press and hol...

  • Page 147

    Mechanical Service14696-0189 rev L June 2005Figure 3.2-11 TRP shim location50 TAPER SWITCH ADJUSTMENT Figure 3.2-12 Tool Clamp / Unclamp Switches.1.Setting the upper switch (Tool Clamped). Push the switch in slowly until it trips, then push it a littlefarther. Lock down the screws. Double-Check ...

  • Page 148

    147Mechanical Service96-0189 rev L June 20052.Setting the lower switch (Tool Unclamped). Use the air pressure regulator on the back of themachine or an extra regulator placed in line.a) Jog the Z-Axis to 0.030” above the aluminum block.b) Go to Parameter 76 write down the value and then change...

  • Page 149

    148Mechanical Service96-0189 rev L June 20053.19 HARMONIC DRIVE COMPONENTSThe Harmonic Drive unit is used to drive the rotary table on machines such as the HS 3,4,6,7 adn the EC-1600.The Harmonic Drive Assembly is made up of the following components:Housed Harmonic DriveO-Ring Pack (included in ...

  • Page 150

    14996-0189 rev L June 2005Mechanical ServiceASSEMBLY - MOTOR / WAVE GENERATOR1.Sweat the Pinion Gear (positioned so the groove is away from the flange) over the shaft of theSigma Adapter and set aside.2.Examine the spindle of your Yaskawa Sigma Motor. If your Motor has the Motor Shaft Spaceralre...

  • Page 151

    150Mechanical Service96-0189 rev L June 2005ASSEMBLY - HARMONIC DRIVE1.Cover your work area with a clean shop rag and place the Harmonic Drive with the smaller-diameterend down on the work surface. You should see the grease cavity of the Harmonic Drive.2.Remove the large O-Ring from the included...

  • Page 152

    15196-0189 rev L June 2005Mechanical Service5.Bolt the Gearbox Adapter to the Harmonic Drive by inserting four SHCS into the countersunk holesin the Gearbox Adapter.NOTE:To test for a dedoidal (out of phase) condition, perform the following operation:Turn the Harmonic Drive/Motor assembly over a...

  • Page 153

    152Mechanical Service96-0189 rev L June 2005INSTALLATION - BACKLASH TUBE AND PLATE1.Apply grease to the outer side of the Tube and top side (as installed) of the Plate. Also applygrease to the counterbore for the Tube and the machined surface underneath the Table the Platewill move against.2.Ass...

  • Page 154

    15396-0189 rev L June 2005Mechanical ServiceINSTALLATION - CARRIER MOUNT BRACKET1.Orient the Carrier Mount bracket so the edge side faces forward and the flush side is toward thecenter of the Table. Turn the Carrier bracket so that the mounting holes face the bottom surface ofthe Table. See the ...

  • Page 155

    154Mechanical Service96-0189 rev L June 20053.204TH AXIS BRAKE ASSEMBLYThe Brake Assembly has five main components:Brake RingBrake ArmPivot BlockPivot PinBearingASSEMBLY1.Orient the Pivot Block so that you will be inserting the Bearings (Step 2) from the 20-degreechamfered side.2.Insert one Bear...

  • Page 156

    15596-0189 rev L June 2005Mechanical ServiceBrake RingPivot PinBrake ArmPivot BlockINSTALLATION - BRAKE ASSEMBLY1.Clean the threaded holes in the table to remove all oil. Apply Red Loctite onto the (6) Studs (49-0024) and thread into the Stud holes indicated below. Install to a height of 2.175...

  • Page 157

    156Mechanical Service96-0189 rev L June 20055.With an assistant, lift and lower the Brake Ring Assembly onto the Table. Fit the Brake Ring overthe Pivot Pins and Studs. The Brake Ring should rest against the Table. If there is interference,make sure the Pivot Block is in the fully retracted posi...

  • Page 158

    15796-0189 rev L June 2005Mechanical ServiceINSTALLATION - RING GEAR1.Lubricate and stone the mating surfaces of the Platter and Ring Gear. Wipe clean to removegrease and contaminents.2.Clean the mating surfaces of the Platter and Ring Gear with alcohol.CAUTION! The Ring Gear is a precision-mach...

  • Page 159

    158Mechanical Service96-0189 rev L June 20053.21 4TH AXIS AIR VALVE ASSEMBLYThis section applies to machines with serial number 51004 and later. See the end of this section for informationspecific to machines built before 51004.The Air Valve Assembly has three main components:3-Way Air ValveHig...

  • Page 160

    15996-0189 rev L June 2005Mechanical Service3.22 4TH AXIS BRAKE CYLINDER PRESSURE BOOSTERTHEORY OF OPERATIONThe Pressure Booster gives the ability to develop and use high hydraulic pressure without incurring the cost ofan on-board HPU. The Pressure Booster has a high-pressure side, a low-pressu...

  • Page 161

    160Mechanical Service96-0189 rev L June 2005Street Elbow (2)7.Thread the Hose Barb into the remaining 90-Degree Elbow and attach to the Pressure Boosterassembly. Orient as shown in the following figure:Hose Barb8.Attach the Braided Hose to the Hose Barb using the supplied hose clamp. Use caution...

  • Page 162

    16196-0189 rev L June 2005Mechanical ServiceFINAL ASSEMBLYOrient the Plate as shown and attach to the bottom of the Pressure Booster.Pressure BoosterAssemblyLow Side PortTubingElbowPlatePressure Booster Final Assembly (bottom view)PRESSURE BOOSTER ASSEMBLYPrior to installation of the Pressure Bo...

  • Page 163

    162Mechanical Service96-0189 rev L June 20051.Identify the low-pressure Tubing line coming from the low-pressure side of the Pressure Booster.Connect this Tubing line to the Low-Pressure Regulator of the Air Valve Assembly.2.Identify the high-pressure Tubing line coming from the high-pressure si...

  • Page 164

    16396-0189 rev L June 2005Mechanical Service6.Tighten the SHCS in a star pattern until the screws are snug. Evenly tighten the screws to seat theBearing, then back off each SHCS 1/16 turn.NOTE:If you are installing the Bearing by yourself, it will be useful to have a mirrorpositioned to see the ...

  • Page 165

    164Mechanical Service96-0189 rev L June 2005NOTE:Adjusting the Bearing in this manner will move the top part of the outer bearingin the direction pressed, placing leverage against the bottom part of the outerbearing.NOTE:During this procedure, it will be necessary to tighten selected bolts in th...

  • Page 166

    16596-0189 rev L June 2005Mechanical ServiceInstallation1.Generously apply red grease to the outer ring of the Brake, completely filling the two grooves.Apply Moly grease around the Stud Flex Nuts filling the counterbores on the Brake Ring, horseshoe brake only. Apply moly grease to the Pinion G...

  • Page 167

    166Mechanical Service96-0189 rev L June 200511. Tighten the SHCS incrementally in a star pattern to avoid misaligning the Bearing. Torque theSHCS in stages up to a final torque of 45 ft./lbs.12. Before replacing the encoder shaft plate, make sure the set screws are backed off.13. Tighten the scr...

  • Page 168

    16796-0189 rev L June 2005Mechanical Service3.700"Shaft Length4.175"Encoder ShaftEncoder MountingPlate(O.D. is precision groundfor measuring concentricity)Encoder Cover PlateEncoder Shaft PlateEncoder Coupler TubeFlex CouplingEncoder MountingCupEncoderMeasure fromthis surfaceSet Screws...

  • Page 169

    168Mechanical Service96-0189 rev L June 200501020304050607080901.03 0.03+Encoder ShaftCoupler (52-4471)Encoder MountingPlate (20-6114B)Encoder(32-1459)6.Install the rotary table platter and indicate its bore concentric with the cross-roller bearing,concentricity NTE 0.0005”.NOTE: Be careful no...

  • Page 170

    16996-0189 rev L June 2005Mechanical Service5.Manually rotate the platter back and forth. At times additional force is required to overcome thefriction. Use platter lifting plates or a fixture on the platter with a cheater bar between them, ifnecessary, to move the platter.6.Take readings from t...

  • Page 171

    170Mechanical Service96-0189 rev L June 2005Tightening this screw willbacklashreduceTightening this screw willbacklashincreaseBacklash Adjusting Screws5.Verify the brake is disengaged and that backlash exists by manually moving the platter back andforth. At times additional force is required to ...

  • Page 172

    17196-0189 rev L June 2005Mechanical Service3.23 4TH AXIS HARMONIC DRIVE ASSEMBLY - EXPLODED PARTS LIST1Tube Backlash Adjuster2Cam Backlash Adjuster3Push Block4SCHS5SHCS6Pinion Gear7Sigma Adapter8Harmonic Drive9O-Ring10 MSHCS11 Shoulder Washer12 Gearbox Adapter13 SHCS14 SHCS15 Flat Washer16 HHB...

  • Page 173

    172Mechanical Service96-0189 rev L June 20053.24 4TH AXIS TABLE ASSEMBLY - EXPLODED PARTS LIST1SHCS2Machined Platter3Ring Gear4SHCS5Brake6SHCS7Bearing Crossroller8Bearing Retainer Ring123456

  • Page 174

    17396-0189 rev L June 2005Mechanical Service3.Thread a Reducer into the hydraulic port. Thread the Swivel Elbow into the Reducer. Thread theHydraulic Hose from the Pressure Booster into the Swivel Elbow. Orient the Swivel Elbow asshown below and tighten.4.Thread Elbow into the air port. Orient t...

  • Page 175

    174Mechanical Service96-0189 rev L June 2005PRESSURE BOOSTER ASSEMBLY BENCH TESTPrior to installation of the Pressure Booster Assembly, a test of the entire system should be performed. Thiswill identify leaks and allow for the system to be bled while it is still easily accessible. Set the Air Va...

  • Page 176

    17596-0189 rev L June 2005Mechanical ServiceINSTALLATION - HYDRAULIC CYLINDER1.Lift the Hydraulic Cylinder into its area beneath the Table. See the Figure below for the approxi-mate location. The hose connections should face the left of the table (away from the PressureBooster) to prevent kinks ...

  • Page 177

    Electrical Service17696-0189 rev L June 20054. ELECTRICAL SERVICE40Install lock-out claspand lock with paddlockto secure Circuit Breakerin the OFF positionMake sure the circuit breaker is locked in the off position before attempting any electrical work to avoid pos-sible shock.CAUTION! Working w...

  • Page 178

    177Electrical Service96-0189 rev L June 20054.1 SOLENOIDSPlease read this section in its entirety before attempting to replace any solenoid assemblies.TOOL RELEASE PISTON AIR SOLENOID ASSEMBLYREMOVAL -1.Turn machine power ON. EC-300 Raise the spindle head to its highest position (EC-400 lower th...

  • Page 179

    Electrical Service17896-0189 rev L June 2005INSTALLATION -1.Replace the air solenoid assembly and attach to the bracket with the screws previously removed.Tighten securely.2.Reconnect all air lines.4.Reconnect the wiring to the plugs on the solenoid bracket.5.Reconnect air supply to the machine,...

  • Page 180

    179Electrical Service96-0189 rev L June 2005Figure 4.1-2. Top view of spindle lube/air solenoid assembly.5.Replace the assembly, ensuring it is approximately horizontal to the floor, and tighten fittingssecurely.6.Reconnect all air lines.7.Reconnect wiring leads at the quick-disconnect in the wi...

  • Page 181

    Electrical Service18096-0189 rev L June 20054.2 LINE VOLTAGE ADJUSTMENTSPlease read this section in its entirety before attempting to adjust the line voltage.TOOLS REQUIRED•Large flat tip screwdriver•Digital voltmeterADJUSTING VOLTAGENOTE:The machine must have air pressure at the air gauge, ...

  • Page 182

    181Electrical Service96-0189 rev L June 2005ELECTRICAL CONNECTIONSNOTE:The machine must have air pressure at the air gauge, or a "Low Air Pressure"alarm will be present on power up.40L1Main Circuit BreakerGround LineT5 TransformerL2L31.Hook up the three power lines to the terminals on ...

  • Page 183

    Electrical Service18296-0189 rev L June 20053.Check the connections on the transformer at the bottom-right corner of the rear cabinet. The threeblack wires labeled 74, 75, and 76 must be moved to the terminal block triple which corresponds tothe average voltage measured in step 2 above. There ar...

  • Page 184

    183Electrical Service96-0189 rev L June 20057.Apply power to the control by pressing the Power-On switch on the front panel. Check the highvoltage buss on the Vector Drive (pin 2 with respect to pin 3 on the terminal bus at the bottom ofthe drive). It must be between 310 and 360 volts. If the vo...

  • Page 185

    Electrical Service18496-0189 rev L June 2005Input Voltage Range Tap493-5101 (504)481-4922 (492)469-4803 (480)457-4684 (468)445-4565 (456)433-4446 (444)420-4327 (432)This should produce a voltage on the secondary side of 234-243 V RMS L-L. Verify this and readjust the tapsas required. At the mach...

  • Page 186

    185Electrical Service96-0189 rev L June 20054.3 FUSE REPLACEMENTPlease read this section in its entirety before attempting to replace any fuses.OVERVOLTAGE FUSESWARNING!WARNING!WARNING!WARNING!WARNING!The electrical panel will have residual voltage, even after power hasbeen shut off and/or disco...

  • Page 187

    Electrical Service18696-0189 rev L June 2005Figure 4.3-2 Power supply board; fuse locations.5.Using a flat tip screwdriver, turn the fuse(s) counterclockwise to remove and replace the blownfuse(s) with ones having the same type and rating (½ amp, type AGC, 250V).CAUTION! When the left fuse is b...

  • Page 188

    187Electrical Service96-0189 rev L June 20054.4 PCB REPLACEMENTPlease read this section in its entirety before attempting to replace any PCBs.MICROPROCESSOR, MOCON & VIDEO / KEYBOARDWARNING!WARNING!WARNING!WARNING!WARNING!The electrical panel will have residual voltage, even after power hasb...

  • Page 189

    Electrical Service18896-0189 rev L June 200510. After all cables have been disconnected, unscrew the standoffs, taking care to hold the board inplace until all standoffs have been removed.NOTE:If the PROCESSOR board needs replacing, please skip the next step.11. Replace the Video / Keyboard, att...

  • Page 190

    189Electrical Service96-0189 rev L June 2005POWER & LOW VOLTAGE SUPPLYPOWER BOARD -NOTE:Refer to "Cable Locations" for a diagram of this board.1.Follow all precautions noted previously before working in the electrical cabinet2.Turn the main switch (upper right of electrical cabinet...

  • Page 191

    Electrical Service19096-0189 rev L June 2005RS-232 PCBNOTE:Refer to "Cable Locations" for a diagram of this board.1.Follow all precautions noted previously before working in the electrical cabinet (See warning atbeginning of "Servo Driver & SDIST" section).2.Turn the main...

  • Page 192

    191Electrical Service96-0189 rev L June 2005RS-232 SERIAL INTERFACEThere are two connectors used for the RS-232 interface. The RS-232 connector on the back of most PC's is amale DB-25, so only one type of cable is required for connection to the controller, or between controllers. Thiscable must ...

  • Page 193

    Electrical Service19296-0189 rev L June 20054.5 FRONT PANELPlease read this section in its entirety before attempting to replace any component of thecontrol panel.LCD ASSEMBLY REPLACEMENTCAUTION! Use an electro-static discharge (ESD) strap on wrist when working insidethe pendant.1.Turn the power...

  • Page 194

    193Electrical Service96-0189 rev L June 20058.Plug the keyboard cables into the new receiver board (P1) and the power supply (TB2).9.Plug the power cable into the power supply board (TB1) and attach the green wire to ground.10. Plug the data cable into the receiver board (J3).11. Replace the bac...

  • Page 195

    Electrical Service19496-0189 rev L June 2005+5VBLK+5VREDGNDWHTAREDBGRNGNDWHT/REDAWHT/YELBWHT/BRNAYELBBRNFigure 4.5-3. Jog Handle removal. Figure 4.5-4. Jog Handle wiring diagram5.Remove the three screws holding the jog handle encoder to the control panel and remove.6.Replacement is reverse of ...

  • Page 196

    195Electrical Service96-0189 rev L June 2005SPINDLE LOAD METER REPLACEMENT1.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 holdthe cover panel in place until all screws have been removed.3.Dis...

  • Page 197

    Electrical Service19696-0189 rev L June 20057.Insert the ribbon cable through the opening in the control panel. Expose the adhesive strip on theback of the keypad and press the keypad in place in the upper right corner of the keypad recess.Press to the control panel to mount. Plug the ribbon cab...

  • Page 198

    197Electrical Service96-0189 rev L June 20054.6 SPINDLE ENCODER REPLACEMENTPlease read this section in its entirety before attempting to remove or replace encoder.REMOVAL -1.Turn machine power on. Lower the spindle head to a position that will allow you to easily work onthe back of the spindle m...

  • Page 199

    198Technical Reference96-0189 rev L June 20055. TECHNICAL REFERENCE5.1 TOOL CHANGERCAUTION!•Extremely heavy tool weights should be distributed evenly•Ensure there is adequate clearance between tools in the toolchanger before running an automatic operation.Tools are always loaded through the...

  • Page 200

    199Technical Reference96-0189 rev L June 2005Tool holders and pull studs must be in good condition and tightened together with wrenches or they may stickin the spindle taper. Clean the tool tapers with a lightly-oiled rag to leave a film to prevent rusting. Tools thatmake a loud bang when being...

  • Page 201

    200Technical Reference96-0189 rev L June 2005TOOL CLAMP/UNCLAMP SENSE SWITCHESThere are two switches located on the tool release piston assembly that are used to sense the position of thetool clamping mechanism. They are both normally closed, but one open once clamped and the other whenunclampe...

  • Page 202

    201Technical Reference96-0189 rev L June 20055.4 CONTROL CABINETLOW VOLT--------------260-244V243-227V226-211V210-195VI/O BoardI/O BoardPower amplifiersX,Y,Z,A,B&PCPower amplifiersX, Y, Z, A, B & PCTransformerTerminal blockTerminal blockHAAS Vector DriveHAAS Vector DriveY-Delta Contact...

  • Page 203

    202Technical Reference96-0189 rev L June 20055.5 SERVOSSERVO ENCODERSHaas machines are equipped with brushless motors, which provide for better performance, and no mainte-nance. The brushless motors have built in 8192 line encoders built in, which result in differences a resolution of32768 par...

  • Page 204

    203Technical Reference96-0189 rev L June 20055.7 TWO-SPEED GEAR TRANSMISSION (EC-1600 HS-3/4/6/7)The spindle head contains a two-speed gear transmission. The spindle motor is directly coupled to the trans-mission and the transmission is cog belt-coupled to the spindle.GEAR BOX LUBRICATIONThe tr...

  • Page 205

    204Technical Reference96-0189 rev L June 20055.8 CONTROL PENDANTJOG HANDLEThe JOG handle is actually a 100-line-per-revolution encoder, used to move one axis at a time. If no axis isselected for jogging, turning of the crank has no effect. When the axis being moved reaches its travel limits, th...

  • Page 206

    205Technical Reference96-0189 rev L June 20055.9 MICROPROCESSOR ASSEMBLYThe microprocessor assembly is in the rear cabinet at the top left position. It contains three large boards. Theyare: microprocessor, the keyboard and the MOCON. All three boards of the processor assembly receive powerfrom ...

  • Page 207

    206Technical Reference96-0189 rev L June 2005+5V+5V logic power supply is present. (Normally On)If this light does not come on, check the low voltage power supply and check that all three phases of 230Vinput power are present.There 1 two-position DIP switch on the processor PCB labled S1. Swit...

  • Page 208

    207Technical Reference96-0189 rev L June 20055.10 HAAS VECTOR DRIVEThe Haas vector drive is a current amplifier controlled by the MOCON software, using the C axis output. Thevector drive parameters are a part of the machine parameters and are accessible through the Haas front panel.The spindle...

  • Page 209

    208Technical Reference96-0189 rev L June 2005MAIN CONTACTOR K1Main contactor K1 is used to turn the control on and off. The POWER ON switch applies power to the coil ofK1 and after it is energized, auxiliary contacts on K1 continues to apply power to the coil. The POWER OFFswitch on the front p...

  • Page 210

    209Technical Reference96-0189 rev L June 20055.13 POWER TRANSFORMER ASSEMBLY (T1)The power transformer assembly is used to convert three-phase input power (50/60Hz) to three phase 230Vand 115V power. Two different transformers are used depending on the input voltage range. The low voltagetransf...

  • Page 211

    210Technical Reference96-0189 rev L June 2005OPTIONAL 480V 60HZ TRANSFORMERAll machines will get the 45KVA transformer.For domestic installations and all others using 60Hz power, the primary side should be wired as follows:Input Voltage RangeTap493-5101 (504)481-4922 (492)469-4803 (480)457-4684...

  • Page 212

    211Technical Reference96-0189 rev L June 20055.15 SPARE USER M CODE INTERFACEThe M code interface uses outputs M21-25 and one discrete input circuit. M codes M21 through M25 willactivate relays labeled M21-25. These relay contacts are isolated from all other circuits and may switch up to120V AC...

  • Page 213

    212Technical Reference96-0189 rev L June 20055.16 LUBRICATION SYSTEMThe lubrication system is a resistance type system which forces oil through metering units at each of thelubricating points within the machine. The system uses one metering unit at each of the lubricating points: onefor each li...

  • Page 214

    213Technical Reference96-0189 rev L June 2005Prior to performing an AUTO ALL AXES operation, there are no travel limits. Thus, you can jog into the hardstops in either direction for X, Y, or Z. After a ZERO RETURN has been performed, the travel limits will operateunless an axis hits the limit s...

  • Page 215

    214Technical Reference96-0189 rev L June 2005EC-400The load station is a 90 degree manual indexing station that holds a pallet securely into place while maintain-ing the ability to index freely. A manual indexing handle withdraws an indexing pin from the load station, whichmakes it possible to ...

  • Page 216

    215Technical Reference96-0189 rev L June 20055.21 THE EQUATIONS OF MOTIONAn analysis of the physics of motion of a machine tool can give some important insights into the “blocks persecond” issue. The following mathematics calculates the block per second requirement in order to achieve awors...

  • Page 217

    216Technical Reference96-0189 rev L June 20055.22 FORMULASTO FIND:TO FIND:S.F.MTO FIND THE SFM OF A CUTTER OR WORKPIECEEXAMPLE: To find the SFM of a cutter rotating at 600RPM with a diameter of 10 inches.SFM==.262xdxRPM123.1416xdxRPMR.P.M.TO FIND THE RPM OF A CUTTER OR WORKPIECEEXAMPLE: To find...

  • Page 218

    217Parameters96-0189 rev L June 20056. PARAMETERSParameters are seldom-modified values that change the operation of the machine. These include servo motortypes, gear ratios, speeds, stored stroke limits, ball screw compensations, motor control delays and macrocall selections. These are all rarel...

  • Page 219

    218Parameters96-0189 rev L June 200523 D FILTER X4 Enables the 4 tap FIR filter. Used to eliminate high frequency vibrations, depending onthe axis motor.24 TORQUE ONLY For HAAS diagnostic use only.25 3 EREV/MREV The 2 EREV/MREV and 3 EREV/MREV bits have two definitions depending on whetherone or ...

  • Page 220

    219Parameters96-0189 rev L June 200511 X TORQUE PRELOAD TORQUE PRELOAD is a signed number that should be set to a value from 0 to 4095 where4095 is the maximum motor torque. It is applied at all times to the servo in the same direction. It is used to compen-sate, in the vertical direction, for...

  • Page 221

    220Parameters96-0189 rev L June 200539 Z TORQUE PRELOAD See Parameter 11 for description.40 Z STEPS/REVOLUTION See Parameter 12 for description.41 Z BACKLASH See Parameter 13 for description.42 Z DEAD ZONE See Parameter 14 for description.43 A SWITCHES See Parameter 1 for description AND make sur...

  • Page 222

    221Parameters96-0189 rev L June 20050 REVERSE CRANK DIR Reverses direction of jog handle.1 DISABLE TOOL CHANGER. Disables tool changer operations.2 DISABLE GEAR BOX Disables gear box functions.3 POWER OFF AT E-STOP Stops spindle then turns the power off at EMERGENCY STOP4 RIGID TAPPING Indicates...

  • Page 223

    222Parameters96-0189 rev L June 200530 SPINDLE ENCODER #2 This parameter bit enables a second encoder that is mounted on thespindle motor and wired into the “C” axis input of the Mocon. It is required to control the vector algorithmon a belted machine when the belts slip at high load.When tw...

  • Page 224

    223Parameters96-0189 rev L June 200570 MIN SPIN DELAY TIME Minimum delay time in program after commanding new spindle speed and before pro-ceeding. Units are milliseconds.71 DRAW BAR OFFSET Offset provided in motion of Z-axis to accommodate the tool pushing out of the spindle whenunclamping to...

  • Page 225

    224Parameters96-0189 rev L June 200588 M MACRO CALL O9007 See parameter 81 for description89 M MACRO CALL O9008 See parameter 81 for description90 M MACRO CALL O9009 See parameter 81 for description91 G MACRO CALL O9010 G code that will call O9010. This parameter can contain a value from 1 throug...

  • Page 226

    225Parameters96-0189 rev L June 2005111 D*D GAIN FOR Z Second derivative gain in servo loop.112 D*D GAIN FOR A Second derivative gain in servo loop.113 X ACC/DEC T CONST Acceleration time constant. Units are 1/10000 seconds. This parameter provides for aconstant ratio between profiling lag and ...

  • Page 227

    226Parameters96-0189 rev L June 2005137 A EXACT STOP DIST. These parameters control how close each axis must be to its end point when exact stop isprogrammed. 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 th...

  • Page 228

    227Parameters96-0189 rev L June 2005161 B BACK EMF See Parameter 11 for description.162 B STEPS/REVOLUTION See Parameter 12 for description.163 B BACKLASH See Parameter 13 for description.164 B DEAD ZONE See Parameter 14 for description.165 B AXIS IN POSITION LIMIT Same definition as Parameter 1...

  • Page 229

    228Parameters96-0189 rev L June 2005184 C MAX ERROR The maximum allowable error (in Hz) between commanded spindle speed and actual speed. Ifset to zero, it will default to 1/4 of Parameter 183.185 C FUSE LEVEL See Parameter 10 for description.186 C DECELERATION Maximum deceleration of axis in enc...

  • Page 230

    229Parameters96-0189 rev L June 2005206 SPIGOT POSITION Vertical mills only. Maximum number of spigot positions.207 SPIGOT TIMEOUT (MS) Vertical mills only. Maximum timeout allowed for spigot to traverse one spigot location.208 SPIN. FAN OFF DELAY Delay for turning the spindle fan off after the ...

  • Page 231

    230Parameters96-0189 rev L June 200525 AUX JOG NACC If the jog handle is moved rapidly the auxiliary axis will not develope extremely largelags.26 ALIAS M PROGR START Alias M codes during program restart.27 DISABLE JOG TEST Disables the encoder test for the jog handle.28 NO ZERO CLAMP During zero...

  • Page 232

    231Parameters96-0189 rev L June 2005220 CONVYR RETRY TIMEOUT Amount of time in 1/50 seconds between consecutive overcurrents in which theovercurrents is considered another retry. If this amount of time passes between overcurrents, then the retry count isset to (0). Default is 1500, 30 seconds.22...

  • Page 233

    232Parameters96-0189 rev L June 2005243 4TH AUX MAX TRAVEL This parameter sets the maximum travel of the fourth auxiliary (W) axis in the positivedirection.244 1ST AUX MIN TRAVEL This parameter sets the maximum travel of the first auxiliary (C) axis in the negativedirection.245 2ND AUX MIN TRAVEL...

  • Page 234

    233Parameters96-0189 rev L June 2005255 CONVEYOR TIMEOUT The number of minutes the conveyor will operate without any motion or keyboard action.After this time, the conveyor will automatically shut off. Note that this parameter value will cause the conveyor to turnoff even if the intermittent fea...

  • Page 235

    234Parameters96-0189 rev L June 2005 201, 132, 133 XYZ SCREW COMP. COEF. =-8000000272, 273, 274 XYZ SCREW COMP. T. CONST. =-28000351 TEMP PROBE OFFSET =45000016 SCALE Z HIST For HAAS diagnostic use only.267 Y SWITCHES Parameter 267 is a collection of single-bit flags used to turn servo relate...

  • Page 236

    235Parameters96-0189 rev L June 2005 201, 132, 133 XYZ SCREW COMP. COEF. =-8000000272, 273, 274 XYZ SCREW COMP. T. CONST. =-28000351 TEMP PROBE OFFSET =45000016 SCALE Z HIST For HAAS diagnostic use only.269 A SWITCHES Parameter 269 is a collection of single-bit flags used to turn servo relat...

  • Page 237

    236Parameters96-0189 rev L June 2005 201, 132, 133 XYZ SCREW COMP. COEF. =-8000000272, 273, 274 XYZ SCREW COMP. T. CONST. =-28000351 TEMP PROBE OFFSET =45000016 SCALE Z HIST For HAAS diagnostic use only.271 C SWITCHES Parameter 271 is a collection of single-bit flags used to turn servo relate...

  • Page 238

    237Parameters96-0189 rev L June 20056 SINGLE CLAMP SWITCH This parameter enables the control to rely up on a single switch to detect theclamp position of the Side Mount Tool Changer arm. When this bit is set to zero, both the upper and thelower switches are used to detect the arm position. Whe...

  • Page 239

    238Parameters96-0189 rev L June 200523 TL CHGR DOOR SWITCH Horizontal tool carousel door configuration. This bit specifies theHorizontal Mill tool carousel door configuration. If it is set to 0, this indicates the configuration where thedoor is driven open by a timed operation. If it is set t...

  • Page 240

    239Parameters96-0189 rev L June 2005289 B LINEAR SCREW OFFS See parameter 285 for description.291 A AXIS BRAKE OIL TIME This parameter supports the EC1600 A-axis brake oil sensor. The units are seconds.When this parameter is set to a non-zero number and the sensor indicates a low oil condition f...

  • Page 241

    240Parameters96-0189 rev L June 2005305 SERVO PO BRK DLY The SRV PO (Servo Power On) discrete output is used to engage and disengage an axisbrake. This parameter is used to specify a time in milliseconds that the control should wait after activating the SRVPO output and turning off power to the ...

  • Page 242

    241Parameters96-0189 rev L June 2005315 COMMON SWITCH 40 ALIS M GRPHC When this bit is set to 0, all user defined M codes (such as M50 normally used to doa pallet change on a horizontal mill) will be ignored when a program is run in graphics mode. If it isnecessary to have graphics recognize s...

  • Page 243

    242Parameters96-0189 rev L June 20059 DOOR OPEN SWITCH The bit allows the software to work with an optional door-open switch. This bitshould be set to 1 on all machines fitted with the second door switch. If this bit is set to 1, the control willlook for a second door switch when the door is open...

  • Page 244

    243Parameters96-0189 rev L June 200525 POWER DICONN RELAY When it is set to zero, the machine behaves as before. When it is set to 1,and parameter 57 SAFETY CIRC is set to 1, and the door is opened, I GAIN on all axes will be cleared.When the door is closed and power to the servos is restored, t...

  • Page 245

    244Parameters96-0189 rev L June 2005336 A SCALES PER REV This parameter is used on machines equipped with linear scales. This parameter shouldbe set to 0 on mills with or without linear scales.337 B SCALES PER REV This parameter is used on machines equipped with linear scales. This parameter shou...

  • Page 246

    245Parameters96-0189 rev L June 2005589 Y ENC. SCALE FACTOR See parameter 588 for description590 Z ENC. SCALE FACTOR See parameter 588 for description591 A ENC. SCALE FACTOR See parameter 588 for description592 B ENC. SCALE FACTOR See parameter 588 for description593 Sp ENC. SCALE FACTOR See par...

  • Page 247

    246Parameters96-0189 rev L June 2005620 X-Axis Plus Travel Limit Note that only parameters 623 and 624 for the A and B axes are intended to be used,and only on the Trunnion Mills (VF5TR and VF6TR) where it is necessary to place the home switch in the middle ofthe travel range (in order to keep th...

  • Page 248

    247Parameters96-0189 rev L June 2005654 Tt Axis Indexer Increment See Parameter 644659 Indexer Down Timeout Supports the indexer rotary table. It specifies the amount of time (in ms) allowed forseeking the indexer Down-switch. If the switch is not detected within the allowed time, alarm 960 INDE...

  • Page 249

    248Parameters96-0189 rev L June 2005711 Pocket Up Settle This parameter supports the vertical mill side mount tool changer. It specifies the amount oftime, in 50ths of a second, that the carousel is to wait after a tool change before it is allowed to move. It should be setto 20 on all mills.715 ...

  • Page 250

    249Parameters96-0189 rev L June 2005734 INPUT MASK (Used for the Office Mills)0 TOOL CHANGER IN16 SPARE1 TOOL CHANGER OUT17 SPARE2 TOOL #1 IN POSITION18 SPARE3 LOW TSC PRESSURE19 SPARE4 TOOL IN POSITION20 LOW TRANS OIL PRESS5 SPINDLE HIGH GEAR21 APC DOOR6 SPINDLE LOW GEAR22 APC PIN CLEAR #17 EME...

  • Page 251

    25096-0189 rev L June 20057. MAINTENANCEGENERAL REQUIREMENTSOperating Temperature Range: 41°F to 104°F (5 to 40°C)Storage Temperature Range: -4°F to 158°F (-20 to 70°C)Ambient Humidity: 20% – 95% relative humidity, non-condensingAltitude: 0-7000 ft.ELECTRICITY REQUIREMENTSAll Machines Re...

  • Page 252

    Maintenance25196-0189 rev L June 2005Input power to the machine must be grounded. For wye power, the neutral must be grounded. For delta power, acentral leg ground or one leg ground should be used. The machine will not function properly on ungrounded power.(This is not a factor with the External ...

  • Page 253

    25296-0189 rev L June 2005MAINTENANCE SCHEDULEThe following is a list of required regular maintenance for the machining center. Listed are the frequency of service,capacities, and type of fluids required. These required specifications must be followed in order to keep your ma-chine in good workin...

  • Page 254

    Maintenance25396-0189 rev L June 2005PERIODIC MAINTENANCEA periodic maintenance page is found on the Current Commands screens titled “Scheduled Maintenance” andaccessed by pressing Page Up or Page Down to activate and deactivate a series of checks.An item on the list can be selected by pressi...

  • Page 255

    25496-0189 rev L June 2005SPINDLE AIR PRESSUREVerify Spindle air pressure using the gauge located behind the air regulator panel. VF, VR and VS mills should beset to 17 psi. EC-series and HS Series should be set to 25psi. Adjust if necessary.15K SpindleThe air pressure for the 15K Spindle is 20 p...

  • Page 256

    Maintenance25596-0189 rev L June 2005LUBRICATION CHARTSystemLubricantQuantityVertical MillsWay lube and pneumaticsMobile Vactra #22-2.5 qtsTransmissionMobil DTE 2540Taper 34 oz50 Taper 51ozA and B axis (VR-Series)Mobile SHC 630A-axis 5qtsB-axis 4qtsEC-SeriesWay lube and pneumaticsMobile Vactra #2...

  • Page 257

    25696-0189 rev L June 2005LUBRICATION SYSTEMAll machine lubrication is supplied by the external lubrication system. Current lube level is visible in the reservoir;Add oil as necessary to maintain proper oil level. Warning! Do not add lube above the “high” line marked on thereservoir. Do not a...

  • Page 258

    Maintenance25796-0189 rev L June 2005SIDE MOUNT TOOL CHANGER GEARBOX OILChecking the oil levelOil Fill Level1131211 10 987654322322212019181716151424CarouselNumber DiscDisc MountingBHCS (6)Oil Fill PlugOilFill LevelDrain PlugVertical MillsEC-Series MillsVertical Mills: View the Oil level sight gl...

  • Page 259

    25896-0189 rev L June 2005EC-1600 AND HS 3/4/6/7 TRANSMISSION OILOil FillOilDrainOil Level ViewOil Fill PortOil DrainPlugOil SightGlassEC-1600HS-3/4/6/7Oil CheckRemove the sheet metal necessary to gain access to the transmission. View the sight glass on the side of thetransmission box as shown. T...

  • Page 260

    Maintenance25996-0189 rev L June 2005EC-400 Full Fourth Axis Rotary Table (Perform Every 2 years)Air Vent(pressurerelief)Oil DrainOil FillSightGlassOil FillConnectionOilReservoirPre-FillPallet SideSpindle SideOil InSolenoidPlunger1. Remove the fourteen (14) BHCS on the right Z-axis way cover at t...

  • Page 261

    26096-0189 rev L June 20054. Command a 180° to 0° rotation for fifteen minutes. This will remove air remaining in the system. The rotaryindexer is full when the oil level is half way on the site glass. Fill as needed.5. Replace the waycover.Oil FillSight GlassOil FillOil DrainAirVentEC-400 Rota...

  • Page 262

    261Cable Locations96-0189 rev L June 20058. PCBS, CABLE LOCATIONS AND BOARD DIAGRAMSShown below are three types of commonly used cable connectors. They are shown as seen when pluggedinto the pc board. These diagrams are to aid in locating the pins for trouble shooting. Note:The numbering sequenc...

  • Page 263

    Cable Locations26296-0189 rev L June 2005PROC.PLUG #CABLE #SIGNAL NAME TO LOCATIONPLUG #J1 ADDRESSADDRESS BUSSVIDEO——-J2 DATADATA BUSSMOTIF PCB——-J3860LOW VOLTAGEPOWER SUPPLY PCB ——-J6N/AREPLACEMENT BAT. CONNECTION——-PORT 1850SERIAL PORT #1KEY. INTERFACE——-PORT 2850ASERIAL PO...

  • Page 264

    263Cable Locations96-0189 rev L June 2005BRUSHLESS SERVO AMPLIFIERPOWER TO SERVO MOTOR335VDC (FROM HAAS VECTOR DRIVE)LOW VOLTAGE POWER (INPUT)SERVO DRIVE CURRENT COMMAND ( FROM MOCON)BLOWN FUSE INDICATOR

  • Page 265

    Cable Locations26496-0189 rev L June 2005BRUSHLESS SERVO AMPLIFIERCABLE CONNECTIONSMOCONPLUG #CABLE #SIGNAL NAME TO LOCATIONPLUG #X AXIS AMPP570LOW VOLTAGEL. V. POWER SUPPLY——-TB A, B, C——-MOTOR DRIVEX SERVO MOTOR——-P610X DRIVE SIGNALMOCON PCBP2TB -HV +HV——-335VDCSPINDLE DRIVE—...

  • Page 266

    265Cable Locations96-0189 rev L June 2005POWER PCBFU7C4C3C2C7C6C5C1NE210A 115VMAIN10A 230VCOOLANT10A 115VRTY/USER POWER10A 230VTSC COOLANTSPARE FUSESP1P2P3P4P5P6P7P8P9P10P11P12P13P14P15P16P17P18P19P20P21P22P23P24P25P26P27P28P30P31P32P33P34P35P29TB1TB3TB2NE1NE4FU8FU12 FU11 FU10FU9NE6NE5NE3FU13FU1...

  • Page 267

    Cable Locations26696-0189 rev L June 2005POWER PCBCABLE CONNECTIONSPLUG #CABLE #SIGNAL NAME TO LOCATIONPLUG#P1+12VDCCNC Unit FanP290B115VACLow Voltage Power SupplyP390B115VACProbe PSP490B115VACWork LightP590B115VACSwitch Door FanP690B115VACServo FanP790B115VACDelta-WyeP8860+12/-12/+5 VDC InFrom ...

  • Page 268

    267Cable Locations96-0189 rev L June 2005I/O PCBI/O PLUG #CABLE # TO LOCATIONPLUG #P1140BChip ConveyorP2820BT/C In/smtc arm mark TP3820DB Up/Down / TC out SMTC / shuttle outP4900TSC Pump (Low TSC pressure)P5770E-Stop Switch A Front PanelP6770AE-Stop Switch BP7770BE-Stop Switch CP81050Side Door O...

  • Page 269

    Cable Locations26896-0189 rev L June 2005I/O PCB CABLE CONNECTIONSI/O PLUG #CABLE # TO LOCATIONPLUG #P15890Spin Head Status / SP DB openP16780Spare/ 2nd VD OV/contactor on/ cntr balanceP17410T/C Air Door SWP18790Pallet CW/CCWP19190Frnt Door sw / Lo phaseP20190AOp Station Locked/Frnt Door sw.P212...

  • Page 270

    269Cable Locations96-0189 rev L June 2005PLUG#CABLE# TO LOCATIONPLUG#P1700BPROCESSOR850P2—-KEYPAD—-P3700ACYCLE START/HOLD SWITCHES—-P4730SP LOAD METER—-P5—-—-P6—-AUX FPANEL—-J1—-—-J2—-REMOTE JOG HANDLE—-J3750MOCONP18J5—-(MIKRON ONLY)—-J7—-EXTERNAL KEYBOARD—-J12860...

  • Page 271

    Cable Locations27096-0189 rev L June 2005VIDEOPLUG #CABLE #SIGNAL NAME TO LOCATIONPLUG #P1860LOW VOLTAGEPOWER SUPPLY PCB——-J3*700KEYBOARD INFO.KEYBOARD INT.——-J4——-ADDRESS BUSSMICRO PROC. PCB——-J5——-DATA BUSSMOTIF PCB——-J10——-FLOPPY DR. POWERFLOPPY DRIVE——-J11—...

  • Page 272

    271Cable Locations96-0189 rev L June 2005MOCON PCBP19JU2P1P15U43INSTALL JUMPERFOR MOCON 2P24P16P10P12P11P14P13P18P20P6P7P8P9P30P31P33P32P5P4P3P2P34P26P21P17P22P27 P28P35

  • Page 273

    Cable Locations27296-0189 rev L June 2005MOCON PCBCABLE CONNECTIONSMOCONPLUG #CABLE #SIGNAL NAME TO LOCATIONPLUG #P1——-DATA BUSSVIDEO PCB——-MICRO PROC. PCB——-P2610X DRIVE SIGNALX SERVO DRIVE AMP. PP3620Y DRIVE SIGNALY SERVO DRIVE AMP. PP4630Z DRIVE SIGNALZ SERVO DRIVE AMP. PP5640A DR...

  • Page 274

    273Cable Locations96-0189 rev L June 2005RS-232 PORT #1 PCBCABLE CONNECTIONSPLUG #CABLE # TO LOCATIONPLUG #P1850VIDEO &J13 INTERNALKEYBOARDJ1——-——-——- EXTERNALGNDPIN 1P1P2P334-4090

  • Page 275

    Cable Locations27496-0189 rev L June 2005Y-DELTA SWITCH ASSEMBLYP/N 32-5851B (40T 10HP)P/N 32-5864A (SUPER SPEED AND 50T)K4K5TO IO PCB, P58TO IO PCB, P12TO HAAS VECTOR DRIVETOSPINDLEMOTOR650ATO K5 AUXTO K5 COILTO K5 COILTO K4 COILTO K4 COIL650BYCOM

  • Page 276

    275Cable Locations96-0189 rev L June 2005M CODE RELAY BOARDCABLE CONNECTIONSPLUG #CABLE #SIGNAL NAME TO LOCATIONPLUG #P1540MOCON INPUTIO PCB`P62P2860A12VD TO M-CODE PCBAPSUPP31P3540AIOPCB OUTPUTP4M21M-FUNCTIONM22PROBE OPTIONM24spareP5M25spareM26spareM27spareP6540BM CODE OUTPUT2nd MCDP1

  • Page 277

    Cable Locations27696-0189 rev L June 200550T TRANSMISSION P.S. / HYDRAULIC C.B. PCBCABLE CONNECTIONSPLUG #CABLE # TO LOCATIONPLUG #P1880BIO PCBP12P290POWER PCBP8P3410GEAR BOXP4350IO PCBP54TB2340HYDRAULIC MTRTB370MAIN TRANSFORMER(VECTOR DRIVE UNIT)FU1115 VAC115 V Servo Brake880B/P1

  • Page 278

    277Cable Locations96-0189 rev L June 2005SERIALPORT1SERIALPORT2ETHERNETSPARE-1SPARE-2-A-AXIS-Z-AXIS-Y-AXIS-X-AXISLIMITSWITCHESTSCTOOLCHANGERCONTROLCABINET5THAXISSPARE-4SPARE-3COOLANTMFIN/CLGCHIPCONVEYORSPARE-5APCDR/RECVRQAPC-RQAPC-L190200300A880A890950UNCLAMPFROMSPINDLEHEADTOI/OPCBCOOLANTSPIGOTM...

  • Page 279

    Cable List27896-0189 rev L June 20059. CABLE LISTWIRE/TERMINAL FUNCTION NAME:NUMBERINCOMING POWER 195-260 VAC (353-480 VAC OPTIONAL)L1INCOMING 195-260VAC PHASE 1, TO CB1-1L2INCOMING 195-260VAC PHASE 2, TO CB1-2L3INCOMING 195-260VAC PHASE 3, TO CB1-371PROTECTED 195-260VAC CB1-4 TO K1-172P...

  • Page 280

    279Cable List96-0189 rev L June 2005100AM-FUNCTION OUTPUT M21 (MCD RELAY BOARD M21) -SHIELD +2101AUNSWITCHED LEG 1 #20102ASWITCHED LEG 2 #20103ASHIELD DRAIN110SPARE (115 VAC SERVO POWER)140230VAC 3PH POWER TO CHIP CONVEYOR MOTOR141PHASE A 230VAC142PHASE B 230VAC143PHASE C 230VAC144STARTING WINDI...

  • Page 281

    Cable List28096-0189 rev L June 2005270115 VAC RELAY OUTPUT TO PURGE SOLENOID - SHIELD +2271UNSWITCHED LEG 1 #20272SWITCHED LEG 2 #20273SHIELD DRAIN280115 VAC RED/GREEN BEACON CABLE -SHIELD +3281RED LAMP 115VAC282GREEN LAMP 115VAC283COMMON 115VAC284SHIELD DRAIN290115VAC TO XFORMER T2 10VAC OUTPU...

  • Page 282

    281Cable List96-0189 rev L June 2005490B325VDC FROM AMPLIFIER TO SERVO POWER SUPPLY491BHIGH VOLT + RED #20492BHIGH VOLT - BLACK #20510RELAY CARD 1 DRIVE CABLE - 16 WIRE RIBBON #24520RELAY CARD 2 DRIVE CABLE - 16 WIRE RIBBON #24530RELAY CARD 3 DRIVE CABLE - 16 WIRE RIBBON #24540RELAY CARD 4 DRIVE...

  • Page 283

    Cable List28296-0189 rev L June 2005650230VAC, THREE PHASE POWER TO SPINDLE MOTOR-SHIELD+3651PHASE 1652PHASE 2653PHASE 3654SHIELD DRAIN650A230VAC, THREE PHASE POWER, CONTACTOR TO SPINDLE MOTOR(WYE-DELTA OPTION)651APHASE 1652APHASE 2653APHASE 3654ASHIELD DRAIN650B230VAC, THREE PHASE POWER, CONTAC...

  • Page 284

    283Cable List96-0189 rev L June 2005710P-COOL / BF COLLET OPEN - BF COLLET CLOSE711SPARE712SPARE713SPARE714SPARE715SPARE720ANALOG SIGNAL FROM MOCON TO SPINDLE DRIVE TO LOAD MONITOR7210 TO +10 VOLTS SPEED COMMAND722COMMON723SHIELD DRAIN740POWER ON/OFF CABLE TO FRONT PANEL - SHIELD +4741POWER ON S...

  • Page 285

    Cable List28496-0189 rev L June 2005760MONITOR VIDEO DATA CABLE - SHIELD +7 (ALL #24)(FROM VIDEO P13 TO CRT)770EMERGENCY STOP INPUT CABLE - SHIELD +2771SIGNAL #20772RETURN (D GROUND) #20773SHIELD DRAIN770ASECOND E-STOP/COUNTER BALANCE - SHIELD +2771ASIGNAL #20772ARETURN (D GROUND) #20773ASHIELD ...

  • Page 286

    285Cable List96-0189 rev L June 2005850SERIAL PORT #1 INTERFACE CABLE (16 WIRE RIBBON #24) 33-0510850ASERIAL PORT #2 INTERFACE CABLE (16 WIRE RIBBON #24) 33-0510 - AUXILIARY PORT TOROTARY CONTROLLER860+5V/+12V/-12V/Gnd FROM MAIN POWER SUPPLY (ALL #18)861+5 VOLTS862LOGIC POWER RETURN863LOGIC POWE...

  • Page 287

    Cable List28696-0189 rev L June 2005910B115 VAC TO SERVO FAN - SHIELD +2911BLEG 1 #20912BLEG 2 #20910C115 VAC TO PURGE SOLENOID - SHIELD +2911CUNSWITCHED LEG 1 #20912CSWITCHED LEG 2 (FROM 270 IOPCB P48)913CSHIELD DRAIN910D115 VAC TO PALLET ALARM - SHIELD +2911DSWITCHED LEG 1 (FROM MCD RELAY BOAR...

  • Page 288

    287Cable List96-0189 rev L June 20051000SPINDLE ENCODER CABLE (MoCon SIDE CONNECTION) ALL #241000-1LOGIC RETURN (D GROUND)1000-2ENCODER A CHANNEL1000-3ENCODER B CHANNEL1000-4+5 VDC1000-5ENCODER Z CHANNEL1000-6NOT USED1000-7SPINDLE MOTOR OVERHEAT SENSOR1000-8ENCODER A* CHANNEL1000-9ENCODER B* CHA...

  • Page 289

    288Electrical Diagrams96-0189 rev L June 2005ELECTRICALWIRING DIAGRAMS

  • Page 290

    289Electrical Diagrams96-0189 rev L June 2005

  • Page 291

    290Electrical Diagrams96-0189 rev L June 2005

  • Page 292

    291Electrical Diagrams96-0189 rev L June 2005

  • Page 293

    292Electrical Diagrams96-0189 rev L June 2005

  • Page 294

    293Electrical Diagrams96-0189 rev L June 2005CNC UNITDATA BUSADDRESS BUSDATA BUSADDRESS BUSBOARDMOCONIOPCBIOPCBIOPCBIOPCBZ DRIVE SIGA DRIVE SIGLOAD METERLOW VOLTAGE POWERX DRIVE SIG.Y DRIVE SIG.530510720540P16520P21 P22RELAYS 1-8RELAYS 9-16RELAYS 17-24RELAYS 25-32610860P15670680550VOLTAGE MONITO...

  • Page 295

    294Electrical Diagrams96-0189 rev L June 2005

  • Page 296

    295Electrical Diagrams96-0189 rev L June 2005

  • Page 297

    296Electrical Diagrams96-0189 rev L June 2005

  • Page 298

    297Electrical Diagrams96-0189 rev L June 2005RELAY COIL DRIVERS, K1 THROUGH K80VDCMOCON PCB+12VDC+12VDCP11PIN 16+12VDCPIN 120VDC+12VDC0VDCPIN 15PIN 14PIN 130VDC+12VDC0VDCPIN 11PIN 10PIN 9SPINDLE LUBEI/O PCBLE 8P1PIN 16GEAR BOX OIL PUMPWAY LUBE PUMPSPINDLE FANLE 6PIN 12LE 7PIN 15PIN 14PIN 13PIN 1...

  • Page 299

    298Electrical Diagrams96-0189 rev L June 2005

  • Page 300

    299Electrical Diagrams96-0189 rev L June 2005

  • Page 301

    300Electrical Diagrams96-0189 rev L June 2005

  • Page 302

    301Electrical Diagrams96-0189 rev L June 2005

  • Page 303

    302Electrical Diagrams96-0189 rev L June 2005

  • Page 304

    303Electrical Diagrams96-0189 rev L June 2005MOTORSPIGOTMK18SPIGOTREVERSEK17FORWARDSPIGOT+12 VDCSINGLE PHASE (REVERSIBLE)CHIP CONVEYOR MOTORMOMIT THESE WIRES FOR3 PHASE MOTOR (OPTIONAL)BFDCGP8ECHIPK35REVERSECONVEYORCHIP CONVEYORGROUNDCIRCUITFU3FU2ONCONVEYORCHIPQ4Q3THREE PHASE210 VAC INCHIP CONVE...

  • Page 305

    304Electrical Diagrams96-0189 rev L June 2005

  • Page 306

    305Electrical Diagrams96-0189 rev L June 2005

  • Page 307

    306Electrical Diagrams96-0189 rev L June 2005Processor StackServo AmplifiersTC Motor (arm)TC CarouselFrom Home SwitchesToolChangerXYChip AugerChip AugerChip AugerJog HandleAZVECTORDRIVEControl PendentFloppyLCDI/O PCB160VDC230VACMicro ProcVideoMoconZYXAHV- HV+ (DC)PCP/CEC-400 Block Diagram

  • Page 308

    307Electrical Diagrams96-0189 rev L June 2005ELECTRICAL SYMBOLSLIMIT SWITCH (OPEN)(LIGHT EMITTING DIODE)LIMIT SWITCH (CLOSED)MOTORMLAMPLEDOPTO-ISOLATORTRANSFORMERCAPACITORSOLENOIDRESISTORFU2FUSECIRCUIT BREAKERCOILDIODEGROUNDCIRCUIT BREAKER(SINGLE)(MULTI)VARISTORRELAY (SINGLE POLEDOUBLE THROW)REL...

  • Page 309

    308Assembly Drawings96-0189 rev L June 2005ASSEMBLY DRAWINGSAND PARTS LISTS

  • Page 310

    309Assembly Drawings96-0189 rev L June 2005EC-300 Front Panels1.25-5682 Tool Trays Panel2.25-5683 Intermediate J-Box Top Cover3.25-5681 Intermediate Top Cover4.25-5678 Front Right Panel5.59-0123 Sanders K 18 Wire Clip6.25-0440 Tool Tray (2x)7.25-6182 Front Table8.25-5740 Front Right Pan9...

  • Page 311

    310Assembly Drawings96-0189 rev L June 2005EC-300 Operator Door PanelsView Rotated 180 (Looking Up)812345678910111213141516171819202122232425261.25-5888 Center Channel Cover Plate2.25-5891 Cable Channel Cross Top3.25-5799 Top Operator Side Cables Tray4.25-5892 Cable Channel Cover Plate5.25-5792 ...

  • Page 312

    311Assembly Drawings96-0189 rev L June 2005EC-300 Rear PanelsView Rotated 90 CCW812345679101213148111.25-5720 Rear Header2.25-5666 Rear Control Box Panel3.25-5722 Control Support Mounting Bracket4.25-5924 Control Intermediate Pan5.25-5665 Front Control Pan6.25-5667 Front Control Box Panel7.25-57...

  • Page 313

    312Assembly Drawings96-0189 rev L June 2005EC-300 Tool Changer PanelsView Rotated 90 CW812345678910111213141516171819202122231.25-5881 Tool Changer Top Cover2.25-5706 T.C. Front Panel3.25-5779 T.C. Side Panel4.25-6682 Removal Tool 40T Holder5.25-9248 Plate Window Handle6.25-5885 T.C. Access Pane...

  • Page 314

    313Assembly Drawings96-0189 rev L June 2005EC-300 Column and Frame Panels1234567891011121314151617181920212223241.59-0706 Shade Roller- 70.5" x 21" (2x)2.25-5833 Shade Roller Left Frame3.25-5837 Top Column Clamp Wiper26-0173 Top Column Wiper Felt4.25-5834 Shade Roller Top Frame5.25-583...

  • Page 315

    314Assembly Drawings96-0189 rev L June 2005EC- 300 Base Assembly1.50-9011 Linear Guide (truck)2.50-0017 Linear Guide (35mm truck)3.20-2587 Saddle Casting4.58-3600 3/8" Nipple5.20-7008 Nut Housing6.25-7267 Prox. Switch Bracket7.25-5780 Y-Axis Trip Bracket8.25-5919 Cable Carrier Bracket9.20-2...

  • Page 316

    315Assembly Drawings96-0189 rev L June 2005EC- 300 Clolumn Assembly123456789101112131415174161071.25-2767 Mounting Bracket2.32-2130 Prox Switch3.62-0017 Servo Motor4.25-7042 Cover Plate5.20-2686 Ballscrew Bumper6.20-2588 Column Casting7.20-6361 Y-Axis Bumper8.25-5732 Column Cover9.20-7009 Bearin...

  • Page 317

    316Assembly Drawings96-0189 rev L June 2005EC- 300 Spindle Head Assembly123456789101112131416171820212219152316141.20-7016 Spindle housing2.50-0017 Linear Guide (35mm truck)3.20-1693 TRP Incline Cylinder4.73-3055 Terminal Buss5.25-5242 Shroud Bracket6.30-6465 TSC Fitting Assembly7.25-5213 Motor ...

  • Page 318

    317Assembly Drawings96-0189 rev L June 2005EC- 300 Pallet Changer1.25-5880A Rotating Door Cap2.25-5878A Rotating Door3.59-0580 Name Plate P24.25-5874 Clamshell Cover Access5.25-5875 Clamshell Cover Access6.25-5873 Clamshell Pallet Cover7.20-2782 Pallet8.HRT2109.20-2688 Pallet Changer Table10. 20...

  • Page 319

    318Assembly Drawings96-0189 rev L June 2005EC- 300 Pallet Changer1234567891011121314151617181920A21222324252627282930313233343536373839404142 43444546471748849505152Note: The “ ” locations illustratelifting points.A1.25-6845 Motor Cover2.62-0014 Servo Motor3.20-2724 Motor Flange4.20-2812 Sta...

  • Page 320

    319Assembly Drawings96-0189 rev L June 2005EC- 300 40-40 Tool changer13245678109111213141516171819202122232425182627282930313233343536371.25-4153 Rear Cover2.20-0731 Carousel3.25-4152 Front Cover4.32-2295 Prox Carousel Mark5.32-1875 Carousel Motor6.20-0809 Carousel Shaft7.20-2759 Mounting Plate8...

  • Page 321

    320Assembly Drawings96-0189 rev L June 2005Load PositionATC Assembly171825192423212022145623151613781012119141. 40-0226SHCS ¾”x3"2. 59-0737Plug Hole3. 20-2911A Hub Index Plate4. 20-2911A Hub Index Plate5. 20-2868A Shaft Assembly6. 40-1663SHCS ½”-13x1¾”7. 25-6029Panel Tools (...

  • Page 322

    321Assembly Drawings96-0189 rev L June 2005123456789310118912131415641EC-400 Base Casting1. 62-0016 Motor2. 32-2130 Limit Switch3. 30-1215 Ball Screw Coupling4. 20-9212 Bearing Housing5. 20-2042 Casting6. 24-0026 Ballscrew7. 20-2084 Hard Stop X Axis8. 20-0152 Bearing Housing9. 50-3400 Linear Gui...

  • Page 323

    322Assembly Drawings96-0189 rev L June 2005EC-400 Operator's Door1. 25-4954 Header Side, Right2. 20-2036 Door Track Upper Operator3. 25-5228 Z-Frame TC/Operator's Door Window (x2)4. 28-0151 Window TC Panels/Operator's Door5. 25-4966 Operator Door6. 20-2038 Door Track Lower7. 25-5198 Panel Operat...

  • Page 324

    323Assembly Drawings96-0189 rev L June 2005EC-400 In-Line Spindle Assmebly1. 20-1686A Key Drawbar Inline2. 20-1693B TRP Cylinder In-Line3. 20-1688 Tranfer-tube In-line4. 25-4761 Shim TRP In-Line5. 20-1694A Standoff Motor In-Line6. 20-1690 Striker plate Inline7. 20-7422D Oil Injector Cover8. 20-...

  • Page 325

    324Assembly Drawings96-0189 rev L June 2005EC-400 Spindle Head Assembly

  • Page 326

    325Assembly Drawings96-0189 rev L June 20051. 58-1680 Fitting Bkhd NPT 1/2x1.125 dia2. 20-7381A Plate, Prog Coolant3. 32-0199 Condit Assembly P-Cool4. 20-7384A Nozzle Body5. 14-1905 P-Cool Cover6. 25-5327 P-Cool Mounting Bracket7. 58-3694 1/4 Valves Loc-Line8. 58-1722 Fittin NPT 3/8F x NPT 3/8M ...

  • Page 327

    326Assembly Drawings96-0189 rev L June 2005EC-400 Top Cover1. 25-4952 Top Cover Front2. 25-4963 Brace Top Intermedite3. 32-0196 Worklight Assembly4. 25-4964 Top Cover Right5. 25-4980 Wire ChannelTop Cover6. 25-4965 Top Cover Left7. 25-4983 Splash Shield Rotating8. 25-5253 Cover Brace Top9. 25-49...

  • Page 328

    327Assembly Drawings96-0189 rev L June 2005EC-400 Tool Changer Panels

  • Page 329

    328Assembly Drawings96-0189 rev L June 20051. 25-4979 Panel Left Intermediate2. 25-4962 Panel TC3. 25-4975 Access Cover TC Front4. 25-5195 Access Cover TC Rear5. 25-4961 Pan TC6. 58-0671 Coolant Drain Tube7. 25-4972 Apron Left Rear8. 58-1679 Fitting Bulkhead 3/8 x 19. 58-1693 (x2) Fitting Elbo 1...

  • Page 330

    329Assembly Drawings96-0189 rev L June 2005EC-400 60 and 70-Tool Tool Changer PanelsSMTC 60 Pocket OnlySMTC 60 Pocket Only18192021222324251918TC Door AssemblyTC Door Assembly(View Rotated 180 )8(View Rotated 180 )838394041261234567891011121314151617272829303132333435363713424344454647484849

  • Page 331

    330Assembly Drawings96-0189 rev L June 20051. 25-4979 Left intermediate panel2. 25-4962B Tool changer panel3. 28-0168 TC access window4. 25-9248 Plate window handle5. 25-6718A SMTC switch box 25-6719 SMTC side panel6. 25-5991A SMTC side panel7. 25-4961A TC pan8. 25-4972 Left rear apron9. 55-0...

  • Page 332

    331Assembly Drawings96-0189 rev L June 20051. 25-5007 Bracket Frame Y-Axis Stop2. 25-5001 Guide Right Y-Axis3. 59-0605 Bellows Y-axis Upper4. 25-5008 Bracket Frame Y-Axis5. 59-0606 Bellow Y-Axis Lower6. 20-2319 Plate Filler Y-Axis Frame7. 25-5000 Guide Left Y-AxisEC-400 Y-Axis Frame Assembly

  • Page 333

    332Assembly Drawings96-0189 rev L June 2005EC-400 Front Trough Assembly (Auger System)1. 57-0334A Gasket Coolant Trough2. 25-0548 Chute Discharge3. 25-5300 End Chute Cover4. 25-5301 Coolant Trough Extension COver5. 25-5025 Extension Box Front Trough6. 57-9846C Gasket Discharge7. 25-5297A Coolant...

  • Page 334

    333Assembly Drawings96-0189 rev L June 2005EC-400 Front Trough Assembly (Chip Conveyor System)1. 30-6477B Chip Conveyor2. 25-5309 Extension Cover Chip Conveyor3. 25-5025A Coolant Trough Extension4. 57-0334A Gasket Coolant Trough5. 25-4944 (x2) Brace Auger Trough6. 25-5292 Motor Access Cover 57...

  • Page 335

    334Assembly Drawings96-0189 rev L June 20051. 58-3680 (x2) Fitting LBO 3/8 x NPT 1/4 M STR2. 58-3618 Fiting NPT 1/4F x NPT 1/4M 90 Brass3. 58-1677 Fitting BKHD NPT 1/4 x .750 Dia4. 25-5009 Brkt Base Cover5. 25-5006 Shield Bottom X-A0xis6. 25-5003 Base Cover7. 25-5004 Cover Trough Right8. 20-6413...

  • Page 336

    335Assembly Drawings96-0189 rev L June 2005EC-400 Front Assembly

  • Page 337

    336Assembly Drawings96-0189 rev L June 20051. 25-4948 Panel Side Top Right2. 25-4999A Header Enclosure3. 25-4951A Stiffener Bracket4. 25-4413 Rack Tool Tray5. 25-4948 Panel Side Top Right6. 25-4946A Panel Front Right7. 25-1258 Cover Switch Box8. 25-1257A Panel Front Switch Box9. 59-0278 Knob and...

  • Page 338

    337Assembly Drawings96-0189 rev L June 20051233456789101112131415161718192021222324252627282729EC-400 Column Assembly1. 20-2043 Column Machined2. 25-4996 BRKT Carrier Column3. 58-3045 Lube Fitg Adaptor4. 58-3045 Lube Fitg Adaptor5. 58-0634 Copper Tubing Column6. 22-7458 Cam Linear Guide7. 58-303...

  • Page 339

    338Assembly Drawings96-0189 rev L June 20051. 25-5238B Shade Rotating Door Top2. 25-4149 Z-Frame Window SMTC3. 28-0043A Window Partition4. 25-1262A (2X) Z-Frame Partition Top5. 25-5233A (2X) Z Channel Rotating Door6. 20-2283A (2X) Support Bar Rotating Door7. 25-5237 (4X) Shade Rotating Door Seal...

  • Page 340

    339Assembly Drawings96-0189 rev L June 200512345678910111213141516171819202122 23242526272829303132333435363738394041104243444547464849EC-400 Receiver Assembly

  • Page 341

    340Assembly Drawings96-0189 rev L June 2005EC-400 Receiver Assembly1. 20-1123A Pallet plug 2-135 parker O-ring2. 20-2048A Pallet machined3. 40-1639 SHCS 3/8-16x1 (8)4. 20-1995 Receiver clamp plate5. 30-6551 Air blast assembly6. 48-1667 Dowel pin 1/2x3 ½ (2)7. 20-2041 Receiver body machined ...

  • Page 342

    341Assembly Drawings96-0189 rev L June 2005EC-1600 Base Assembly1. 20-2509 Casting2. 30-6953 Lube Line Assy3. 30-0472 Bearing Assy4. 32-2133 Limit Switch5. 30-1222 Bearing Assy6. 30-3988 Coupling7. 20-0151 Motor Mount Assy8. 62-0008 Motor9. 50-9010 Linear Guid...

  • Page 343

    342Assembly Drawings96-0189 rev L June 2005EC-1600 Column Assembly1. 20-2506 Casting2. 62-0017 Motor3. 30-1517 Coupling4. 30-0764 Bearing5. 32-2131 Limit Switch6. 24-0003a Ballscrew7. 30-0472 Bearing Assy8. 20-0156 Bumper9. 30-6954 Lube Line Assy10. 20-2677 Bumper11. 50-9010 ...

  • Page 344

    343Assembly Drawings96-0189 rev L June 2005EC-1600 Saddle Assembly1. 20-2536 Casting2. 20-0151 Motor Mount Assy3. 32-2133 Limit Switch4. 25-7267 Switch Brkt5. 30-7410 Lube Line Assy6. 20-0150 Nut Housing7. 20-0152 Bearing Housing8. 20-9822 Guide Bar9. 24-9961c Ballscrew10. 50-98...

  • Page 345

    344Assembly Drawings96-0189 rev L June 200512345678219101111121314151617182021222324192925262827303125323334353637384039414243444546484950471. 25-5615 Panel Encl Top2. 25-5621 Post Encl Top Cross3. 25-5622 Track Encl Door Roll4. 25-5623 Post Encl LT Top5. 25-5625 Cover Encl Top LT6. 25...

  • Page 346

    345Assembly Drawings96-0189 rev L June 2005EC-1600 Spindle Assembly34567891011121314151617181920212223242526272829303132121.20-0011A 50T Shaft Spindle2.20-0001A Spindle Lock3.30-7395 EC-1600 P Cool4.30-7394 Plumbing Assembly5.20-0004 50T spindle Housing6.30-6954 Lube Line Assembly-Y Axis7.32-145...

  • Page 347

    346Assembly Drawings96-0189 rev L June 2005EC-1600 Tool Release Piston12345678934107681112131516171811279625242321202619281729TSCStandard 50TSub Plate14221.20-0018 Air Cyl. Shaft2.57-0027 O Ring 2-121 (4X)3.57-0082 O Ring 2-448 (2X)4.20-0019 Air Cyl. Piston (2X)5.20-0020 Lower Air Cyl. Spacer6.5...

  • Page 348

    347Assembly Drawings96-0189 rev L June 2005EC-1600 Table Assembly(5° Indexer)12345 678910111213141516171819202122232425262728293031323334351.25-5541 Left Shroud2.25-5542 Top Shroud3.25-5544 Pump Cover Access4.57-0373 Pump Cover Gasket5.32-6929 Hydraulic Solenoid6.25-5546 Hydraulic Valve Bracket...

  • Page 349

    348Assembly Drawings96-0189 rev L June 2005EC-1600 Table Assembly(Full-Fouth Indexer)12345678121314172224233435910111516181920212526272829303132331.25-5541 Left Shroud2.25-5542 Top Shroud3.25-5544 Pump Cover Access4.57-0373 Pump Cover Gasket5.30-7398A Hydraulic Solenoid Assembly6. 32-1459 Encode...

  • Page 350

    349Assembly Drawings96-0189 rev L June 2005HS3-7R Harmonic Drive Assembly1. 20-6047 Tube Backlash Adjuster (HS3R)2. 20-6048 Cam Backlash Adjuster (HS3R)3. 20-6005 Push Block (HS3R)4. 20-6102 Pinion Gear (HS3R)5. 20-6109 Sigma Adapter (HS3R)6. 59-2930 Harmonic Drive7. 20-6112 Shoulder Wash...

  • Page 351

    350Assembly Drawings96-0189 rev L June 2005HS3-7R Table Assembly1. 20-6101 Machined Platter2. 20-6103 Ring Gear3. 30-7754 Brake Assy4. 51-2038 Bearing Crossroller5. 20-6113 Bearing Retainer Ring6. 20-6100 Table Machined (HS3R) 20-1511 Table Machined (H...

  • Page 352

    351Assembly Drawings96-0189 rev L June 2005HS3-7R Encoder Assembly20-6115Encoder Shaft20-6114Encoder Mounting Plate20-6006Encoder Cover Plate20-6116Encoder Shaft Plate20-6027Encoder Coupler Tube52-4471Encoder Shaft Coupling20-6025Encoder Mounting Cup32-1459EncoderSet Screws

  • Page 353

    352Assembly Drawings96-0189 rev L June 2005HS-3 Sheet Metal and Parts List021232425262728303132333436353529221236915161718191924511101213873634141. 25-0528 Back panel sheet metal2. 25-0163 Y-Axis bellows top edge cover3. 59-0268 Y-Axis upper bellows4. 25-6017 Y-Axis splash cover5. 25-6051 Doo...

  • Page 354

    353Assembly Drawings96-0189 rev L June 2005Pendant ArmKnuckle(25-6661)Knuckle Cover(25-6660)Knuckle SwivelPlate (25-6659)Pendant ArmMount (20-7109)Wavy Washer(55-0020)Levelling Screw(40-164391)Pendant Mount(20-7110)PARAMSETNGGRAPHHELPCALCNEXTTOOLRELEASETOOLPARTZEROSETTOOLOFFSETMEASUREMESGSALARMD...

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