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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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    June 1998TROUBLESHOOTING96-90101COMMON ABBREVIATIONS USED IN HAAS MACHINESACAlternating CurrentAMPAmpereAPCAutomatic Pallet ChangerAPLAutomatic Parts LoaderASCIIAmerican Standard Code for Information InterchangeATCAutomatic Tool ChangerATC FWDAutomatic Tool Change ForwardATC REVAutomatic Tool Cha...

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    TROUBLESHOOTINGJune 1998296-9010NCNormally ClosedNONormally OpenODOutside DiameterOPEROperatorPARAMParameterPCBPrinted Circuit BoardPGMProgramPORPower On ResetPOSITPositionsPROGProgramPSIPounds Per Square InchPWMPulse Width ModulationRAMRandom Access MemoryREPT RIG TAPRepeat Rigid TapRETReturnREV...

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    June 1998TROUBLESHOOTING96-901031. TROUBLESHOOTINGThis section is intended for use in determining the solution to a known problem. Solutions given are intendedto give the individual servicing the CNC a pattern to follow in, first, determining the problem’s source and,second, solving the problem...

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    TROUBLESHOOTINGJune 1998496-90101.1 GENERAL MACHINE OPERATION MACHINE NOT RUNNING´ Machine cannot be powered onl Check input voltage to machine (see "Electrical Service").l Check main circuit breaker at top right of electrical cabinet; switch must be at the on position.l Check overvolt...

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    June 1998TROUBLESHOOTING96-90105 VIBRATIONVibration is a subjective evaluation with perceptions varying among individuals, making it difficult todetermine in mild cases if there is an actual problem. In obvious cases, it is a matter of determining the source- which is not easy, since all parts...

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    TROUBLESHOOTINGJune 1998696-9010´ Machine will not interpolate a round hole.lCheck that the machine is level (see "Installation" section).lCheck for backlash ("Servo Motors/Leadscrews" section).´ Bored holes do not go straight through the workpiece.lCheck that the machine is...

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    June 1998TROUBLESHOOTING96-90107Note: The leadscrew will always expand away from the motor end.VERIFY THERMAL GROWTHThere are a number of ways to verify the problem. The following procedure will verify thermal growth of theX-axis leadscrew in a machine that has not been warmed up:1. Home the ma...

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    TROUBLESHOOTINGJune 1998896-90101.2 SPINDLE NOT TURNING´ Spindle not turninglIf there are any alarms, refer to "Alarms" section.lCheck that the spindle turns freely when machine is off.lIf motor turns but spindle does not, see "Spindle Drive Belts" and "Transmission&quo...

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    June 1998TROUBLESHOOTING96-90109S1500 M03S5000 M03G04 P900.M97 P6040M97 P6040M05S2000 M03S5500 M03G04 P900.M97 P6040M97 P6040G04 P900.S2500 M03S6000 M03M99M97 P6040M97 P6040S3000 M03S6500 M03M97 P6040M97 P6040S3500 M03S7000 M03M97 P6040M97 P6040This program will step the s...

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    TROUBLESHOOTINGJune 19981096-9010Vector DrivelCheck alarm history. Look for Spindle Z Fault, or Spindle Reference Missing alarms. If these alarms exist,there may be a defective spindle encoder, or a broken ground or shield connection.lCheck parameters.lCheck for a mechanical slip at the contact p...

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    June 1998TROUBLESHOOTING96-901011Note: If a lead screw fails, it is most often due to a failed bearing sleeve. When replac-ing the lead screw in an older machine, always replace the bearing sleeve with thecurrent angular contact bearing sleeve ("Bearing Sleeve Removal and Installation"...

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    TROUBLESHOOTINGJune 19981296-9010 ACCURACY / BACKLASHAccuracy complaints are usually related to tooling, programming, or fixturing problems. Eliminate thesepossibilities before working on the machine.´ Poor positioning accuracylCheck for a loose encoder on the servo motor. Also, ensure the ke...

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    June 1998TROUBLESHOOTING96-901013An alternate method for checking backlash is to place the dial indicator as shown in Fig. 1-1 and manuallypush the mill column to the left and right while listening for a 'clunk'. The dial indicator should return to zeroafter releasing the column.Note: The servo ...

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    TROUBLESHOOTINGJune 19981496-9010CHECKING Z-AXIS:1.Set up a dial indicator and base on the mill table as shown in Fig. 1-3.Figure 1-3. Dial indicator in position to check Z-axis.2.Set dial indicator and the “Distance to go” display in the HANDLE JOG mode to zero as follows:lZero the dial indic...

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    June 1998TROUBLESHOOTING96-901015lLoose SHCS attaching the bearing sleeve to the motor housing or top of column. Tighten as describedin "Lead Screw" section.lDefective thrust bearings in the bearing sleeve. Replace the bearing sleeve as outlined in "BearingSleeve" section.lL...

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    TROUBLESHOOTINGJune 19981696-90101.4 AUTOMATIC TOOL CHANGER DEFLECTIONDeflection is usually caused by ATC misalignment, and sometimes caused by damaged or poor quality tooling,a damaged spindle taper, or a damaged drawbar. Before beginning any troubleshooting, observe the directionof the ATC d...

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    June 1998TROUBLESHOOTING96-901017´ Tool holders spin at all pockets of the ATClATC is rotationally misaligned. Check the CAROUSEL OFFSET (Parameter 215). Realign the ATC("Automatic Tool Changer")Note: Observe the direction the tool holder rotates, as this will be the direction in wh...

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    TROUBLESHOOTINGJune 19981896-9010 SPINDLE OPERATION´ ATC out of orientation with the spindle. Incorrect spindle orientation will cause the ATCto crash, and Alarm 113 to be generated.lCheck the orientation of the spindle.´ ATC will not runlCheck to be sure that the tool changer has been define...

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    June 1998TROUBLESHOOTING96-901019 GEARS WILL NOT CHANGE´ Machine will not execute a gear change.Note: Whenever a gear change problem occurs, an alarm will also occur. Refer to theALARMS section to diagnose each problem before working on the machine.lCheck air supply pressure. If pressure is ...

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    TROUBLESHOOTINGJune 19982096-9010COURSE OF ACTIONŒ Execute an M50 command (pallet change) inMDI mode, ensuring the sequence is completedthis time.Œ Orient the load station, then execute an M50command (pallet change) Free indexing handle.Ž Ensure switch is plugged in. If so, replace.Œ Repla...

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    June 1998TROUBLESHOOTING96-9010211004CW/CCW SWITCH ILLEGALCONDITIONLimit switches erroneouslyindicate that the pallet changeris rotated fully CW and CCWat the same time.1007UP/DOWN SWITCH ILLEGALCONDITIONLimit switches erroneouslyindicate that the pallet changeris fully lifted and lowered atthe s...

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    TROUBLESHOOTINGJune 19982296-90101010MAIN DRAWBAR SWITCHILLEGAL CONDITIONLimit switches erroneouslyindicate that drawbar hastripped the down switch, butnot the up switch.1011MAIN DRAWBARUNCLAMP TIMEOUTMain drawbar has unscrewedfrom pallet nut, but reachedthe down position too slowly.1012MAIN DRA...

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    June 1998TROUBLESHOOTING96-901023EXECUTION OF AN M50RESULTS IN A "RUNNING"MESSAGE, BUT NOTHINGHAPPENS, AND NO ALARM ISGENERATED.Œ Load station not properly oriented or, if M36 isbeing used, PART READY light not pressed. Pallet changer macro program was loadedbefore MACROS were enable...

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    TROUBLESHOOTINGJune 19982496-90101.7 THROUGH THE SPINDLE COOLANTNote: Abrasive swarf from grinding or ceramic machining operations will cause heavywear of TSC coolant pump, coolant tip and drawbar. This is not covered by warranty onnew machines. Notify HAAS Service Dept. if machine is being used...

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    June 1998TROUBLESHOOTING96-901025lMay be generated if another machine alarm occurs during TSC operation.lFor the old TSC system, if the drawbar was replaced, check that the hole through the drawbar is 0.156dia and not 0.190 dia. Replace the drawbar with the correct one if it is 0.190 dia. COOLAN...

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    TROUBLESHOOTINGJune 19982696-9010´ Over Current alarmslPressure is set too highlPressure is set too lowlToo much oil has been added. (Insufficient gas volume causes large pressure rise)lHydraulic cylinder is binding or is misaligned. Replace cylinder assembly.lLength of replacement cylinder in...

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    June 1998TROUBLESHOOTING96-901027´ Servo Error Too LargelThis alarms occurs when the difference between the commanded axis position and the actualposition becomes larger than the maximum that is set in the parameter.This condition occurs when the amplifier is blown, is not receiving the commands...

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    TROUBLESHOOTINGJune 19982896-9010 KEYBOARD DIAGNOSTICNote: Refer to the "Cable Locations" section of this manual for a drawing of the Key-board Interface PCB.The following is an example of how to troubleshoot the keypad:NOTE: Keypad Diodes 1-24 correspond to chart numbers 1-24Examp...

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    96-901029ALARMSJune 19982. ALARMSAny time an alarm is present, the lower right hand corner of the screen will have a blinking "ALARM". Push the ALARMdisplay key to view the current alarm. All alarms are displayed with a reference number and a complete description.If the RESET key is pr...

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    3096-9010ALARMSJune 1998108X Servo OverloadExcessive load on X-axis motor. This can occur if the load on the motorover a period of several seconds or even minutes is large enough toexceed the continuous rating of the motor. The servos will be turned offwhen this occurs. This can be caused by runn...

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    96-901031ALARMSJune 1998122Control OverheatThe control internal temperature is above 150 degrees F. This can becaused by almost anything in the control overheating. But is usually causedby overheat of the two regen resistors for servos and spindle drive. Thisalarm will also turn off the servos, ...

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    3296-9010ALARMSJune 1998136Y Motor Over Heatsame as 135.137Z Motor Over Heatsame as 135.138A Motor Over Heatsame as 135.139X Motor Z FaultEncoder marker pulse count failure. This alarm usually indicates that theencoder has been damaged and encoder position data is unreliable. Thiscan also be caus...

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    96-901033ALARMSJune 1998155Z-axis Zsame as 153.Ch Missing156A-axis Zsame as 153.Ch Missing157MOCON WatchdogThe self-test of the MOCON has failed. Replace the MOCON.Fault158Video/KeyboardInternal circuit board problem. The VIDEO PCB in the processor stack isPCB Failuretested at power-on. This cou...

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    3496-9010ALARMSJune 1998172UNUSED173Spindle RefThe Z channel pulse from the spindle encoder is missing for rigid tappingSignal Missingsynchronization.174Tool Load ExceededThe tool load monitor option is selected and the maximum load for a toolwas exceeded in a feed. This alarm can only occur if t...

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    96-901035ALARMSJune 1998198Precharge FailureDuring Through the Spindle Coolant operation, the precharge failed forgreater than 0.1 seconds. It will shut off the feed, spindle and pump allat once. If received, check all air lines and the air supply pressure.199Negative RPMA negative spindle RPM ...

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    3696-9010ALARMSJune 1998219Z Axis Phasing ErrorSame as above.220A Axis Phasing ErrorSame as above.221B Axis Phasing ErrorSame as above.222C Axis Phasing ErrorSame as above.223Door Lock FailureIn machines equipped with safety interlocks, this alarm occurs when thecontrol senses the door is open bu...

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    96-901037ALARMSJune 1998249Prog DataPossible corrupted program. Save all programs to floppy disk, delete all,Begins Oddthen reload.250Program Data ErrorSame as 249.251Prog Data Struct ErrorSame as 249.252Memory OverflowSame as 249.253Electronics OverheatThe control box temperature has exceeded ...

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    3896-9010ALARMSJune 1998277C Zero Ret MarginSame as 165.Too Small278C Cable FaultSame as 182.291Low Air Volume/PressureAn automatic tool change was not completed due to insufficient volume orDuring ATCpressure of compressed air. Check air supply line.302Invalid R In G02 or G03Check your geometry....

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    96-901039ALARMSJune 1998321Auto Off AlarmA fault turned off the servos automatically; occurs in debug mode only.322Sub Prog Without M99Add an M99 code to the end of program called as a subroutine.324Delay Time Range ErrorP code in G04 is greater than or equal to 1000 seconds (over 999999milliseco...

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    4096-9010ALARMSJune 1998343Display QueueA block exists that is too long for displaying queue. Shorten title block.Record Full344Cutter Comp WithCutter comp only allowed in XY plane (G17).G18 and G19345Diff Step RatioParameters 5 and 19 must be same value.On G17 Plane346Diff Step RatioParameters 5...

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    96-901041ALARMSJune 1998363Coolant Locked OffOverride is off and program tried to turn on coolant.364No Circ InterpOnly rapid or feed is allowed with aux axes.Aux Axis367Cutter CompG01 cannot be done with tool size.Interference368Groove Too SmallTool too big to enter cut.369Tool Too BigUse a smal...

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    4296-9010ALARMSJune 1998386Invalid Address FormatAn address A..Z was used improperly.387Cutter Comp NotIf block buffering has been limited, Cutter comp cannot be used.Allowed With G103388Cutter Comp NotCoordinates cannot be altered while cutter comp is active. Move G10Allowed With G10outside of ...

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    96-901043ALARMSJune 1998409RS-232 Invalid N CodeBad Parameter or Setting data. User was loading settings or parametersand something was wrong with the data.410RS-232 Invalid V CodeBad parameter or setting data. User was loading settings or parametersand something was wrong with the data.411RS-232...

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    4496-9010ALARMSJune 1998435 Floppy AbortCould not read disk.436Floppy File Not FoundCould not find floppy file.501Too Many AssignmentsOnly one assignment “=” is allowed per block. Divide block in error intoIn One Blockmultiple blocks.502[ Or = Not First TermAn expression element was found where...

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    96-901045ALARMSJune 1998519Term ExpectedIn the evaluation of a macro expression an operand was expected andnot found.520Operator ExpectedIn the evaluation of a macro expression an operator was expected andnot found.521Illegal FunctionalAn illegal value was passed to a function, such as SQRT[ or A...

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    4696-9010ALARMSJune 1998537RS-232 AbortWhile a DPRNT statement was executing, the RS-232 communicationsOn DPRNTfailed.538Matching END NotA WHILE-DO statement does not contain a matching END statement.FoundAdd the proper END statement.539Illegal GotoExpression after "GOTO" not valid.540M...

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    MECHANICAL SERVICE96-901047June 19983. MECHANICAL SERVICERECOMMENDED TORQUE VALUES FOR MACHINE FASTENERSThe following chart should be used as a reference guide for torquing machine fasteners where specified.DIAMETERTORQUE1/4 - 2015 ft. lb.5/16 - 1830 ft. lb.3/8 - 1650 ft. lb.M10 - 10050 ft. lb.M...

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    MECHANICAL SERVICE4896-9010June 1998 LOWER Y-AXIS WAY COVERREMOVAL-1. Zero return all axes.2. POWER OFF the machine.3. Remove the seven SHCS that attach the top of the lower Y-axis way cover to the spindle head casting.Collapse the way cover down fully.4. Remove the X-axis chip guard (seven ...

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    MECHANICAL SERVICE96-901049June 19983.2 TOOL RELEASE PISTON (TRP) TOOL RELEASE PISTON REPLACEMENTTOOLS REQUIREDü2.5" diameter, 2.5' long steel tubeü TRP alignment tool, TSC (T-1519)üMagnetic base indicators (2)REMOVAL-1. Remove the rear enclosure panel (seven SHCS).2. IMPORTANT! Jo...

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    MECHANICAL SERVICE5096-9010June 199811. Remove the seal housing from the tool release piston.Figure 3-2. TSC tool release piston.INSTALLATION-1. Ensure spindle, drawbar and spindle drive belt are properly in place.2. Loosely reinstall the tool release piston with two SHCS at the bottom and tw...

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    MECHANICAL SERVICE96-901051June 1998Figure 3-3. Purge line routing.Note: The drain line must run straight through the cable tie loop on the transmission,and must not interfere with the pulley or belts.8. Allow the bore of the seal housing to rest on the drawbar. Tighten the TRP mounting sc...

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    MECHANICAL SERVICE5296-9010June 1998Steps 9-11 apply to machines with modified TSC housing. If not applicable, skip to Step 12.9. Place the alignment tool (T-1519) on top of the drawbar with the pins facing the TRP.10. Lift the TRP assembly slightly and push the pins into the TSC Housing.11. ...

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    MECHANICAL SERVICE96-901053June 19984. Go to "Parameters" page of CRT and ensure PRE-CHARGE DELAY is set to 300. If not, set it at this time.5. Press the TOOL RELEASE button on control panel. A banging noise will be heard as the tool release pistoncontacts the drawbar.6. Turn the ai...

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    MECHANICAL SERVICE5496-9010June 19983.3 SPINDLE DRIVE BELTSPlease read this section in its entirety before attempting to replace the drive belts.TOOLS REQUIREDü2.5" diameter, 2.5' long steel tubeüLift fixture (T-1491)üBelt tensioning fixture (T-1511) BELT REMOVALNote: For easier belt ...

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    MECHANICAL SERVICE96-901055June 1998Figure 3-6. Spindle drive belt replacement.2. Install the tool release piston assembly in accordance with appropriate section, and reconnect all switchesand air lines.3. Loosen the top two transmission mounting SHCS about 1-1/2 turns.4. Refer to the "B...

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    MECHANICAL SERVICE5696-9010June 1998 BELT TENSION ADJUSTMENTNote: The drive belt's tension should be adjusted after every service on the transmissionor spindle of the machine.1. Place the lift fixture onto the transmission (Figure 3-7). Attach to the motor mounting plate with two SHCS.2. Plac...

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    MECHANICAL SERVICE96-901057June 19983.4 SPINDLETOOLS REQUIREDü2.5" diameter, 2.5' long steel tube SPINDLE CARTRIDGEREMOVAL-1. Remove the rear enclosure panel (seven SHCS).2. IMPORTANT! Jog the X-axis all the way to the operator side of the machine. Place the steel tube throughthe 3&qu...

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    MECHANICAL SERVICE5896-9010June 1998Figure 3-8. Spindle cartridge.10. IMPORTANT! Remove the steel tube from the column. CAUTION! This step must be followed or themachine will be seriously damaged.11. Replace the rear enclosure panel with seven SHCS. SPINDLE ORIENTATION1. Remove the rear en...

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    MECHANICAL SERVICE96-901059June 1998Figure 3-9. Rear view of spindle orientation components.7. Using an open end wrench, rotate the spindle until the appropriate alignment is attained. If the spindleis very difficult to rotate, STOP and return to Step 3.8. Tighten the orientation screws evenl...

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    MECHANICAL SERVICE6096-9010June 1998 ORIENTATION - VECTOR DRIVE1. Place the machine in low gear.2. Adjust Parameter 257, "SPINDL ORIENT OFSET", until the spindle dogs are parallel to the X-axis.Ensure that the dogs are within 0.030" using a dial indicator. See Figure 3-10.Figure ...

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    MECHANICAL SERVICE96-901061June 19983.5 DRAWBAR REPLACEMENTTOOLS REQUIREDü2.5" diameter, 2.5' long steel tubeREMOVAL-1. Remove the rear enclosure panel (seven SHCS).2. IMPORTANT! Jog the X-axis all the way to the operator side of the machine. Place the steel tubethrough the 3" d...

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    MECHANICAL SERVICE6296-9010June 19985. Remove the tool release piston.6. Install the snap ring on the spindle shaft.7. Reinstall the tool release piston.8. Complete installation of the spindle.9. Refer to the appropriate sections and set the drawbar height, and clamp and unclamp switches.NOT...

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    MECHANICAL SERVICE96-901063June 1998SETTING DRAWBAR HEIGHT1. Press the MDI key and turn the jog handle to zero (0).2. Press HANDLE JOG and set the increments to .01. Jog the Z-axis in the positive (+) direction .100".3. Press and hold the TOOL RELEASE button, and try to move the block by...

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    MECHANICAL SERVICE6496-9010June 19984. Put a drop of serviceable (blue) Loctite® on the threads of the tool release bolt and install. If replacingtool release coolant tip, put a drop of Loctite® on the threads of the three set screws before installing.5. Install the tool release piston asse...

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    MECHANICAL SERVICE96-901065June 1998UPPER (CLAMP) SWITCHCAUTION! Remove the tool holder from the spindle before performing the upper (CLAMP)switch adjustment. Failure to remove it could result in damage to the tool holder, the milltable, or cause severe personal injury.6. Place a shim (approxi...

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    MECHANICAL SERVICE6696-9010June 19983.7 TRANSMISSIONPlease read this section in its entirety before attempting to remove or replace thetransmission.TOOLS REQUIREDü Transmission removal kit, includes:ltransmission removal fixture (T-1482)ltransmission lift fixture (T-1491)ü Chain hoistREMOVAL-1...

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    MECHANICAL SERVICE96-901067June 1998Disconnect the electrical and oil lines from the oil pump. Plug the oil lines to prevent contamination. Mostof the lines should be marked and identified. If not marked, do so as it is removed.If machine is equipped with the Through the Spindle Coolant option...

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    MECHANICAL SERVICE6896-9010June 1998Figure 3-16. Transmission removal fixture and chain hoist.INSTALLATION-1. If machine is equipped with Through the Spindle Coolant option, reinstall the pressure regulator, checkvalve assembly, and bracket onto the new transmission.2. Remove the lift fixture ...

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    MECHANICAL SERVICE96-901069June 199810. IMPORTANT! Remove the two shipping lockbolts from the column and spindle head.CAUTION! Serious machine damage will occur if the axes are moved with the lockbolts inplace.11. Zero return the machine. Jog the Y-axis all the way up.12. IMPORTANT! Insert...

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    MECHANICAL SERVICE7096-9010June 19983.8 TOOL CHANGER ASSEMBLY CT-EXTRACTOR REPLACEMENTREMOVAL -1. Zero return all axes and remove any tooling.2. Rotate the carousel into position by pressing M39 T_ (Enter the tool position number that needsreplacement.)3. Jog the Y-axis down, away from the t...

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    MECHANICAL SERVICE96-901071June 1998 CAROUSEL MOTORREMOVAL-1. POWER OFF the machine.2. Disconnect the carousel wire harness at carousel motor junction box.3. Remove the four bolts mounting motor to carousel reduction transmission.Figure 3-19. Tool changer carousel motor.4. Motor output shaf...

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    MECHANICAL SERVICE7296-9010June 19985. Remove the cylinder front mount from the door, being careful not to lose the small spring or nylon doorslider.6. Rotate the trap door clockwise past the "closed" position. Continue rotating and gently pull down on thedoor. It will slide down on...

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    MECHANICAL SERVICE96-901073June 1998CAUTION! Make sure that fingers are clear of carousel while performing the following:9. While someone holds the 4x4 (fingers clear), press the turret "IN" solenoid and hold while the 4x4 isremoved.10. After the 4x4 is removed, release the "IN&q...

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    MECHANICAL SERVICE7496-9010June 19984. Install the locking cap. (Fig. 3-20, #6)5. Install the cylinder cap. Pull the shaft of the shock absorber through the front hole of the cylinder cap.6. Install the shock absorber nut. (Fig. 3-20, #5)7. Install the six SHCS that attach the cylinder cap t...

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    MECHANICAL SERVICE96-901075June 1998Figure 3-21. Tool Changer IN/OUT adjustment nutNOTE: Do not loosen the 1/4" nut located at center. Tighten the 1/2" locknut without turningthe adjustment screw.Adjustments are made by loosening the 1/2" locknut located at the nose of the actu...

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    MECHANICAL SERVICE7696-9010June 1998If the carousel is too far in the clockwise direction, Parameter 215, "Carousel Offset", must be set to alower value. Increase the value if the carousel is too far counterclockwise.On machines before software version 9.14, the carousel offset number ...

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    MECHANICAL SERVICE96-901077June 19985. Slowly jog the Y-axis up past the HOME position, into the tool change position.6. Visually watch for the tool carousel fingers to expand over the tool and close in around it.7. Continue jogging up slowly just until the tool applies slight pressure upwards...

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    MECHANICAL SERVICE7896-9010June 1998 SIDE MOUNT TOOL CHANGER ALIGNMENT (HS-2RP)1. Remove the tool changer’s shipping retainer bolt. Refer to Figure 3-22.Figure 3-22.2. There are four tool changer cable connectors that must be plugged in before the tool changer isoperable.Cables shipped in the...

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    MECHANICAL SERVICE96-901079June 19985. Press the ZERO RET and then the AUTO ALL AXES button. The machine will move the spindle to itshome position (Zero X, Y, Z, A and W).6. Go to the SETTINGS screen. Cursor to Setting 51, DOOR HOLD OVERRIDE. Toggle the DOORHOLD OVERRIDE to “ON”. With the set...

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    MECHANICAL SERVICE8096-9010June 199815. Continue to handle jog the tool changer’s carousel to achieve a level condition. Record the Carou-sel Offset number given on the POS-RAW DAT screen. Move to the PARAMETER screen. Enter therecorded Carousel Offset value into PARAMETER 215.16. Remove the...

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    MECHANICAL SERVICE96-901081June 199825. Next, move to PARAMETERS screen. Record the values for the Settings #210 (X-axis), #211 (Y-axis) and #64 (Z-axis). After recording the values for these Parameters, enter "0" for their values.26. Go to ALARMS page, enter “DEBUG” from the keypa...

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    MECHANICAL SERVICE8296-9010June 199830. Handle Jog the spindle in the -Z direction (towards the front of the machine) and align the toolchanger's fingers with the groove in the tool holder. Handle jog the spindle in the +X direction (to-wards the tool changer) and slowly move the tool holder i...

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    MECHANICAL SERVICE96-901083June 199840. Press the MDI/DNC button, then ATC FORWARD button. Repeat step 22, to manually move thecarousel into the machine enclosure.NOTE: The spindle will move to its tool change position and the machine will fault-outand display a SHUTTLE FAULT ALARM. This is du...

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    MECHANICAL SERVICE8496-9010June 19983.9 AXIS MOTORPlease read this section in its entirety before attempting to remove or replace the axismotors. X-AXIS MOTORREMOVAL-1. Power ON the machine. Zero return all axes and put machine in HANDLE JOG mode.2. Jog the Y-axis to the bottom of it's travel....

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    MECHANICAL SERVICE96-901085June 19982. Reconnect all wiring to the motor.3. Align the key on the motor shaft. Slide the motor into the motor housing, inserting the end of thelead screw into the motor coupling.4. Reinstall and tighten down the four SHCS that hold the motor to the housing.5. T...

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    MECHANICAL SERVICE8696-9010June 19988. Loosen the four SHCS and remove the motor from the motor mount.9. Disconnect all wiring from the motor.10. Remove the motor.INSTALLATION-1. Inspect the motor coupling and replace it if required. Visually inspect the flex plates to ensure they areparall...

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    MECHANICAL SERVICE96-901087June 1998Figure 3-30. Z-axis motor and lead screw assembly.5. On the motor mount, loosen the four BHCS and remove the cover plate.6. Loosen the SHCS on the motor coupling at the lead screw.7. Loosen the four SHCS and remove the motor from the mount.8. Disconnect al...

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    MECHANICAL SERVICE8896-9010June 19987. Replace the Z-axis way cover with thirteen SHCS.8. Check for backlash in the Z-axis lead screw ("Troubleshooting" section) or noisy operation.9. Check the grid offset after the new motor has been changed. COUPLING REPLACEMENTREMOVAL-1. Remove...

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    MECHANICAL SERVICE96-901089June 19983.10 BEARING SLEEVEPlease read this section in its entirety before attempting to remove or replace the bearingsleeve. X-AXIS BEARING SLEEVEREMOVAL-1. POWER ON the machine. Zero return all axes and put the machine in HANDLE JOG mode.2. Remove the rear enclo...

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    MECHANICAL SERVICE9096-9010June 1998INSTALLATION-1. 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, seriously affectingthe proper op...

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    MECHANICAL SERVICE96-901091June 19985. Jog the Y-axis until the two upper holes in the column and the corresponding holes in the spindle headare aligned. Place two of the original shipping lockbolts (5/8-11 x 4" SHCS) through the two holes and tighten.CAUTION! This step must be followed to...

  • Page 93

    MECHANICAL SERVICE9296-9010June 1998Figure 3-34. Y-axis lead screw motor end clamp nut and bearing sleeve.INSTALLATION-1. Ensure all mating surfaces on the bearing sleeve, motor housing, top of column, and ball nut are free ofdirt, burrs, grease, or other contaminants.CAUTION! Mating surfaces ...

  • Page 94

    MECHANICAL SERVICE96-901093June 19988. CAUTION! Remove the shipping lockbolts from the column and spindle head. Failure to remove these willcause severe damage to the machine.9. Check for backlash in the lead screw (Troubleshooting section), or noisy operation.10. Replace the rear enclosure ...

  • Page 95

    MECHANICAL SERVICE9496-9010June 19985. Loosen all of the SHCS on the bearing sleeve approximately 1/4 turn, then torque to 15 ft-lbs. DO NOTSKIP THIS STEP. It ensures the lead screw is installed and runs parallel and flat to the linear guides and thesaddle.6. The following sequence is importa...

  • Page 96

    MECHANICAL SERVICE96-901095June 199810. Remove the X-axis motor and bearing sleeve in accordance with appropriate sections.11. Push column towards the control box. CAUTION! Do not move the column too far over since the hardstops are removed!12. Pull the lead screw toward control box side, ...

  • Page 97

    MECHANICAL SERVICE9696-9010June 1998ØWith a T-handle wrench hand tighten the clamp nut screw and mark with yellow paint.ØRemove the shaft lock.ØLoosen the clamp nut screw and clamp nut at the bearing support end and tighten to 4 IN-LBS.against the bearing. Retighten the clamp screw.12. Replac...

  • Page 98

    MECHANICAL SERVICE96-901097June 1998Figure 3-35. Y-axis lead screw and motor assembly (from rear).7. Remove the SHCS securing the hood to the machine. Unplug the service light and gently move the hoodforward approximately one foot.NOTE: It is not necessary to fully remove the hood from the ma...

  • Page 99

    MECHANICAL SERVICE9896-9010June 1998Figure 3-36. Y-axis lead screw bearing support end clamp nut.Figure 3-37. Y-axis lead screw motor end clamp nut and bearing sleeve.14. Remove the lead screw from the column by lifting it out of the bearing support, pulling the lower endof the lead screw out ...

  • Page 100

    MECHANICAL SERVICE96-901099June 1998NOTE: Correct alignment is critical to sliding the ball screw into the bearing. Bindingwill not occur if it is guided carefully and correctly into the bearing.4. Place the bearing sleeve onto the lead screw and attach it to the top of the column with the six...

  • Page 101

    MECHANICAL SERVICE10096-9010June 199812. Reinstall the axis motor in accordance with "Y-Axis Motor - Installation".13. Reconnect the oil line to the ball nut.14. Check for backlash in the lead screw ("Troubleshooting" section), or noisy operation.15. Check the grid offset ...

  • Page 102

    MECHANICAL SERVICE96-9010101June 1998INSTALLATION-1. Ensure all mating on the bearing sleeve, motor housing, nut housing, and ball nut are free of dirt, burrs,grease, or other contaminants.CAUTION! Mating surfaces must be clean or misalignment may occur, seriously affectingthe proper operation ...

  • Page 103

    MECHANICAL SERVICE10296-9010June 1998Note: The 40/50 mm leadscrew clamp nut should be torqued to 50 FT-LBS.ØWith a T-handle wrench hand tighten the clamp nut screw and mark with yellow paint.ØRemove the shaft lock.ØLoosen the clamp nut screw and clamp nut at the bearing support end and tighten...

  • Page 104

    MECHANICAL SERVICE96-9010103June 19983.12 PALLET CHANGER STABILIZER REPLACEMENTREMOVAL-1. Loosen the six BHCS and one SHCS that attach the left front splash shield (on side opposite operator) andremove.2. Loosen the hex bolts (2) that mount the stabilizers to the mounting bracket at each end an...

  • Page 105

    MECHANICAL SERVICE10496-9010June 19987. Go to the “Diagnostics” page on the control, in order to monitor the limit switch’s performance.8. Execute an M50 cycle start, and ensure that the drawbar data is correct.Note: The switches are designated as “RPDBUP” and “RPDBDN” on the “Diagnost...

  • Page 106

    MECHANICAL SERVICE96-9010105June 1998 ROTARY TABLE DRAWBAR CLUTCH INSPECTION CLUTCH SLIP TEST1. Loosen the sixteen BHCS that attach the right side access panel (closest to operator) to the rotary tabletop cover, and remove.2. Visually inspect the drawbar motor assembly to verify that the bel...

  • Page 107

    MECHANICAL SERVICE10696-9010June 1998As the pulley rotates clockwise, (as viewed from above the clutch) during the pallet unclamp sequence,the spring loaded dowel pin rides down the spiral inside the pulley and slams against the machined stopat the bottom of the spiral. This action overrides th...

  • Page 108

    MECHANICAL SERVICE96-9010107June 19983) Standard HAAS machines with 2.5 in. thick pallets--------------------------------nutC4) MIKRON machines with metric pallets----------------------------------------------nut DFigure 3-40. Torque tester.4. Gently set the torque tester on the pallet so the 1...

  • Page 109

    MECHANICAL SERVICE10896-9010June 199810. When the torque test is complete, reinstall the pallet nut, six 1/4-20 SHCS and V-seal and the rotary tableaccess cover.ROTARY TABLE DRAWBAR CLUTCH / MOTOR SUBASSEMBLYREMOVAL-1. Loosen the sixteen BHCS that attach the right side access panel (closest to o...

  • Page 110

    MECHANICAL SERVICE96-9010109June 199810. Complete 50 continuous pallet change cycles to check for any faults.11. Apply sealant and install a gasket, then replace the right side access panel. Tighten the sixteen BHCS.12. Apply sealant and install a gasket where the Z-axis way cover meets the r...

  • Page 111

    MECHANICAL SERVICE11096-9010June 19988. Install the key and clutch/pulley onto the shaft, pushing down until it is in contact with the thrust washers.Tighten the set screw onto the key.9. Remove the four SHCS that mount the drive motor and pulley assembly to the casting, and slip the pulleyinto...

  • Page 112

    MECHANICAL SERVICE96-9010111June 19985. Remove the four drawbar motor mounting SHCS. Slip the rotary table drawbar drive motor and pulley outof the drive belt.6. Slide the drive belt between the driven pulley and the air blast adapter (beneath the rotary table), andremove.INSTALLATION-7. Slid...

  • Page 113

    MECHANICAL SERVICE11296-9010June 1998Figure 3-42. Rotary table motor and belt assemblyINSTALLATION-8. Replace the drive belt on the motor pulley, then replace the four SHCS into the mounting plate and tighten.9. Mount the motor assembly onto the side of the rotary table with the two mounting H...

  • Page 114

    MECHANICAL SERVICE96-9010113June 19985. Pull the pallet nut and drawbar up and remove them from the center of the rotary table.6. Unscrew the drawbar from the nut housing and pallet nut.INSTALLATION -7. Lubricate (using Molybdenum disulfide grease) the threads of the new drawbar, and it's two thr...

  • Page 115

    MECHANICAL SERVICE11496-9010June 1998DRAWBAR INSERT (PULL STUD TYPE)REMOVAL-1. Remove the pallet, in accordance with the "Pallet Replacement" section.2. Command the drawbar into its clamp position. E-Stop the machine.3. Loosen the three mounting BHCS that retain the insert into the dr...

  • Page 116

    MECHANICAL SERVICE96-9010115June 1998Figure 3-43LOAD STATION DRAWBARREMOVAL-1. Remove the pallet according to the appropriate section.2. Loosen the hex nut that tightens the indexing handle onto the load station and remove the handle.3. Loosen the four BHCS that attach the load station bottom ...

  • Page 117

    MECHANICAL SERVICE11696-9010June 199810. Reconnect the load station motor power supply cord.11. Replace the load station bottom cover onto the load station and tighten the six BHCS.12. Replace the indexing handle into the actuator yoke, and tighten the hex nut.13. Replace the pallet in accord...

  • Page 118

    MECHANICAL SERVICE96-9010117June 19984. Check that the pads under the pallet are clean, and the V-ring seal is intact around the pallet nut.5. After removing, set the pallet down on a clean surface, preferably wood, cardboard, or masonite for storage(even for temporary storage).6. To remove th...

  • Page 119

    MECHANICAL SERVICE11896-9010June 199811. Reconnect the oil and air lines to the air blast adaptor.12. Reconnect the main air line to the machine.13. Replace the pallet in accordance with the previous section.14. Apply sealant and install a gasket where the Z-axis way cover meets the rotary ta...

  • Page 120

    MECHANICAL SERVICE96-9010119June 19984. Loosen the two SHCS that hold each of the hardstops (2) in place and remove hardstop(s). Manuallyrotate H-frame to its full rotational swing and perform an M12 (H-frame down).5. Remove the pallet (from the load station side) in accordance with the "P...

  • Page 121

    MECHANICAL SERVICE12096-9010June 19986. Press the ZERO RET key, the A key, then the ZERO SINGL AXIS key. This will zero return the A-axis only.7. Handle jog the A-axis counterclockwise until the rotary table pins are aligned with the center pin on theH-frame.Figure 3-47. Use of the H-frame al...

  • Page 122

    MECHANICAL SERVICE96-9010121June 19983.13 HYDRAULIC COUNTERBALANCETOOLS REQUIREDüHydraulic Counter Balance Service Kit consists of :lPressure tank with manifold assembly, prefilled with (2) Quarts DTE-25 Hydraulic OillHydraulic cylinder with hose not attached (if necessary)HYDRAULIC TANK REPLAC...

  • Page 123

    MECHANICAL SERVICE12296-9010June 19986. POWER ON the machine and zero return (ZERO RET) the Y-axis only. Check for any leaks or abnormal noises.Verify tank pressure (600 psi) at top of travel. Remove charging system and replace valve cap. Zero returnall axes.Figure 3-48. View of hydraulic co...

  • Page 124

    MECHANICAL SERVICE96-9010123June 1998INSTALLATION-1. Install cylinder (with cylinder rod extended) through the large hole (closest to front) on top of the column.The cylinder rod should pass through spindle head mounting hole.2. Orient cylinder body with hydraulic hose fitting facing toward th...

  • Page 125

    MECHANICAL SERVICE12496-9010June 1998Note: At top of machine travel (HS-1/R/RP/HCE-400/400P), the correct pressure for thehydraulic counterbalance is 600 psi.Note: If Y-axis overcurrent alarm is received at top or bottom of travel, call HAAS Automa-tion Service Department immediately for assi...

  • Page 126

    MECHANICAL SERVICE96-9010125June 1998Note: On old TSC system, If the drawbar was replaced, check that the ID of the drawbaris 0.156 dia, and not 0.190 dia. Replace it with the correct one if it is 0.190 dia.CHECKING PUMP PRESSURENote: If the coolant pressure with no tool in the spindle is 60 psi...

  • Page 127

    MECHANICAL SERVICE12696-9010June 19983.15 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 less ...

  • Page 128

    MECHANICAL SERVICE96-9010127June 19983.16 AIR / OIL LINE DIAGRAM

  • Page 129

    MECHANICAL SERVICE12896-9010June 1998THROUGH THE SPINDLE COOLANTSYSTEM FLOW DIAGRAM

  • Page 130

    ELECTRICAL SERVICE96-9010129June 19984. ELECTRICAL SERVICE4.1 SOLENOIDSPlease read this section in its entirety before attempting to replace any solenoid assem-blies.AIR SOLENOID ASSEMBLYREMOVAL -1. Turn machine power ON and lower spindle head to the lowest position. Turn power OFF.2. Remove th...

  • Page 131

    ELECTRICAL SERVICE13096-9010June 199810. Reconnect the two leads to the low air pressure sensor.11. Reconnect the wiring to the plugs on the solenoid bracket (See step 6).12. Reconnect air supply to the machine.13. Replace the rear enclosure panel (seven SHCS). TOOL RELEASE PISTON ASSEMBLY AIR ...

  • Page 132

    ELECTRICAL SERVICE96-9010131June 19984.2 LINE VOLTAGE ADJUSTMENTSPlease read this section in its entirety before attempting to adjust the line voltage.TOOLS REQUIREDüLarge flat tip screwdriverüDigital voltmeterADJUSTING VOLTAGENote: The machine must have air pressure at the air gauge or an int...

  • Page 133

    ELECTRICAL SERVICE13296-9010June 1998Figure 4-3. Control panel general overview.1. Hook up the three power lines to the terminal on top of the main switch at upper right of electrical paneland the separate ground line to the ground bus to the left of the terminals.WARNING! Through the Spindle C...

  • Page 134

    ELECTRICAL SERVICE96-9010133June 1998Figure 4-4. Power lines; hookup location.Note: Make sure that the service wires actually go into the terminal-block clamps. [It iseasy to miss the clamp and tighten the screw. The connection looks fine but themachine runs intermittently or has other problems,...

  • Page 135

    ELECTRICAL SERVICE13496-9010June 1998Figure 4-5. Transformer connections.CAUTION! Make sure that the main breaker is set to OFF and the power is off at your supplypanel BEFORE you change the transformer connections. Make sure that all three black wiresare moved to the correct terminal block and ...

  • Page 136

    ELECTRICAL SERVICE96-9010135June 19984. Set the main switch to on (rotate the shaft that engages the handle on the panel door clockwise untilit snaps into the on position). Check for evidence of problems, such as the smell of overheatingcomponents or smoke. If such problems are indicated, set the...

  • Page 137

    ELECTRICAL SERVICE13696-9010June 1998Figure 4-8. Unscrew the three screws to open the cabinet door. (Newer control cabinets may require a key)3. Open the cabinet door and wait until the red CHARGE light on the servo drive assembly goes out beforebeginning any work inside the electrical cabinet.4...

  • Page 138

    ELECTRICAL SERVICE96-9010137June 1998Figure 4-9. Location of operator's lamp fuses.4. Unscrew the fuse casing to remove and replace the blown fuse with one having the same type and rating(operator's lamp: 5 amp, type AGC, 250V).4.4 PCB REPLACEMENTPlease read this section in its entirety before ...

  • Page 139

    ELECTRICAL SERVICE13896-9010June 19984. Disconnect all leads to the Motor Controller (MOCON) board. Ensure all cables are properly labeled forreconnecting later.5. After all cables have been disconnected, unscrew the standoffs, taking care to hold the board in placeuntil all standoffs have been r...

  • Page 140

    ELECTRICAL SERVICE96-9010139June 1998I/O BOARDNote: Refer to "Cable Locations" for a diagram of this board.1. Follow all precautions noted previously before working in the electrical cabinet.2. Turn the main switch (upper right of electrical cabinet) to the off position.3. Using a larg...

  • Page 141

    ELECTRICAL SERVICE14096-9010June 1998LOW VOLTAGE POWER SUPPLY -Note: Refer to "Cable Locations" for a diagram of this board.8. Remove the Power Distribution (POWER) board as described in steps 1-5.9. Disconnect all leads to the Low Voltage Power Supply (LVPS) board. Ensure all cables a...

  • Page 142

    ELECTRICAL SERVICE96-9010141June 1998* Serial interface replaces cable 700 with cable 700B.Figure 4-10. RS-232 wiring pictorial (with serial keyboard).5. To remove the RS-232 board, unscrew the two hex screws (on the exterior of the cabinet) holdingthe connector to the cabinet. From the inside ...

  • Page 143

    ELECTRICAL SERVICE14296-9010June 19984.5 FRONT PANELPlease read this section in its entirety before attempting to replace any component of the control panel.CRT ASSEMBLY REPLACEMENT1. Turn the power off and disconnect power to the machine.2. Remove the screws holding the cover panel on the back o...

  • Page 144

    ELECTRICAL SERVICE96-9010143June 1998JOG HANDLE REPLACEMENTThe JOG handle is actually a 100-line-per-revolution encoder. We use 100 steps per revolution to move oneof the servo axes. If no axis is selected for jogging, turning of the crank has no effect. When the axis beingmoved reaches its tr...

  • Page 145

    ELECTRICAL SERVICE14496-9010June 1998Figure 4-13. Jog Handle removal. Figure 4-14. Jog Handle wiring diagram5. Remove the three screws holding the jog handle encoder to the control panel and remove.6. Replacement is reverse of removal. Keep in mind the important notice in Step 3. SWITCH REPL...

  • Page 146

    ELECTRICAL SERVICE96-9010145June 1998 SPINDLE 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 hold thecover panel in place until all screws have been removed.3. Disconn...

  • Page 147

    ELECTRICAL SERVICE14696-9010June 19988. Insert the ribbon cable through the opening in the control panel and place the keypad in the upper rightcorner of the lower opening and press to the control panel to mount. Plug the ribbon cable into theKeyboard Interface board, taking care to not bend the ...

  • Page 148

    ELECTRICAL SERVICE96-9010147June 19984.6 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 on theencoder. Turn machine off.2...

  • Page 149

    ELECTRICAL SERVICE14896-9010June 199810. Feed the encoder cable through the flexible tube and connect at the plug in the box on top of theelectrical cabinet.11. Place the 18 tooth belt on the pulley, then loop the 36 tooth pulley over the 18-tooth pulley. Place theencoder assembly on the four st...

  • Page 150

    96-9010149TECHNICAL REFERENCEJune 19985. TECHNICAL REFERENCE5.1 TOOL CHANGERTools are always loaded through the spindle and should never be installed directly in the carousel in orderto avoid crashes. The pocket open to the spindle must always be empty in the retracted position. All wiringto ...

  • Page 151

    15096-9010TECHNICAL REFERENCEJune 19983)Y moves to machine zero as spindle is oriented,4)TSC pump turns off, (optional)5)Y moves up to deposit the tool in the carousel,6)Tool unclamps,7)Carousel shuttles out,8)Carousel rotates,9)Carousel shuttles in,10) Tool clamps,11) Y moves to machine zero,12)...

  • Page 152

    96-9010151TECHNICAL REFERENCEJune 19985.3 SPINDLE OPERATIONSpindle speed functions are controlled primarily by the S address code. The S address specifies RPM ininteger values from 1 to maximum spindle speed (Parameter 131). NOT TO BE CHANGED BY USER! Whenusing the Through the Spindle Coolant ...

  • Page 153

    15296-9010TECHNICAL REFERENCEJune 1998SPINDLE ORIENTATION SEQUENCEWhen spindle orientation is commanded, the following sequence of operations occurs:1) If the spindle is turning, it is commanded to stop,2) Pause until spindle is stopped,3) Spindle orientation speed is commanded forward,4) Pause u...

  • Page 154

    96-9010153TECHNICAL REFERENCEJune 19985.4 CONTROL CABINETFigure 5-1. Control cabinet general overview.

  • Page 155

    15496-9010TECHNICAL REFERENCEJune 1998Figure 5-2. Connectors on side of control cabinet.5.5 SERVOS (BRUSHLESS) SERVO ENCODERS (BRUSHLESS)Haas machines are equipped with brushless motors, which provide for better performance, and nomaintenance. In addition to the performance differences, the...

  • Page 156

    96-9010155TECHNICAL REFERENCEJune 1998 SERVO CHARACTERISTICS (BRUSHLESS)This machine is not capable of instantly changing speed. That is, it takes some non-zero time to accelerateand decelerate. Acceleration and deceleration in this machine have both a constant accel/decel mode and anexponenti...

  • Page 157

    15696-9010TECHNICAL REFERENCEJune 1998There is a 10 amp supply fuse for failure protection. This fuse is relatively slow, therefore it can handle the30 amp peak. Actual continuous current limit to the motor is controlled by software.Commands to the amplifier are +/-5 volts current in two legs of...

  • Page 158

    96-9010157TECHNICAL REFERENCEJune 1998P20 Overheat input (830)P21 Spindle drive status inputs (780)P22 M-FIN input (100)P23 Load station locked* (190)P24 Pal CW / CCW* (790)P25 Pal Up / Down* (200)P26 Spare terminals for M21 to M24P27 CE Door Interlock* (1040)P28 115V AC from CB4 (910)P29 A-axis ...

  • Page 159

    15896-9010TECHNICAL REFERENCEJune 1998P5 CONTAINS:M25 PALLET CW*M26 PALLET CCW*M27 AIR BLAST*M28 SPAREP116-PIN RELAY DRIVERS FROM MOCON (M21- M28) (540) (INPUT)P316-PIN RELAY OUTPUT TO IOPCB (540)P212 VDC FROM POWER SUPPLY BOARD (860A)* INDICATES HS-1RP MACHINESFigure 5-3 M-Code relay board.5.7 ...

  • Page 160

    96-9010159TECHNICAL REFERENCEJune 1998 GEAR BOX SENSE SWITCHESThere are two switches in the gear box used to sense the position of the gears. One switch indicates HIGHby opening and the other indicates LOW by opening. Between gears, both switches are closed indicating abetween-gear condition....

  • Page 161

    16096-9010TECHNICAL REFERENCEJune 1998There are different types of spindle drive that are used in the control. They are all equivalent in performancebut are adjusted differently. EMERGENCY STOP SWITCHThe EMERGENCY STOP switch is normally closed. If the switch opens or is broken, power to the ...

  • Page 162

    96-9010161TECHNICAL REFERENCEJune 1998The eight LED’s are used to diagnose internal processor problems. As the system completes power uptesting, the lights are turned on sequentially to indicate the completion of a step. The lights and meaningsare:+5V+5V logic power supply is present. (Normal...

  • Page 163

    16296-9010TECHNICAL REFERENCEJune 1998 MEMORY RETENTION BATTERYThe memory retention battery is initially soldered into the processor PCB. This is a 3.3V Lithium battery thatmaintains the contents of CMOS RAM during power off periods. Prior to this battery being unusable, an alarmwill be genera...

  • Page 164

    96-9010163TECHNICAL REFERENCEJune 1998P13I/O relays K17-24 (530)P14I/O relays K25-32 (540)P15Low Voltage Power (860)P16Spindle command output (720)P19Address busP24Axis home switches (990)5.10 SPINDLE DRIVE ASSEMBLYThe spindle drive is located in the main cabinet on the right side and halfway d...

  • Page 165

    16496-9010TECHNICAL REFERENCEJune 1998 OVERHEAT SENSE SWITCHThere is an overtemperature sense switch mounted near the above-mentioned regen resistors. This sensoris a normally-closed switch that opens at about 1000 C. It will generate an alarm and all motion will stop.After four minutes of an o...

  • Page 166

    96-9010165TECHNICAL REFERENCEJune 1998P11 +5/+12/Gnd form low volt supply to logic boards (860)P12 +5/+12/Gnd form low volt supply to logic boards (860)P13 +5/+12/Gnd form low volt supply to logic boards (860)P14 12V AC to pallet ready lamp switch (800A)P15 230V AC from main transformer for coo...

  • Page 167

    16696-9010TECHNICAL REFERENCEJune 19985.13 POWER TRANSFORMER ASSEMBLY (T1)The power transformer assembly is used to convert three-phase 190/260V to three-phase 115V and isprimarily used by the servo drives. The video monitor, solenoids, fans, and oiler also use 115V AC. Thistransformer’s max...

  • Page 168

    96-9010167TECHNICAL REFERENCEJune 19985.14 FUSESThe servo drive (DRIVER) cards have three fuses on each of the X, Y, Z, and A PCB's (F1, F2, F3). If thesefuses are ever blown, the associated motor will stop. This will only happen if there is a failure of the drivecard, and the user should neve...

  • Page 169

    16896-9010TECHNICAL REFERENCEJune 19985.15 SPARE USER M CODE INTERFACEThe M code interface uses outputs M21-23, M28 and one discrete input circuit. M codes M21 through M23,and M28 will activate relays labeled M21-23, and M28. These relay contacts are isolated from all othercircuits and may switc...

  • Page 170

    96-9010169TECHNICAL REFERENCEJune 1998 TURNING M FUNCTIONS ON AND OFFThe M code relays can also be separately turned on and off using M codes M51-M53, M58 and M61-M63, M68. M51 to M53, and M58 will turn on one of the eight relays and M61 to M63, and M68 will turnthe relays off. M51 and M61 co...

  • Page 171

    17096-9010TECHNICAL REFERENCEJune 19985.16 LUBRICATION SYSTEMThe lubrication system is a resistance type system which forces oil through metering units at each of the 16lubricating points within the machine. The system uses one metering unit at each of the lubricating points:one for each linear...

  • Page 172

    96-9010171TECHNICAL REFERENCEJune 1998Z - Rear of base by Z-axis motorThe machine zero position is defined by a limit switch for each of the X, Y, and Z axes. After the search formachine zero has been completed, these switches are used to limit travel in the positive direction. Inaddition, trav...

  • Page 173

    17296-9010TECHNICAL REFERENCEJune 19985.19 PALLET CHANGER FOR THE HS-1RP ROTARY TABLE (HRT310HRPA)The rotary table is a standard HAAS 310 equipped with a special platter compatible with the pallet operation.The table is mounted on the pallet changer casting, and a drive shaft bearing assembly ...

  • Page 174

    96-9010173TECHNICAL REFERENCEJune 1998 LIFTING ASSEMBLYThe pallet lifting assembly consists of a large guided pneumatic cylinder and an H-frame. Pins are mountedin the H-frame to engage the pallets from below and to give aid in stabilizing the load during rotation of thepallets. The H-frame it...

  • Page 175

    17496-9010TECHNICAL REFERENCEJune 1998PALLET UP/DOWN SWITCHES[Switch bracket on lifting assembly mounting plate (2)]The lift cylinder has two switches that sense the cylinder lifted position (pallet up) or cylinder loweredposition (pallet down). Both switches are tripped when the cylinder is in ...

  • Page 176

    96-9010175TECHNICAL REFERENCEJune 1998of the main drawbar, to the drawbar and pallet nut.5.20 PALLET CHANGER MACRO EXPLANATIONMACRO VARIABLES THAT CORRELATE DIRECTLY TO DIAGNOSTICS:IMPORTANT!!THE MACRO PROGRAM LISTED IN THIS SECTION SHOULD NOT BE MODIFIED IN ANY WAY ANDIS FOR REFERENCE ONLY.CHAN...

  • Page 177

    17696-9010TECHNICAL REFERENCEJune 1998 OUTPUT: #1124=1 (SUPPLY POWER TO MAIN); #1124=0 (CUT OFF POWER TO MAIN)7) MAIN DRAWBAR CLOCKWISE RELAY (SCREW IN DRAWBAR). OUTPUT: #1108=1 (TURN MOTOR CW); #1108=0 (TURN OFF CW MAIN)8) MAIN DRAWBAR COUNTERCLOCKWISE RELAY (SCREW OUT DRAWBAR). ...

  • Page 178

    96-9010177TECHNICAL REFERENCEJune 1998IT IS THE ONLY ONE WITH A PALLET CHANGER.PARAMETER 256: VALUE SHOULD BE SET TO “4”FUNCTION OF 256?: SPECIFIES THE MAIN DRAWBAR “UP” SWITCHPARAMETER 278: “CK PALLET IN”: VALUE SHOULD BE “1” (HS-1RP ONLY)FUNCTION OF “CK PALLET IN”?: TELLS SOFTWARE TO...

  • Page 179

    17896-9010TECHNICAL REFERENCEJune 19987) TURN ON THE BEEPER8) TURN ON THE AIR BLAST9) ROTATE THE PALLETS CLOCKWISE TO RECOVER THE PALLET CHANGER10) LOWER THE PALLETS11) CLAMP THE PALLETS BY SCREWING IN THE DRAWBARS12) CLEAR THE PALLET CHANGER MACRO INCOMPLETE BITSITUATION 3:NOW LET US ASSUME T...

  • Page 180

    96-9010179TECHNICAL REFERENCEJune 1998 PALLETS GOT ALL THE WAY DOWN. THE PALLETS ARE NOT EVEN PARTIALLY CLAMPED **13) CLAMP THE PALLETS BY SCREWING IN THE DRAWBARS ** INTERRUPTION OF THE PALLET CHANGER SEQUENCE MAY HAVE HAPPENED BEFORE THE DRAWBARS FULLY CLAMPED THE PALLETS **14) CLEAR THE PALLE...

  • Page 181

    18096-9010TECHNICAL REFERENCEJune 1998ALARM FLAG IS SET DURING THE SWITCH CHECK AND DURING THE ROTATION SEQUENCES.REFER TO TROUBLESHOOTING THE PALLET CHANGER FOR MORE INFORMATION.1007 (UP/DOWN SWITCH ILLEGAL POSITION - LIFT CYLINDER)THE ILLEGAL CONDITION IS DEFINED BY THE PALLET CHANGER MACRO AS:...

  • Page 182

    96-9010181TECHNICAL REFERENCEJune 19981012 (MAIN DRAWBAR CLAMP TIMEOUT)THE ALARM FLAG IS SET FOR THIS WHEN THE MACRO ENTERS THE DRAWBAR CLAMPING ROUTINE. THEDRAWBAR HAS SUCCESSFULLY COME OFF THE DRAWBAR DOWN SWITCH WHILE ON THE WAY UP, BUT ITJUST CAN’T SEEM TO GET OFF THE DRAWBAR UP SWITCH EVE...

  • Page 183

    18296-9010TECHNICAL REFERENCEJune 1998(* ELSE SAME AS RPLMAC OF 29JUN95 *)(MODIFICATIONS 4/24/96)(#3001 GT 3500 WAS 2000 N7)(#3001 - #134 GE 1300 WAS 350 N8)(CLAMP TIMEOUT IS 8500 WAS 7500 N80)(* MODIFIED 8JUN 95 *)(.3SEC RATCHET MAIN 1/3 FOR N94 LOCK)(THIS CODE HAS ALARMS 1 TO 12)(N88 SLIP CLUTC...

  • Page 184

    96-9010183TECHNICAL REFERENCEJune 1998#1135= 1 (AUDIBLE ALARM ON/CE DISABLE FRNT SWITCHES)turns on beeperM97 P97 (SYNC)synchronizes lookahead(*** START SWITCH STATUS CHECK HERE ***)checks for broken switches on lift cylinder, main drawbar, and cw/ccw positions[ #1027 EQ 0 ] GOTO18 (PALLET NOT DOW...

  • Page 185

    18496-9010TECHNICAL REFERENCEJune 1998circuit. if the switch is tripped, then the drawbar must be down already and power is not required.IF [ #1002 EQ 0 ] #1109= 1 (BACK OUT MAIN IF NOT DOWN)check the drawbar down switch. if the drawbar down switch is not tripped will supply power to unscrew t...

  • Page 186

    96-9010185TECHNICAL REFERENCEJune 1998routine passes this one time, but sees it second timeM97 P90 (CHECK OPER LOCK SW / SYNC)check index station orientation and synchronize lookahead.#133= 1 (SET FLAG FOR MAIN SHUTDOWN DELAY)now set to 1. next loop bypasses this line, goes to n8#134= #3001 (SET ...

  • Page 187

    18696-9010TECHNICAL REFERENCEJune 1998if it doesn’t come off the top switch in 6 seconds then it will fall thru the next conditional test.M97 P90 (CHECK OPER LOCK SW / SYNC)check index station orientation and synchronize lookahead.G04 P0.5 (WAIT FOR PALLET UP)if not sent to retry subroutine, che...

  • Page 188

    96-9010187TECHNICAL REFERENCEJune 1998checks switches while rotating for illegal conditionM97 P97 (SYNC)synchronize lookahead by executing 3 blank lines at n97.IF [ #1022 EQ 0 ] GOTO30 (WAIT FOR CW)if it hasn’t finished cw rotation, loop until cw switch is tripped or an alarm occursM97 P97 (SYNC...

  • Page 189

    18896-9010TECHNICAL REFERENCEJune 1998M97 P97 (SYNC)synchronize lookahead by executing 3 blank lines at n97.#1137= 0 (CCW OFF)disable ccw rotation solenoid(*** END CCW MOVEMENT ***)(*** BEGIN PALLETS DOWN ***)N60 (* PALLETS DOWN *)#191= 3preset alarm variable to pallets jammed#1122= 0 (PALLETS UP...

  • Page 190

    96-9010189TECHNICAL REFERENCEJune 1998M97 P97 (SYNC)IF [ #1002 AND [ #1004 EQ 0 ] ] #191= 10 GOTO91if main drawbar up switch is off, but the down switch is on, alarm: illegal conditionM97 P97 (SYNC)(* CLAMP TIME, FRONT MOTOR *)IF [ #3001 GT 7500. ] #1110= 0 (FRONT UP, STOP IT)after 7.5 seconds o...

  • Page 191

    19096-9010TECHNICAL REFERENCEJune 1998end pallet change macro, m50 complete(* BEGIN TEST OPER LOCK SUB *)N90 (TEST OPER LOCK SUB)IF [ #1024 ] #191= 1 GOTO91check index station orientation. if not oriented alarm: index station unlockedM99(* END TEST OPER LOCK SUB *)(* BEGIN ALARM SUBROUTINE*)N91...

  • Page 192

    96-9010191TECHNICAL REFERENCEJune 1998[ #191 EQ 12 ] #3000= 12 (MN DB CL TIMEOUT,CHK MTR/SW,M50)(GOT OFF THE DOWN SWITCH BUT NOT LOCKED)set alarm to 1012 (message displayed)#3000= 119 (UNKNOWN ALARM,M50)set alarm to 1119 (message displayed) got here because something weird happened like an undefi...

  • Page 193

    19296-9010TECHNICAL REFERENCEJune 1998END2 (SCREW UP 20 TRIES)M97 P97 (SYNC)got here because after 20 attempts, could not get off down switch#1124= 0 (MAIN MOTOR DISABLE)turn off power supply to main drawbar gearmotorGOTO91 (MAX LIMIT RETRYS)go to alarm: drawbar locked downM97 P97 (SYNC)N93 #300...

  • Page 194

    96-9010193TECHNICAL REFERENCEJune 1998#1108= 1.turn on power to screw in(RATCHET TIME)G04 P1. (UP TIME)screw in for 1 secondM97 P90 (CHECK OPER LOCK SW / SYNC)#1108= 0turn off power to screw inG04 P3.wait 3 seconds for i/o board circuit to cool downM97 P90 (CHECK OPER LOCK SW / SYNC)N98 #1109= 1 ...

  • Page 195

    19496-9010TECHNICAL REFERENCEJune 1998WHILE [ #5 LT 3 ] DO1for 3 tries, do this loop#5= #5 + 1increment counter for next try#1125= 1 (FRONT ENABLE)power on front drawbarG04 P0.2 (RELAY DELAY)protect relaysM97 P97 (SYNC)#1111= 1 (BACK OUT FRONT)turn on direction of front drawbar to unscrewG04 P1. ...

  • Page 196

    96-9010195TECHNICAL REFERENCEJune 19985.21 DIAGNOSTIC DATAThe ALARM MSGS display is the most important source of diagnostic data. At any time after the machinecompletes its power-up sequence, it will either perform a requested function or stop with an alarm. Referto the "Troubleshooting&...

  • Page 197

    19696-9010TECHNICAL REFERENCEJune 1998DISCRETE INPUT #NameDescription #NameDescription1OOOTC INTC Carousel Extended1O16sparespare1OO1TC OUTTC Carousel Parked1O17sparespare1OO2RPDBDNMain Drawbar Down1O18sparespare1OO3LO CNTLow Coolant1O19sparespare1OO4RPDBUPMain Drawbar Up1O20LO OILLow Sp.Coola...

  • Page 198

    96-9010197TECHNICAL REFERENCEJune 1998board, and are displayed on page 3 of the Diagnostics display.NameDescriptionNameDescriptionM21spareRP CWPallet Rotate CWM22spareRP CCWPallet Rotate CCWM23spareRPAIRBAir blastRPWARNAudible alarmM28spareThe second page of diagnostic data is displayed using the...

  • Page 199

    19896-9010TECHNICAL REFERENCEJune 1998ANALOG DATANameDescriptionDC BUSSVoltage from Haas Vector Drive (if equipped)uP TEMPMicroprocessor enclosure temperature (displayed only when Parameter 278 bit "uP ENCLTEMP" is set to 1)SP LOADSpindle load in %SP SPEEDSpindle RPM CW or CCWRUN TIMEMa...

  • Page 200

    96-9010199TECHNICAL REFERENCEJune 1998I MACHINES BEFORE #50149 (EXCEPT #50132 AND #50139) MACHINE W/HAAS VECTOR DRIVENumCircuit #IOPCBHS-1HS-1HS-1HS-1RPHS-1RPHS-1RPHS-1/RHS-1RPNO Air Doo...

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    20096-9010TECHNICAL REFERENCEJune 1998 MACHINES BEFORE #50149 (EXCEPT #50132 AND #50139) MACHINE W/HAAS VECTOR DRIVENum Circuit # IOPCB HS-1HS-1HS-1HS-1RPHS-1RPHS-1RPHS-1/RHS-1RPNO Air DoorW/Air Do...

  • Page 202

    96-9010201TECHNICAL REFERENCEJune 1998 MACHINE W/HAAS VECTOR DRIVENum Circuit # RLYBRDHS-1HS-1HS-1HS-1RPHS-1RPHS-1RPHS-1HS-1RPNO Air D...

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    20296-9010TECHNICAL REFERENCEJune 1998

  • Page 204

    96-9010203PARAMETERSJune 1998 6. PARAMETERSParameters are seldom-modified values that change the operation of the machine. These include servo motortypes, gear ratios, speeds, stored stroke limits, lead screw compensations, motor control delays and macrocall selections. These are all rarely chan...

  • Page 205

    20496-9010PARAMETERSJune 1998LINEAR DISPLThis bit changes the display from degrees to inches (ormillimeters) on the A and B axes.SCALE/X LOWith SCALE/X HI bit, determines the scale factor used in bitSCALE FACT/X,SCALE/X HIWith SCALE/X LO bit, determines the scale factor used in bitSCALE FACT/X. ...

  • Page 206

    96-9010205PARAMETERSJune 1998Parameter13XBACKLASHBacklash correction in encoder steps.Parameter14XDEAD ZONEDead zone correction for driver electronics. Units are 0.0000001 seconds.Parameter15YSWITCHESSee Parameter 1 for description.Parameter16YP GAINSee Parameter 2 for description.Parameter17YD G...

  • Page 207

    20696-9010PARAMETERSJune 1998Parameter31ZD GAINSee Parameter 3 for description.Parameter32ZI GAINSee Parameter 4 for description.Parameter33ZRATIO (STEPS/UNIT)See Parameter 5 for description.Parameter34ZMAX TRAVEL (STEPS)See Parameter 6 for description.Parameter35ZACCELERATIONSee Parameter 7 for ...

  • Page 208

    96-9010207PARAMETERSJune 1998Parameter49AACCELERATIONSee Parameter 7 for description.Parameter50AMAX SPEEDSee Parameter 8 for description.Parameter51AMAX ERRORSee Parameter 9 for description.Parameter52AFUSE LEVELSee Parameter 10 for description.Parameter53ABACK EMFSee Parameter 11 for descriptio...

  • Page 209

    20896-9010PARAMETERSJune 1998INVERT SKIPInvert sense of skip to active low=closed.HANDLE CURSREnable use of jog handle to move cursor.NEG WORK OFSSelects use of work offsets in negative direction.SPIN COOLANTEnables spindle low oil pressure detection.ENA QUIKCODEEnables conversational programming...

  • Page 210

    96-9010209PARAMETERSJune 1998Parameter69A AIR BRAKE DELAYDelay provided for air to release from brake on A-axis prior to moving. Unitsare milliseconds.Parameter70MIN SPIN DELAY TIMEMinimum delay time in program after commanding new spindle speed and beforeproceeding. Units are milliseconds.Parame...

  • Page 211

    21096-9010PARAMETERSJune 1998Parameter85M MACRO CALL O9004 same as 81Parameter86M MACRO CALL O9005 same as 81Parameter87M MACRO CALL O9006 same as 81Parameter88M MACRO CALL O9007 same as 81Parameter89M MACRO CALL O9008 same as 81Parameter90M MACRO CALL O9009 same as 81Parameter91G MACRO CAL...

  • Page 212

    96-9010211PARAMETERSJune 1998Parameter112D*D GAIN FOR ASecond derivative gain in servo loop.Parameter113X ACC/DEC T CONSTExponential acceleration time constant. Units are 1/10000 seconds. This parameterprovides for a constant ratio between profiling lag and servo velocity. It is also the ratiobe...

  • Page 213

    21296-9010PARAMETERSJune 1998Parameter129GEAR CH SETTLE TIMEGear change settle time. This is the number of one millisecond samples that the gearstatus must be stable before considered in gear.Parameter130GEAR STROKE DELAYThis parameter controls the delay time to the gear change solenoids when per...

  • Page 214

    96-9010213PARAMETERSJune 1998Parameter146Y ACCEL FEED FORWARDSame as Parameter 145.Parameter147Z ACCEL FEED FORWARDSame as Parameter 145.Parameter148A ACCEL FEED FORWARDSame as Parameter 145.Parameter149PRE-CHARGE DELAYThis parameter sets the delay time from pre-charge to tool release. Units arem...

  • Page 215

    21496-9010PARAMETERSJune 1998Parameter 164B DEAD ZONESee Parameter 14 for description.Parameter 165IN POSITION LIMIT BSame definition as Parameter 101.Parameter166B MAX CURRENTSame definition as Parameter 105.Parameter167D*D GAIN FOR BSecond derivative gain in servo loop.Parameter168B ACC/DEC T C...

  • Page 216

    96-9010215PARAMETERSJune 1998Parameter 180C SLIP GAINThe value that the slip rate would assume at maximum speed and maximumcurrent.Parameter 181C MIN SLIPThe minimum value allowed for the slip rate.Parameter182C ACCELERATIONSee Parameter 7 for description.Parameter183C MAX FREQThe frequency at wh...

  • Page 217

    21696-9010PARAMETERSJune 1998Parameter194SPINDLE STOP FREQThe spindle is considered to be stopped (discrete input SP ST*=0) when thespeed drops below this value. Units are encoder steps/millisecond.Parameter 195C START/STOP DELAYThis delay is used at the start of motion to magnetize the rotor be...

  • Page 218

    96-9010217PARAMETERSJune 1998ENA CONVEYOREnables chip conveyor, if machine is equipped.50% RPD KBDWhen (1) the control will support the new style keyboards with the 50% rapidtraverse key. For controls without a 50% rapid keypad set this bit to (0).FRONT DOORWhen enabled the control will look fo...

  • Page 219

    21896-9010PARAMETERSJune 1998AUX JOG NACCDoes not allow accumulation on auxiliary axis jog.ALISM PRGRSTAlias M codes during program restart.DSBL JOG TSTDisables the encoder test for the jog handle.AIR DR @ M24On Horizontal mill, air door uses M24. When set to zero, air door output is at M23.RESE...

  • Page 220

    96-9010219PARAMETERSJune 1998Parameter 220CONVYR RETRY TIMEOUTAmount of time in 1/50 seconds between consecutive overcurrents in which theovercurrents is considered another retry. If this amount of time passes betweenovercurrents then the retry count is set to (0). Default is 1500, 30 seconds.P...

  • Page 221

    22096-9010PARAMETERSJune 1998Parameter 236TSC LOW PR FLTAfter the TSC system has stabilized following startup, Alarm 151 is generated ifcoolant pressure falls below 40 psi for the amount of time set in this parameter. Thedefault is 1000 milliseconds.Parameter 237TSC CLNT LINE PURGEThe amount o...

  • Page 222

    96-9010221PARAMETERSJune 1998number of encoder steps between the Z pulse and the correct spindle orient-ation position.Parameter 258LS PER INCHThe number of steps on the linear scale per inch of travel.Parameter 259LS PER REVThe number of steps between Z pulses on the linear scale.Parameter 266X ...

  • Page 223

    22296-9010PARAMETERSJune 1998A DSBL LS ZTSTUsed to disable the linear scale Z test.A ZERO AXIS TCUsed to return axis prior to toll change.A 2ND HOME BTNUsed to move axis to coordinates specified in Work Offset G129A NEG COMP DIRUsed to negate the direction of thermal compensation.A DELAY AXIS 0Us...

  • Page 224

    96-9010223PARAMETERSJune 1998RESERVEDNot currently used.SPND DRV LCKThis bit must be set to 0 if machine is equipped with a Haas vector spindledrive.RESERVEDNot currently used.CNCR SPINDLE(Concurrent Spindle) When set to 1, the spindle will be commanded to startconcurrently with other commands in...

  • Page 225

    22496-9010PARAMETERSJune 1998Parameter 282A MAX 3rd DERIVSee parameter 279 for descriptionParameter 283B MAX 3rd DERIVSee parameter 279 for descriptionParameter 284C MAX 3rd DERIVSee parameter 279 for descriptionParameter 294MIN BUSS VOLTAGEThis parameter specifies the minimum Haas Vector Driv...

  • Page 226

    96-9010225PARAMETERSJune 1998 LEAD SCREW COMPENSATIONSeparate lead screw compensation is provided for each of the X, Y, and Z axes. The operator-enteredcompensation values are spaced at 0.5 inch intervals within the machine coordinate system. The compen-sation values are entered in inches with a...

  • Page 227

    MAINTENANCE22696-9010June 19987. MAINTENANCE SCHEDULE AND LUBRICATION CHARTThe following is a list of required regular maintenance for the HAAS HS Series Horizontal MachiningCenters. Listed are the frequency of service, capacities, and type of fluids required. These requiredspecifications must...

  • Page 228

    MAINTENANCE96-9010227June 1998TSC MAINTENANCEü Top off the coolant tank every eight hour shift during heavy TSC usage.ü Refer to the next section, and check gauge (G2) on 100 micron filter with TSC system runningand no tool in the spindle. Change element when the indicator reaches the red zone...

  • Page 229

    MAINTENANCE22896-9010June 1998 TSC MAINTENANCEü Check dirt indicator on 100 micron filter (Figure 7-3) with TSC system running and no tool in the spindle. Change elementwhen the indicator reaches the red zone.ü Clean pump intake filter when indicator is in red zone. Reset indicator with butto...

  • Page 230

    MAINTENANCE96-9010229June 1998CHECKING DRAWBAR HEIGHTTOOLS REQUIREDüRight angle fixture, such as a right angle plateüMachined aluminum block (2"x4"x4")üTool holder (without a tool)1. Secure the rigid fixture in place on the table. Place a sheet of paper on the table for protec...

  • Page 231

    MAINTENANCE23096-9010June 19986. Press the MDI key and turn the jog handle to zero (0). Press HANDLE JOG. Jog the Z-axis in the positive(+) direction .100".7. Press and hold the TOOL RELEASE button, and try to move the block by hand. The block should be tightat .100" and loose at ....

  • Page 232

    96-9010231CABLE LOCATIONSJune 19988. PCB'S, CABLE LOCATIONS AND BOARD DIAGRAMS

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    CABLE LOCATIONS23296-9010June 1998

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    96-9010233CABLE LOCATIONSJune 1998MICRO PROCESSOR PCB - P/N 32-3091CABLE CONNECTIONS PROC.PLUG #CABLE #SIGNAL NAMEð TO ðLOCATIONPLUG # ADDRESSADDRESS BUSSVIDEO——- & DATADATA BUSSMOTIF PCB——-P3860LOW VOLTAGEPOWER SUPPLY PCB——-P6N/AEXTERNAL BATTERY(EXT. BATTERY)——-PORT 1850SERIA...

  • Page 235

    CABLE LOCATIONS23496-9010June 1998BRUSHLESS SERVO AMPLIFIER P/N 32-5550B

  • Page 236

    96-9010235CABLE LOCATIONSJune 1998BRUSHLESS SERVO AMPLIFIER - P/N 32-5550BCABLE CONNECTIONSMOCONPLUG #CABLE #SIGNAL NAMEð TO ðLOCATIONPLUG #P570LOW VOLTAGEL. V. POWER SUPPLY——-TB A, B, C——-MOTOR DRIVEX SERVO MOTOR——-P610X DRIVE SIGNALMOCON PCBP2TB -HV +HV——-320VDCSPINDLE DRIVE——-Y A...

  • Page 237

    CABLE LOCATIONS23696-9010June 1998POWER PCB 32-5010

  • Page 238

    96-9010237CABLE LOCATIONSJune 1998POWER PCB 32-5010CABLE CONNECTIONSPLUG #CABLE #SIGNAL NAMEð TO ðLOCATIONPLUG #P1——190-260VAC INPUTCB1—--P3——K1 COILK1 CONTACTOR——P4170AUTO OFFI/O PCBP8P5PRI-SECPRI-SEC/T5T5——P6930230VAC/COOLANT PUMPI/O PCBP6P7910115VAC CB3/SOLENOIDI/O PCBP28P890115VAC...

  • Page 239

    CABLE LOCATIONS23896-9010June 1998I/O PCB - P/N 32-3080 VER. MA

  • Page 240

    96-9010239CABLE LOCATIONSJune 1998I/O PCB - P/N 32-3080 VER. MA CABLE CONNECTIONSI/O PLUG #CABLE #ð TO ðLOCATIONPLUG #P1510MOCON PCBP11P2520MOCON PCBP12P3540MOCON PCBP14P4550MOCON PCBP10P5110SERVO POWER ON——-P6930POWER PCBP6P7940COOLANT PUMP——-P8170POWER PCBP4P9710SPARE——-P10300SP FAN/G...

  • Page 241

    CABLE LOCATIONS24096-9010June 1998SERIAL KEYBOARD INTERFACE PCB WITH HANDLE JOGP/N 32-4030

  • Page 242

    96-9010241CABLE LOCATIONSJune 1998SERIAL KEYBOARD INTERFACE PCB WITH HANDLE JOGP/N 32-4030CABLE CONNECTIONSPLUG#CABLE#ð TO ðLOCATIONPLUG#P1700BPROCESSOR850P2—-KEYPAD—-P3700ACYCLE START/HOLD SWITCHES—-P4730SP LOAD METER—-P5—-SPEAKER—-P6—-AUX FPANEL—-J1—-JOG HANDLE—-J2—-REMOTE JOG HAND...

  • Page 243

    CABLE LOCATIONS24296-9010June 1998VIDEO & KEYBOARD PCB W/ FLOPPY DRIVE

  • Page 244

    96-9010243CABLE LOCATIONSJune 1998VIDEO & KEYBOARD PCB W/ FLOPPY DRIVE P/N 32-3201ACABLE CONNECTIONSVIDEOPLUG #CABLE #SIGNAL NAMEð TO ðLOCATIONPLUG #P1860LOW VOLTAGEPOWER SUPPLY PCB——-J3*700KEYBOARD INFO.KEYBOARD INT.——-J4——-ADDRESS BUSSMICRO PROC. PCB——-J5——-DATA BUSSMOTIF PCB—...

  • Page 245

    CABLE LOCATIONS24496-9010June 1998

  • Page 246

    96-9010245CABLE LOCATIONSJune 1998VIDEO & KEYBOARD PCB - P/N 32-3200CABLE CONNECTIONSVIDEOPLUG #CABLE #SIGNAL NAMEð TO ðLOCATIONPLUG #ADDRESS &——-ADDRESS BUSSMICRO PROC. PCB——-DATA——-DATA BUSSMOTIF PCB——-P1860LOW VOLTAGE POWER——-SUPPLY PCBP13760VIDEO SIGNALCRT——P4700KEYBOA...

  • Page 247

    CABLE LOCATIONS24696-9010June 1998

  • Page 248

    96-9010247CABLE LOCATIONSJune 1998MOCON PCB - P/N 32-4023GCABLE CONNECTIONS MOCONPLUG #CABLE #SIGNAL NAMEð TO ðLOCATIONPLUG #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.PP5...

  • Page 249

    CABLE LOCATIONS24896-9010June 1998,17(51$/3/8*(;7(51$/3/8*3-RS-232 PORT #1 PCB - P/N 32-4090CABLE CONNECTIONSPLUG #CABLE #ð TO ðLOCATIONPLUG #P1850VIDEO &J13 INTERNALKEYBOARDJ1——-——-——- EXTERNAL

  • Page 250

    96-9010249CABLE LOCATIONSJune 1998Y-DELTA SWITCH ASSEMBLYP/N 32-5850A

  • Page 251

    CABLE LOCATIONS25096-9010June 1998

  • Page 252

    CABLE LIST96-9010251June 19989. CABLE LISTJUNE 1998WIRE/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-...

  • Page 253

    CABLE LIST25296-9010June 1998100A M-FUNCTION OUTPUT M21 (MCD RELAY BOARD M21) -SHIELD +2101A UNSWITCHED LEG 1 #20102A SWITCHED LEG 2 #20103A SHIELD DRAIN110 SPARE (115 VAC SERVO POWER)140 230VAC 3PH POWER TO CHIP CONVEYOR MOTOR141 PHASE A 230VAC142 PHASE B 230VAC143 PHASE C 230VAC144 S...

  • Page 254

    CABLE LIST96-9010253June 1998270 115 VAC RELAY OUTPUT TO PURGE SOLENOID - SHIELD +2271 UNSWITCHED LEG 1 #20272 SWITCHED LEG 2 #20273 SHIELD DRAIN280 115 VAC RED/GREEN BEACON CABLE -SHIELD +3281 RED LAMP 115VAC282 GREEN LAMP 115VAC283 COMMON 115VAC284 SHIELD DRAIN290 115VAC TO X...

  • Page 255

    CABLE LIST25496-9010June 1998550 INPUTS CARD CABLE (MoCon-P10) 34 WIRE RIBBON #24570 LOW VOLTAGE BRUSHLESS AMPLIFIER POWER CABLE ASSEMBLY571 +12 VDC #22572 GROUND573 -12 VDC #22610 X AXIS HAAS AMPLIFIER CABLE TO MOTOR CONTROLLER BOARD(MOTOR CONTROLLER BOARD SIDE CONNECTION)610-1 +A CHANNEL6...

  • Page 256

    CABLE LIST96-9010255June 1998 (WYE-DELTA OPTION)651B PHASE 1651B PHASE 2651B PHASE 3660 X-AXIS ENCODER CABLE (ALL #24)660-1 LOGIC RETURN (D GROUND)660-2 ENCODER A CHANNEL660-3 ENCODER B CHANNEL660-4 +5 VDC660-5 ENCODER Z CHANNEL (OR C)660-6 HO...

  • Page 257

    CABLE LIST25696-9010June 1998742 POWER ON SWITCH LEG 2 #20 N.O.743 POWER OFF SWITCH LEG 1 (24 VAC) #20744 POWER OFF SWITCH LEG 2 #20 N.C.745 SHIELD DRAIN750 JOG-CRANK DATA CABLE (REM JOG SIDE CONNECTION)(ALL #24)750-1 LOGIC RETURN (D GROUND) 0 VDC750-2 ENCODER A CHANNEL...

  • Page 258

    CABLE LIST96-9010257June 1998781 SPARE782 SPARE783 SPARE784 SPARE790 PALLET CHANGER CW/CCW - SHIELD +3 (ALL #20)791 PALLET CW792 PALLET CCW793 COMMON794 SHIELD DRAIN800 10VAC TO PALLET READY LAMP - SHIELD +2801 UNSWITCHED LEG 1 #20802 SWITCHED LEG 2 #20803 SHIELD DRAIN...

  • Page 259

    CABLE LIST25896-9010June 1998865 LOGIC POWER RETURN (D GROUND) #20863 SHIELD DRAIN860C 12 VDC POWER TO MONITOR FAN - SHIELD +2861C +12 VOLTS #20862C LOGIC POWER RETURN #20863C SHIELD DRAIN880A 115 VAC TO SPINDLE HEAD SOLENOIDS - SHIELD +6 (ALL #24)881 WYE -DELTA SWITCH COMMAND8...

  • Page 260

    CABLE LIST96-9010259June 1998932 LEG 2 #20933 SHIELD DRAIN940 230 VAC SINGLE PHASE POWER TO COOLANT PUMP941 LEG 1 #20942 LEG 2 #20940A 230 VAC SINGLE PHASE POWER TO THROUGH SPINDLE COOLANT PUMP941A LEG 1 #20942A LEG 2 #20950 LOW AIR PRESSURE/OIL LUBE SENSOR - SHIELD +3951 LO...

  • Page 261

    CABLE LIST26096-9010June 19981017 SHIELD DRAIN1030 SPINDLE LOAD RESISTOR - SHIELD +21031 REGEN LOAD RESISTOR FOR SPINDLE DRIVE #181032 REGEN LOAD RESISTOR FOR SPINDLE DRIVE #181040 115 VAC TO MIKRON DOOR INTERLOCK SWITCH - SHIELD +21041 LEG 1 #201042 LEG 2 #201043 SHIELD DRAIN105...

  • Page 262

    96-9000261ELECTRICAL DIAGRAMSJune 1998ELECTRICALWIRING DIAGRAMS

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    26296-9000ELECTRICAL DIAGRAMSJune 1998

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    96-9000263ELECTRICAL DIAGRAMSJune 1998

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    26496-9000ELECTRICAL DIAGRAMSJune 1998

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    96-9000265ELECTRICAL DIAGRAMSJune 1998

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    26696-9000ELECTRICAL DIAGRAMSJune 1998

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    96-9000267ELECTRICAL DIAGRAMSJune 1998

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    26896-9000ELECTRICAL DIAGRAMSJune 1998

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    96-9000269ELECTRICAL DIAGRAMSJune 1998

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    27096-9000ELECTRICAL DIAGRAMSJune 1998

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    96-9000271ELECTRICAL DIAGRAMSJune 1998

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    27296-9000ELECTRICAL DIAGRAMSJune 1998

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    96-9000273ELECTRICAL DIAGRAMSJune 1998

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    27496-9000ELECTRICAL DIAGRAMSJune 1998

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    96-9000275ELECTRICAL DIAGRAMSJune 1998

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    27696-9000ELECTRICAL DIAGRAMSJune 1998

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    96-9000277ELECTRICAL DIAGRAMSJune 1998

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    27896-9000ELECTRICAL DIAGRAMSJune 1998

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    96-9000279ELECTRICAL DIAGRAMSJune 1998

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    28096-9000ELECTRICAL DIAGRAMSJune 1998

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    96-9000281ELECTRICAL DIAGRAMSJune 1998

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    28296-9000ELECTRICAL DIAGRAMSJune 1998

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    96-9000283ELECTRICAL DIAGRAMSJune 1998

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    28496-9000ELECTRICAL DIAGRAMSJune 1998

  • Page 286

    285ASSEMBLY DRAWINGSJune 199896-9010ASSEMBLY DRAWINGSANDPARTS LIST

  • Page 287

    286ASSEMBLY DRAWINGSJune 199896-901030-1100A Ball Screw Assembly 32mm

  • Page 288

    287ASSEMBLY DRAWINGSJune 199896-9010

  • Page 289

    288ASSEMBLY DRAWINGSJune 199896-9010HS Tool Release Piston

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    289ASSEMBLY DRAWINGSJune 199896-9010

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    290ASSEMBLY DRAWINGSJune 199896-9010HS Pallet Changer

  • Page 292

    291ASSEMBLY DRAWINGSJune 199896-9010Load Station AssemblyITEMQTYDWG_NUMBERTITLE1120-9444MANIFOLD, AIR BLAST2157-2257O-RING (326)3157-2835O-RING (2-236)4458-2100COMPRESSION SLEEVE5458-2110SLEEVE NUT6458-9427ATUBING, AIR BLAST

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    292ASSEMBLY DRAWINGSJune 199896-9010Clutch Motor Assembly30-9413 CLUTCH/MOTOR ASSEMBLYITEMQTYDWG_NUMBERTITLE1125-9443BBRACKET MOTOR MOUNT2130-9412CLUTCH ASSEMBLY3132-0301ADRAW BAR MOTOR EP 33184440-1976BHCS, 1/4-20 x 3/4'’5445-16390WASHER, 1/4'’ ID x 5/8'’ OD. SAE6245-2020WASHER, NYLON

  • Page 294

    293ASSEMBLY DRAWINGSJune 199896-9010ITEMQTYDWG_NUMBERTITLE1120-9444MANIFOLD, AIR BLAST2157-2257O-RING (326)3157-2835O-RING (2-236)4458-2100COMPRESSION SLEEVE5458-2110SLEEVE NUT6458-9427ATUBING, AIR BLAST

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    294ASSEMBLY DRAWINGSJune 199896-9010

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    295ASSEMBLY DRAWINGSJune 199896-9010ITEMQTYDWG_NUMBERTITLE1120-9449ADAPTER, LUBE TUBE2125-9445AAIR BLAST ADAPTER PLATE3133-8009LIMIT SWITCH, MAIN DB. DOWN4133-8014LIMIT SWITCH, MAIN DB. UP5440-1800SHCS, 8-32 x 3/4"6249-1012SHLDR SCREW, 1/4-20 x 5/16"7257-2259O-RING, 211 VITON, AIR8158-3...

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    296ASSEMBLY DRAWINGSJune 199896-9010

  • Page 298

    297ASSEMBLY DRAWINGSJune 199896-9010ITEMQTYDWG_NUMBERTITLE1120-9486BEARING SLEEVE2120-9490DRIVE SHAFT, ROT. TABLE3122-9485SPACER, BEARING4151-2015BRNG. LOCK NUT, BH-075251-7003BALL BRNG.6156-2083SNAP RING

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    298ASSEMBLY DRAWINGSJune 199896-9010

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    299ASSEMBLY DRAWINGSJune 199896-9010ITEMQTYDWG_NUMBERTITLE1120-9487NUT, DRAWBAR2120-9489NUT HOUSING3156-2096SNAP RING4157-2258O-RING5159-0002COMPRESSION SPRING, 2"

  • Page 301

    300ASSEMBLY DRAWINGSJune 199896-9010 30-9418ITEMQTYDWG_NUMBERTITLE1120-9795ARACK MOD.2120-9796AROLLER MTG. PLATE3125-9573SHOCK MOUNT, RACK END4125-9797AROTATE CYLINDER MOUNT5540-16385SHCS, 5/16-18 x 3/4'’6240-2030SHCS, 3/8-16 x 3/4'’7443-7000HHB, 5/16-18 x 1 3/4'’8445-16005/16'’ LOCK WAS...

  • Page 302

    301ASSEMBLY DRAWINGSJune 199896-9010ITEMQTYDWG_NUMBERTITLE 1120-9439BUSHING, MAIN LIFT CYLINDER 2120-9767H-FRAME 3120-9768CAP, CYLINDER 4120-9769BODY, CYLINDER 5120-9770PILOT, CYLINDER ROD 6120-9771AROD, PISTON 7120-9772PINION MOD 8120-9773PISTON, CYLINDER 9620-9793SPACER, H-FRAME PALLET...

  • Page 303

    302ASSEMBLY DRAWINGSJune 199896-9010ITEMQTYDWG_NUMBERTITLE1120-9450TUBE, AIR BLAST2120-9491DRAW BAR, ROT. TABLE3122-9451APLUG, AIR LUBE TUBE4156-0051SNAP RING5156-0110RETAINING RING6157-0020O-RING, 2-210 BUNA7158-9446TUBE, LUBE

  • Page 304

    303ASSEMBLY DRAWINGSJune 199896-9010

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    304ASSEMBLY DRAWINGSJune 199896-9010ITEMQTYDWG NO.TITLE1.120-9463ACOUPLING, GEARMOTOR2.132-1900ATURRET MOTOR ASS’Y (37 RPM)

  • Page 306

    305ASSEMBLY DRAWINGSJune 199896-9010ITEMQTYDWG. NO.TITLE1125-9448MOUNTING BRACKET2132-5651AIR SOLENOID3133-8019CONDUIT, PALLET CHANGER4136-30675SOLENOID ASS’Y, WP5240-16204SHCS, 10-32 X 1 5/86140-1850SHCS, 10-32 X 3/87245-1620WASHER, SPLT LOCK, #108258-16271/8-27 PIPE PLUG9158-16700STREET ELBOW...

  • Page 307

    306ASSEMBLY DRAWINGSJune 199896-9010HS Base

  • Page 308

    307ASSEMBLY DRAWINGSJune 199896-9010ITEMQTYDWG_NUMBERTITLE1120-7187BUMPER, Z AXIS, MOTOR END2120-7474BUMPER, X AXIS, VF-23120-9502BBASE, MACHINING4120-9595ASPACER, TABLE53222-7458CAM, LINEAR GUIDE6424-7325METRIC, LIN. GUIDE, M6 TO 5/16-247125-7042BCOVER PLATE, LEAD SCREW8125-7080BUMPER BRACKET, B...

  • Page 309

    308ASSEMBLY DRAWINGSJune 199896-9010HS Column

  • Page 310

    309ASSEMBLY DRAWINGSJune 199896-9010ITEMQTYDWG_NUMTITLE1220-9364SPACER2120-9390BUMPER, COLUMN3120-9391HARDSTOP, SPINDLE HEAD4220-9392COOLANT MANIFOLD5120-9393BEARING PLATE, COLUMN6120-9435AMOTOR MOUNT7120-9501BCOLUMN, MACHINING8120-9505BSPINDLE HEAD, MACHINING9120-9669ABUMPER STOP, Y AXIS103422-7...

  • Page 311

    310ASSEMBLY DRAWINGSJune 199896-9010ITEMQTYDWG_NUMTITLE49440-2030SHCS, 3/8-16 x 3/4"50243-7105HHB, 3/8-16 x 2 3/8"51445-1600WASHER, SPLIT LOCK, 5/16 MED.521645-1620WASHER , SPLIT LOCK, #1053445-1731WASHER, FLAT, 5/16"54445-1800WASHER, SPLIT LOCK 1/4"55445-1820WASHER, LOCK 3/8&...

  • Page 312

    311ASSEMBLY DRAWINGSJune 199896-9010HS Saddle

  • Page 313

    312ASSEMBLY DRAWINGSJune 199896-9010ITEMQTYPART_NOTITLE1120-7185BUMPER, 7/8"2120-7186BUMPER, 3"3220-7456CONDUIT STRAIN RELIEF4120-9007NUT HOUSING5120-9503CSADDLE, MACHINED6420-9557BEXTENDER BAR73422-7458CAM SCREW, LINEAR GUIDE8424-7325STR FIT METRIC, LINEAR GUIDE9124-9514BLEAD SCREW1012...

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    313ASSEMBLY DRAWINGSJune 199896-9010

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    314ASSEMBLY DRAWINGSJune 199896-9010

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    315ASSEMBLY DRAWINGSJune 199896-9010

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    316ASSEMBLY DRAWINGSJune 199896-9010

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    317ASSEMBLY DRAWINGSJune 199896-9010

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    318ASSEMBLY DRAWINGSJune 199896-9010

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    319ASSEMBLY DRAWINGSJune 199896-9010

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    320ASSEMBLY DRAWINGSJune 199896-9010

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    321ASSEMBLY DRAWINGSJune 199896-9010

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    322ASSEMBLY DRAWINGSJune 199896-9010

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