Haas vf3 руководство по обслуживанию

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Manuals and User Guides for Haas VF-3. We have 1 Haas VF-3 manual available for free PDF download: Operator’s Manual

Detail Specifications: 1743/1743958-vf_series.pdf file (06 Jan 2023)

Accompanying Data:

Haas VF-SERIES Power Tool, Sander PDF Operator’s Manual (Updated: Friday 6th of January 2023 01:56:56 AM)

Rating: 4.6 (rated by 15 users)

Compatible devices: 96-8000, 52213, Mill, PS6110, Mini Mill, 241-9801, CM Series, MFE 65.

Recommended Documentation:

Text Version of Operator’s Manual

(Ocr-Read Summary of Contents, UPD: 06 January 2023)

Recommended Instructions:

R840-ST8402, Diamond Edge S-50376, PROX-USB-HID, Catalyst 2360, SGH V205, BTHFO2 Oreillette

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Additional Information:

Popular Right Now:

Operating Impressions, Questions and Answers:

Manual_Archive_Cover_Page Rev A

June 6, 2013

Haas Technical Publications

HAAS SERVICE AND OPERATOR MANUAL ARCHIVE

VF-Series Service Manual 96-8100 English June 1998

This content is for illustrative purposes.

Historic machine Service Manuals are posted here to provide information for Haas machine owners.

Publications are intended for use only with machines built at the time of original publication.

As machine designs change the content of these publications can become obsolete.

You should not do mechanical or electrical machine repairs or service procedures unless you are qualified and knowledgeable about the processes.

Only authorized personnel with the proper training and certification should do many repair procedures.

WARNING: Some mechanical and electrical service procedures can be

extremely dangerous or life-threatening.

Know your skill level and abilities.

All information herein is provided as a courtesy for Haas machine owners for reference and illustrative purposes only. Haas Automation cannot be held responsible for repairs you perform. Only those services and repairs that are provided by authorized Haas Factory Outlet distributors are guaranteed.

Only an authorized Haas Factory Outlet distributor should service or repair a

Haas machine that is protected by the original factory warranty. Servicing by any other party automatically voids the factory warranty.

June 1998

TROUBLESHOOTING

COMMON ABBREVIATIONS USED IN HAAS MACHINES

CW

DB

DC

DGNOS

DIR

DNC

ENA CNVR

EOB

EOF

EPROM

E-Stop

FHCS

FT

FU

FWD

GA

AC

AMP

APC

APL

ASCII

ATC

ATC FWD

ATC REV

BHCS

CB

CC

CCW

CNC

CNCR SPINDLE

CRC

CRT

HHB

HP

HS

ID

IN

IOPCB

LB

LED

LO CLNT

LOW AIR PR

LVPS

MCD RLY BRD

MDI

MEM

M-FIN

MM

MOCON

MOTIF

MSG

NC

Alternating Current

Ampere

Automatic Pallet Changer

Automatic Parts Loader

American Standard Code for Information Interchange

Automatic Tool Changer

Automatic Tool Change Forward

Automatic Tool Changer Reverse

Button Head Cap Screw

Circuit Breaker

Cubic Centimeter

Counter Clock Wise

Computerized Numeric Control

Concurrent Spindle with axis motion

Cyclic Redundancy Check Digit

Cathode Ray Tube

Clock Wise

Draw Bar

Direct Current

Diagnostic

Directory

Direct Numerical Control

Enable Conveyor

End Of Block

End Of File

Erasable Programmable Read Only Memory

Emergency Stop

Flat Head Cap Screw

Foot

Fuse

Forward

Gauge

Hex Head Bolts

Horse Power

Horizontal Series Of Machining Centers

Inside Diameter

Inch

Input Output Printed Circuit Board

Pound

Light Emitting Diode

Low Coolant

Low Air Pressure

Low Voltage Power Supply

M-Code Relay Board

Manual Data Input

Memory

M-Code Finished

Millimeter

Motor Control

Motor Interface

Message

Numerical Control

96-8100

1

2

TROUBLESHOOTING

SIO

SKBIF

SP

T

TC

TIR

TNC

TRP

RJH

RPDBDN

RPDBUP

RPM

S

SDIST

SFM

SHCS

TS

TSC

VF

VF-E

VMC

NC

NO

OD

OPER

PARAM

PCB

PGM

POR

POSIT

PROG

PSI

PWM

RAM

REPT RIG TAP

RET

REV CNVR

Normally Closed

Normally Open

Outside Diameter

Operator

Parameter

Printed Circuit Board

Program

Power On Reset

Positions

Program

Pounds Per Square Inch

Pulse Width Modulation

Random Access Memory

Repeat Rigid Tap

Return

Reverse Conveyor

Remote Jog Handle

Rotary Pallet Draw Bar Down

Rotary Pallet Draw Bar Up

Revolutions Per Minute

Spindle Speed

Servo Distribution PCB

Surface Feet Per Minute

Socket Head Cap Screw

Serial Input/Output

Serial Key Board Inter Face PCB

Spindle

Tool Number

Tool Changer

Total Indicated Runout

Tool Nose Compensation

Tool Release Piston

Tail Stock

Through The Spindle Coolant

Vertical Mill (very first)

Vertical Mill- Extended

Vertical Machining Center

June 1998

96-8100

June 1998

TROUBLESHOOTING

1. TROUBLESHOOTING

This section is intended for use in determining the solution to a known problem. Solutions given are intended to give the individual servicing the CNC a pattern to follow in, first, determining the problem’s source and, second, solving the problem.

The troubleshooting tips are organized in this section according to the area of the CNC that may be giving sign of a problem. (Ex.: Out-of round circles in drilling will be found under the heading General Machine

Operation — Accuracy).

If the problem you are experiencing cannot be found under the heading you expect, please try several other possible headings. If the problem is still not found, contact Haas Automation for further details.

BEFORE YOU BEGIN:

USE COMMON SENSE

Many problems are easily overcome by correctly evaluating the situation. All machine operations are composed of a program, tools, and tooling. You must look at all three before blaming one as the fault area.

If a bored hole is chattering because of an overextended boring bar, don’t expect the machine to correct the fault. Don’t suspect machine accuracy if the vise bends the part. Don’t claim hole mis-positioning if you don’t first center-drill the hole.

FIND THE PROBLEM FIRST

Many mechanics tear into things before they understand the problem, hoping that it will appear as they go.

We know this from the fact that more than half of all warranty returned parts are in good working order. If the spindle doesn’t turn, remember that the spindle is connected to the gear box, which is connected to the spindle motor, which is driven by the spindle drive, which is connected to the I/O BOARD, which is driven by the MOCON, which is driven by the processor. The moral here is don’t replace the spindle drive if the belt is broken. Find the problem first; don’t just replace the easiest part to get to.

DON’T TINKER WITH THE MACHINE

There are hundreds of parameters, wires, switches, etc., that you can change in this machine. Don’t start randomly changing parts and parameters. Remember, there is a good chance that if you change something, you will incorrectly install it or break something else in the process. Consider for a moment changing the processor’s board. First, you have to download all parameters, remove a dozen connectors, replace the board, reconnect and reload, and if you make one mistake or bend one tiny pin it WON’T WORK. You always need to consider the risk of accidentally damaging the machine anytime you work on it. It is cheap insurance to double-check a suspect part before physically changing it. The less work you do on the machine the better.

96-8100

3

4

TROUBLESHOOTING

1.1 GENERAL MACHINE OPERATION

M

ACHINE

N

OT

R

UNNING

´

Machine cannot be powered on.

l l l l l l l l

Check input voltage to machine (see «Electrical Service»).

Check main circuit breaker at top right of electrical cabinet; switch must be at the on position.

Check overvoltage fuses (see «Electrical Service»).

Check wiring to POWER OFF button on front control panel.

Check wiring to AUTO OFF relay to IOPCB.

Check connection between 24V transformer and K1 contactor

Replace IOPCB (see «Electrical Service»).

Replace POWER PCB (see «Electrical Service»).

´

Machine can be powered on, but turns off by itself.

l l l l l l l

Check settings #1 and #2 for Auto Off Timer or Off at M30.

Check alarm history for OVERVOLTAGE or OVERHEAT shutdown.

Check AC power supply lines for intermittent supply.

Check connection between 24V transformer and K1 contactor.

l

Check wiring to POWER OFF button on front control panel.

Replace IOPCB (see «Electrical Service»).

Check Parameter 57 for Power Off at E-STOP.

Replace MOTIF or MOCON PCB (see «Electrical Service»).

´

Machine turns on, keyboard beeps, but no CRT display.

l l l

Check for green POWER LED at front of CRT.

Check for power connections to CRT from IOPCB.

Close doors and Zero Return machine (possible bad monitor).

l l

Check video cable (760) from VIDEO PCB to CRT.

Check for lights on the processor.

l

Replace CRT (see «Electrical Service»).

´

Machine turns on, CRT works, but no keyboard keys work.

l l l

Check keyboard cable (700B) from VIDEO to SKBIF PCB.

Replace keypad (see «Electrical Service»).

Replace SKBIF PCB (see «Electrical Service»).

´

Constant E-Stop Condition (will not reset)

l

Check Hydraulic counterbalance pressure, low pressure switches and cabling.

June 1998

96-8100

June 1998

TROUBLESHOOTING

96-8100

V

IBRATION

Vibration is a subjective evaluation with perceptions varying among individuals, making it difficult to determine in mild cases if there is an actual problem. Because the VF Series uses a gear head, it will be noisier than a direct drive or belt system. In obvious cases, it is a matter of determining the source — which is not easy, since all parts rotate together and sound can be transferred readily. Vibrations also need to be distinguished from noise such as a bad bearing. We will assume that vibrations would be something that could be felt by putting your hand on the spindle covers. One crude method of measurement would be to take an indicator on a magnetic base extended 10 inches between the table and spindle housing and observe the reading of the indicator. A reading of more than .001 would indicate excessive vibration. The two common sources of noise are the spindle and axis drives. Most complaints about vibration, accuracy, and finish can be attributed to incorrect machining practices such as poor quality or damaged tooling, incorrect speeds or feeds, or poor fixturing. Before concluding that the machine is not working properly, ensure that good machining practices are being observed. These symptoms will not occur individually (Ex. A machine with backlash may vibrate heavily, yielding a bad finish.). Put all of the symptoms together to arrive at an accurate picture of the problem.

´

Machine vibrates while jogging the axis with the hand wheel.

l

The HAAS control uses very high gain accelerations curves. This vibration as you jog is simply the servos quickly trying to follow the handle divisions. If this is a problem, try using a smaller division on the handle. You will notice the vibration more at individual clicks than when you are turning the handle faster. This is normal.

´

The machine vibrates excessively in a cut.

l

This is a tough one to call because machining practices come into play. Generally speaking, the least rigid element of a cut is the tool because it is the smallest part. Any cutter will vibrate if pushed beyond its tensile strength. In order to eliminate the machine as the source of the problem, you need to check the spindle and the backlash of the axes as described in the following sections. Once machining practices have been eliminated as the source of vibration, observe the machine in both operation and

“cutting air.” Move the axes (individually) without the spindle turning and then turn the spindle without moving the axes. Isolate whether the vibration comes from the spindle head or from an axis. Isolate the source of vibration per «Spindle», «Servo Motors/Leadscrews», and «Gearbox and Spindle Motor» sections.

A

CCURACY

Before you complain of an accuracy problem, please make sure you follow these simple do’s and don’ts: l l l l l l l l l l l l

Ensure that the machine has been sufficiently warmed up before cutting parts. This will eliminate mispositioning errors caused by thermal growth of the leadscrews (see «Thermal Growth» section).

Don’t ever use a wiggler test indicator for linear dimensions. They measure in an arc and have sine/cosine errors over larger distances.

Don’t use magnetic bases as accurate test stops. The high accel/decel of the axis can cause them to move.

Don’t attach magnetic base to the sheet metal of the spindle head or table.

Don’t mount the magnetic base on the spindle dogs.

Don’t check for accuracy/repeatability using an indicator with a long extension.

Ensure that test indicators and stops are absolutely rigid and mounted to machined casting surfaces

(e.g. spindle head casting, spindle nose, or the table).

Don’t rapid to position when checking accuracy. The indicator may get bumped and give an inaccurate reading. For best results, feed to position at 5-10 inches per minute.

Check a suspected error with another indicator or method for verification.

Ensure that the indicator is parallel to the axis being checked to avoid tangential reading errors.

Center drill holes before using jobber length drills if accuracy is questioned.

Once machining practices have been eliminated as the source of the problem, determine specifically what the machine is doing wrong.

5

6

TROUBLESHOOTING

´

Machine will not interpolate a round hole.

l l

Check that the machine is level (see «Installation» section).

Check for backlash («Servo Motors/Leadscrews» section).

´

Bored holes do not go straight through the workpiece.

l l

Check that the machine is level (see «Installation» section).

Check for squareness in the Z axis.

´

Machine bores holes out-of-round.

l l

Check that the machine is level (see «Installation» section).

Check the sweep of the machine (see «Spindle Sweep Adjustment» section).

´

Bored holes are out of round or out of position.

l l

Check for thermal growth of the leadscrew (see «Thermal Growth» section).

The spindle is not parallel to the Z axis. Check the spindle sweep to the table and the squareness of the Z axis with a cylinder square. If available use a spindle master bar and indicate the spindle to the Z axis.

´

Machine mis-positions holes.

l l l l

Check for thermal growth of the leadscrew (see «Thermal Growth» section).

Check that the machine is level (see «Installation» section).

Check for backlash (see «Servo Motors/Leadscrews» section).

Check the squareness of the X axis to the Y axis.

´

Machine leaves large steps when using a shell mill.

l l l

Check that the machine is level (see «Installation» section).

Check the sweep of the machine (see «Spindle Sweep Adjustment» section).

Cutter diameter too large for depth of cut.

´

Boring depth inaccurate

l l

Check for thermal growth of the leadscrew (see «Thermal Growth» section).

Check the hydraulic counterbalance system pressure. If pressure is low, check for:

Ø

Ø

Ø abnormal noises from counterbalance system oil leaks (esp. at fittings and at filter at top of cylinder) bound cylinder

F

INISH

´

Machining yields a poor finish.

l l l l l l

Check for gearbox vibration. This is the most common cause of a poor finish.

Check for backlash («Accuracy/Backlash» section)

Check the condition of the tooling and the spindle.

Check for spindle failure.

Check the condition of the servo motors.

Check that the is machine level.

June 1998

96-8100

June 1998

TROUBLESHOOTING

T

HERMAL

G

ROWTH

A possible source of accuracy and positioning errors is thermal growth of the leadscrew. As the machine warms up, the leadscrews expand in all three linear axes, causing accuracy and positioning errors, or inaccurate boring depths. This is especially critical in jobs that require high accuracy, machining multiple parts in one setup, or machining one part with multiple setups.

Note: On machines equipped with linear scales, thermal growth will not affect machine positioning or accuracy. However, it is still recommended that the machine be warmed up before cutting parts.

Note: The leadscrew will always expand away from the motor end.

VERIFY THERMAL GROWTH

There are a number of ways to verify the problem. The following procedure will verify thermal growth of the X-axis leadscrew in a machine that has not been warmed up:

1. Home the machine. In MDI mode, press POSIT and PAGE DOWN to the OPER page.

2. Jog to an offset location on the table (example: X-15.0″ Y-8.0″ ). Select the X axis and press the

ORIGIN key to zero it. Select the Y axis and zero it.

3. Press the OFSET key, then scroll down to G110 (or any unused offset). Cursor to X and press PART

ZERO SET twice. This will set X0, Y0 at this position.

4. Enter the following program. It will start at the new zero position, rapid 10 inches in the X direction, feed the final .25 inches at 10 inches/min., and then repeat the X movement.

G00 G90 G110 X0 Y0;

X10.0;

G01 X10.25 F10. ;

M99;

5. In order to set up the indicator, run the program in SINGLE BLOCK mode, and stop it when X is at

10.25″. Set the magnetic base on the table, with the indicator tip touching the spindle housing in the

X-axis, and zero it.

6. Exit SINGLE BLOCK mode, and run the program for a few minutes. Enter SINGLE BLOCK mode again, stop the program when X is at 10.25″, and take a final reading on the indicator. If the problem is thermal growth, the indicator will show a difference in the X position.

Note: Ensure the indicator setup is correct as described in «Accuracy» section. Errors in setup are common, and often incorrectly appear to be thermal growth.

7. A similar program can be written to test for thermal growth in the Y and Z axes, if necessary.

SOLUTIONS

Since there are many variables that affect thermal growth, such as the ambient temperature of the shop and program feed rates, it is difficult to give one solution for all problems.

Thermal growth problems can generally be eliminated by running a warm-up program for approximately 20 minutes before machining parts. The most effective warm-up is to run the current program, at an offset

Z position above the part or table, with the spindle «cutting air». This will allow the leadscrews to warm up to the correct temperature and stabilize. Once the machine is at temperature, the leadscrews won’t expand any further, unless they’re allowed to cool down. A warm-up program should be run after each time the machine is left idle.

96-8100

7

8

TROUBLESHOOTING

1.2 SPINDLE

N

OT

T

URNING

´

Spindle not turning.

l l l l l l l l l

If there are any alarms, refer to «Alarms» section.

Check that the spindle turns freely when machine is off.

If motor turns but spindle does not, see «Belt Assembly» and «Spindle Motor & Transmission» sections.

Command spindle to turn at 1800 RPM and check spindle drive display. If display blinks “bb”, check spindle orientation switch («Spindle Orientation» section). If spindle drive does not light the RUN

LED, check forward/reverse commands from IOPCB («Electrical Service»).

Check the wiring of analog speed command from MOTIF PCB to spindle drive (cable 720).

If spindle is still not turning, replace MOTIF PCB («Electrical Service»).

If spindle is still not turning, replace spindle drive («Electrical Service»).

Check for rotation of the gearbox (if applicable) or the motor (VF-0). If the motor or gearbox operates, check the drive belt («Belt Assembly» section).

Disconnect the drive belt. If the spindle will not turn, it is seized and must be replaced («Spindle

Assembly» section).

Note: Before using the replacement spindle, the cause of the previous failure must be determined.

N

OISE

Most noises attributed to the spindle actually lie in the motor/gearbox or drive belt of the machine. Isolate the sources of noise as follows:

´

Excessive noise coming from the spindle head area.

On VF-1 through 6 models, first determine if the noise is related to the RPM of the motor or the RPM of the spindle. For example: If the noise appears at 2000 RPM in high gear, listen for a similar noise at 500 RPM in low gear. If the same noise persists, the problem lies with the gearbox. If the noise disappears, the problem could be either the gearbox or the spindle, and further testing is necessary.

l l l l

Note: The gear ratio is 1:1.25 in high gear, and 3.2:1 in low gear.

Remove the head covers and check the machine’s drive belt tension («Tension Adjustment» section).

Ø If the noise persists, turn the drive belt over on the pulleys. If the noise is significantly different, the belt is at fault. Replace the belt («Belt Assembly» section).

Ø If the noise does not change, remove the belt and go on to the next step.

Check the pulleys for excessive runout (more than 0.003″ axial or radial).

Run the motor (VF-0) or the gearbox (VF-1, VF-2, VF-3) with the drive belt disconnected. If the noise persists, the problem lies with the gearbox/motor. If it disappears, go on to the next step.

Check for the correct amount of lubrication to the spindle bearings (0.5-1.0 cc every two hours) in a an air mist-lubricated spindle.

Ø If the spindle is not getting lubrication, correct the problem per the lube and air diagram at the back of this manual and replace the spindle («Spindle Assembly» section).

Ø If the spindle is getting lubrication, replace the spindle («Spindle Assembly» section).

June 1998

96-8100

June 1998

TROUBLESHOOTING

O

VERHEATING

When investigating complaints of overheating, a temperature probe must be used to accurately check the temperature at the top of the spindle taper. The temperature displayed in Diagnostics is not relevant. A machine that runs at high RPM continuously will have a much warmer spindle than a machine that runs at a lower RPM. New spindles tend to run much warmer than spindles that have already been broken in. In order to run a valid test on a new spindle, ensure that it is properly broken in.

To break in a spindle, run the following program (it will take approximately 6 hours):

N100 S300 M03

G04 P900.

M05

G04 P900.

N200 S1000 M03

G04 P900.

M05

G04 P900.

N300 S2000 M03

G04 P900.

M05

G04 P900.

G04 P900.

N400 S3000 M03

G04 P900.

M05

G04 P900.

G04 P900.

N500 S4000 M03

G04 P900.

M05

G04 P900.

G04 P900.

N600 S5000 M03

G04 P900.

M05

G04 P900.

G04 P900.

N700 S6000 M03

G04 P900.

M05

G04 P900.

G04 P900.

N800 S7500 M03

G04 P900.

M05

G04 P900.

G04 P900.

M99 l

Note: This program will step the spindle speed from 300 RPM up to either 5000 or 7500

RPM at regular intervals of time, stop the spindle and allow it to cool to room temperature, then restart it so the temperature can be monitored.

If at any time during this procedure the spindle temperature rises above 150 degrees, start the procedure over from the beginning.

If the spindle fails this test for any reason, check the following: l

Check for correct amount of lubrication.

l l

Note: Over lubrication is a common source of overheating. Check the oil flow carefully.

Check the drive belt tension. Too-tight belts will cause heating of the top bearing in the spindle housing.

Ensure that the correct oil is being used (refer to «Maintenance Schedule»).

S

TALLING

/ L

OW

T

ORQUE

Generally, complaints of stalling or low torque relate to incorrect tooling or machining practices. A spindle that is tending to seize will yield a poor finish machining, run very hot and very loud. Investigate machining problems before concluding the problem exists with the spindle or spindle drive.

96-8100

9

10

TROUBLESHOOTING

S

PINDLE

D

RIVE

Low line voltage may prevent the spindle from accelerating properly. If the spindle takes a long time to accelerate, slows down or stays at a speed below the commanded speed with the load meter at full load, the spindle drive and motor are overloaded. High load, low voltage, or too fast accel/decel can cause this problem.

If the spindle is accelerated and decelerated frequently, the regenerative load resistor on top of the control may heat up. If this resistor heats beyond 100

0

C, a thermostat will generate an “overheat” alarm.

If the regen load resistors are not connected or open, this could then result in an overvoltage alarm. The overvoltage occurs because the regenerative energy being absorbed from the motor while decelerating is turned into voltage by the spindle drive. If this problem occurs, the possible fixes are to slow the decel rate or reduce the frequency of spindle speed changes.

O

RIENTATION

´

Spindle loses correct orientation.

Non Vector Drive

l l l l l

Check alarm history, looking for spindle overload and axis overcurrent alarms. These alarms mean the machine is not being properly operated.

Check the orientation ring for tightness. Ensure the shaft on which the ring mounts is clean and is free of grease and oil.

Check the orientation ring for cracks near the bolt holes or near the balancing holes.

Ø If there are cracks, replace the ring.

Check the shot pin on the gearbox for binding, damage, and proper operation. Replace it if it is damaged.

Check the switch on the shot pin against the Diagnostic display. Replace the switch if it is found to be faulty.

Vector Drive

l

Check alarm history. Look for Spindle Z Fault, or Spindle Reference Missing alarms. If these alarms

exist, there may be a defective spindle encoder, or a broken ground or shield connection.

l

Check parameters.

l

Check for a mechanical slip at the contact points of all components between the spindle and the

spindle encoder

T

OOLS

S

TICKING

I

N

T

APER

´

Tool sticking in the taper causes ATC to be pulled up; accompanied by a popping noise as the tool holder pops out of the spindle taper.

June 1998

Note: This problem may occur after loading a cold tool into a hot spindle (a result of thermal expansion of the tool holder inside the spindle taper). It may also occur due to heavy milling, milling with long tooling, or cuts with heavy vibration. If sticking only occurs during these situations, no service is necessary. If tool is pulled out of extractors due to a tool stuck in the taper then the unclamp switch is not adjusted correctly or the switch could be bad.

l l

Check the condition of the tooling, verifying the taper on the tooling is ground and not turned. Look for damage to the taper caused by chips in the taper or rough handling. If the tooling is suspected, try to duplicate the symptoms with different tooling.

Check the condition of the spindle taper. Look for damage caused by chips or damaged tooling. Also, look for damage such as deep gouges in the spindle taper caused by tool crashing.

96-8100

June 1998

TROUBLESHOOTING

l l l l

Duplicate the cutting conditions under which the deflection occurs, but do not execute an automatic tool change. Try instead to release the tool using the tool release button on the front of the spindle head. If sticking is observed, the deflection is not caused by improper ATC adjustment, but is a problem in the spindle head on the machine.

Ensure the spindle is not running too hot.

Check air supply.

Check drawbar height adjustment.

1.3 SERVO MOTORS / LEADSCREWS

N

OT

O

PERATING

All problems that are caused by servo motor failures should also register an alarm. Check the alarm history to determine the problem’s cause before any action is taken.

´

Servo motor is not functioning.

l l l l l l l l l

Check the power cable from rear electrical cabinet to ensure connection is tight.

Encoder is faulty or contaminated (Alarms 139-142, 153-156, 165-168, 182-185). Replace motor assembly on brushless machines, replace the encoder on brush machines.

Open circuit in motor (Alarms 139-142, 153-156, 182-185). Replace motor assembly («Axis Motor

Removal / Installation»).

Motor has overheated, resulting in damage to the interior components (Alarms 135-138, 176).

Replace motor assembly («Axis Motor Removal/Installation»).

Wiring is broken, shorted, or missing shield (Alarms 153-156, 175, 182-185).

Dust in the motor from brushes has shorted out the motor (VF-E only) (Alarms 153-156, 175, 182-

185). Replace motor assembly («Axis Motor Removal/Installation»).

Motor has overheated; no damage to the interior components. OVERHEAT alarm has been triggered.

After thorough check of motor (DO NOT DISASSEMBLE!), take necessary steps to eliminate the problem and alarm to resume operation. If motor is still inoperable, replace motor assembly

(«Axis Motor Removal/Installation»).

Check for broken or loose coupling between the servo motor and the lead screw. Replace or repair the coupling («Axis Motor Removal/Installation»)

Check for a damaged lead screw, and replace if necessary («Lead Screw Removal and Installation» section).

NOTE: If a lead screw fails, it is most often due to a failed bearing sleeve. When replacing the lead screw in an older machine, always replace the bearing sleeve with the current angular contact bearing sleeve («Bearing Sleeve Removal and Installation» section).

N

OISE

Lead screw noise is usually caused by a lack of lubrication and is usually accompanied by heating. Other causes are misalignment, bearing sleeve damage, or ball nut damage. Check the alarm history of the machine and look for axis overcurrent and following error alarms.

Note: Do not replace lead screws or bearing sleeves without due consideration; they are extremely durable and reliable. Verify that customer complaints are not due to tooling, programming, or fixturing problems.

96-8100

11

12

TROUBLESHOOTING

´

Servo motor noise.

l l l

Disconnect the servo motor from the lead screw and rotate by hand. If the noise persists, replace the motor assembly («Axis Motor Removal/Installation» section).

Noise is caused by motor brushes (VF-E only). No problems will occur and noise should eventually go away.

Noise is caused by bearings. Rolling, grinding sound is heard coming from the motor. ENSURE NOISE

IS NOT COMING FROM THE BRUSHES. If bearings are making a consistently loud sound, replace the bearing sleeve.

´

Lead screw noise.

l l

Ensure oil is getting to the lead screw through the lubrication system (See Air and Oil Diagrams).

Look for a plugged metering valve.

Check for damage to the bearing sleeve.

June 1998

Note: The current angular contact design sleeve has a fixed pre-load; it cannot be adjusted.

l

Run the axis back and forth. The motor will get very hot if the bearing sleeve is damaged. If so, turn the axis by hand and feel for roughness in the lead screw. Loosen the clamp nuts at both ends of the lead screw. If the symptom disappears, replace the bearing sleeve. Be certain to check for damage to the lead screw shaft where the bearing sleeve is mounted.

Ø If the noise persists, the lead screw is damaged and must be replaced. When replacing the lead screw in an older machine, always replace the bearing sleeve with the current angular contact design bearing sleeve.

l l

Check the lead screw for misalignment. If incorrect, perform alignment procedure.

Misalignment in the lead screw itself will tend to cause the lead screw to tighten up and make excessive noise at both ends of the travel. The ballnut may get hot. Misalignment radially at the yoke where the lead screw ball nut mounts is indicated by heating up of the ball nut on the lead screw, and noise and tightness through out the travel of the lead screw. Misalignment at the yoke where the ball nut mounts is indicated by noise and tightness at both ends of the travel of the lead screw. The ball nut may get hot.

A

CCURACY

/ B

ACKLASH

Accuracy complaints are usually related to tooling, programming, or fixturing problems. Eliminate these possibilities before working on the machine.

´

Poor mill table-positioning accuracy.

l l l

Check for a loose encoder on the servo motor. Also, ensure the key in the motor or the lead screw is in place and the coupling is tight (Brush machines only).

Check parameters for that axis

Check for backlash in the lead screw as outlined below:

INITIAL PREPARATION —

Turn the VMC ON. ZERO RET the machine and move the mill table to the approximate center of its travel in the X and Y directions. Move the spindle head to approximate center of the Z-axis travel, also.

CHECKING X-AXIS:

1.

Set up a dial indicator and base on the mill table as shown in Fig. 1-1.

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TROUBLESHOOTING

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2.

Figure 1-1. Dial indicator in position to check X-axis.

Set dial indicator and the “Distance to go” display in the HANDLE JOG mode to zero as follows:

Ø Zero the dial indicator.

Ø Press the MDI button on the control panel.

Ø Press the HANDLE JOG button on the control panel.

The “Distance to go” display on the lower right hand corner should read: X=0 Y=0 Z=0

3.

Set the rate of travel to .001 on the control panel and jog the machine .010 in the positive (+) X direction. Jog back to zero (0) on the display. The dial indicator should read zero (0) ± .0001.

Repeat Step 3 in the negative (-) direction.

4.

TOTAL DEVIATION BETWEEN THE DIAL INDICATOR AND THE CONTROL PANEL DISPLAY SHOULD NOT

EXCEED .0002.

An alternate method for checking backlash is to place the dial indicator as shown in Fig. 3-1 and manually push on the mill table in both directions. The dial indicator should return to zero after releasing the table.

Note: The servos must be on to check backlash by this method.

CHECKING Y-AXIS:

1. Set up a dial indicator and base on the mill table as shown in Fig. 1-2.

13

TROUBLESHOOTING

June 1998

14

2.

Figure 1-2. Dial indicator in position to check Y-axis.

Set dial indicator and the “Distance to go” display in the HANDLE JOG mode to zero as follows:

Ø Zero the dial indicator.

Ø Press the MDI button on the control panel.

Ø Press the HANDLE JOG button on the control panel.

The “Distance to go” display on the lower right hand corner should read: X=0 Y=0 Z=0

3.

Set the rate of travel to .001 on the control panel and jog the machine .010 in the positive (+) Y direction. Jog back to zero (0) on the display. The dial indicator should read zero (0) ± .0001.

Repeat Step 3 in the negative (-) direction.

4.

TOTAL DEVIATION BETWEEN THE DIAL INDICATOR AND THE CONTROL PANEL DISPLAY SHOULD NOT

EXCEED .0002.

An alternate method for checking backlash is to place the dial indicator as shown in Fig. 1-2 and manually push on the mill table in both directions. The dial indicator should return to zero after releasing the table.

Note: The servos must be on to check backlash by this method.

CHECKING Z-AXIS:

1.

Set up a dial indicator and base on the mill table as shown in Fig. 1-3.

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2.

TROUBLESHOOTING

Manually push up and down on the spindle head while listening for a ‘clunk’. Also, watch for any rapid change in the dial indicator. Either of these indicate possible backlash.

Note: Servos must be on to check for backlash in the Z-axis.

Note: Do not mistake deflection for backlash in the system.

96-8100

Figure 1-3. Dial indicator in position to check Z-axis.

If backlash is found in the system, check for the following possible causes: l

Loose SHCS attaching the ball nut to the nut housing. Tighten the SHCS as described in Mechanical l l l l

Service.

Loose SHCS attaching the nut housing to the mill table, spindle head, or saddle, depending on the axis.

Tighten the SHCS as described in Mechanical Service.

Loose clamp nut on the bearing sleeve. Tighten the SHCS on the clamp nut.

Loose motor coupling. Tighten as described in Mechanical Service.

Broken or loose flex plates on the motor coupling.

l l l l l

Note: The coupling cannot be serviced in the field and must be replaced as a unit if it is found to be defective.

Loose SHCS attaching the bearing sleeve to the motor housing. Tighten as described in «Lead Screw

Removal and Installation».

Defective thrust bearings in the bearing sleeve. Replace the bearing sleeve as outlined in «Bearing

Sleeve Removal and Installation».

Loose SHCS attaching the axis motor to the motor housing. If the SHCS are found to be loose, inspect the motor for damage and if none is found, tighten as described in «Axis Motor Removal/Installation».

If damage is found, replace the motor.

Incorrect backlash compensation number in the parameter in the machine. Check Parameters 13, 27, and 41.

Worn lead screw.

15

16

TROUBLESHOOTING

V

IBRATION

´

Excessive servo motor vibration.

l l l

If no “A” axis is present, swap the suspected bad servo motor with the “A” driver and check to see if there is a driver problem. If needed, replace the DRIVER PCB («Electrical Service» section).

Check all Parameters of the suspected axis against the Parameters as shipped with the machine. If there are any differences, correct those and determine how the Parameters were changed.

PARAMETER LOCK should normally be on.

A bad motor can cause vibration if there is an open or short in the motor. A short would normally cause a GROUND FAULT or OVERCURRENT alarm; check the ALARMS. An ohmmeter applied to the motor leads should show between 1 and 3 ohms between leads, and over 1 megohm from leads to chassis. If the motor is open or shorted, replace.

O

VERHEATING

´

Servo motor overheating.

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If a motor OVERHEAT alarm occurs (ALARMS 135-138), check the Parameters for an incorrect setting. Axis flags in Parameters 1, 15, or 29 can invert the overheat switch (OVER TEMP NC).

If the motor is actually getting hot to the touch, there is excessive load on the motor. Check the user’s application for excessive load or high duty cycle. Check the lead screw for binding («Accuracy/

Backlash» section). If the motor is binding by itself, replace in accordance with «Axis Motor Removal/

Installation».

F

OLLOWING

E

RRORS

´

FOLLOWING ERROR (VF-E only) or SERVO ERROR TO0 LARGE alarms 103-106, 187 occur on one or more axes sporadically.

l l l l l

Check DC bus voltage on diagnostics page #2 (VF-E only). Verify this voltage on the drive cards in the control panel. If it is at the low side of the recommended voltages, change the transformer tap to the next lower voltage group as explained in the Installation Manual.

Check motor wiring for a short.

Replace driver card («Electrical Service»).

Replace servo motor («Axis Motor Removal/Installation»).

Replace encoder (VF-E only)

´

Z-axis motor overcurrent.

Brake won’t release (leadscrew won’t rotate) l

Alarm not cleared l l l l l

Low counterbalance pressure

Check Z axis parameters

Check the lead screw for binding

Check motor and cable for shorts

Replace amplifier (drive card on a VF-E)

VF-6 with Z axis brake only

l

Brake power fuse blown l l l l

Brake power transformer blown

Brake power rectifier blown

Cabling pinched

Brake failed

June 1998

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TROUBLESHOOTING

1.4 AUTOMATIC TOOL CHANGER

D

EFLECTION

Deflection is usually caused by ATC misalignment, and sometimes caused by damaged or poor quality tooling, a damaged spindle taper, or a damaged drawbar or poor air supply. Before beginning any troubleshooting, observe the direction of the ATC deflection.

´

During a tool change, ATC appears to be pushed down.

l l

Check to see if pull studs on the tool holder are correct and tight.

Check the adjustment of the “Z” offset («Setting Parameter 64»).

Note: If the offset is incorrect a tool changer crash has occured and a thorough inspection of the ATC is necessary at this time.

l l l l l

Check the adjustment of the “Z” offset. Check parameters 71, 72, and 143 against the values that are in the documentation sent with the machine.

Ensure the tool holders are held firmly in place by the extractor forks.

Ensure the balls on the drawbar move freely in the holes in the drawbar when the tool release button is pressed. If they do not move freely, the a ATC will be pushed down about 1/4″ before the tool holder is seated in the taper, resulting in damage to the roller bolts on the ATC shuttle. Replace the drawbar.

Check Drawbar height adjustment.

If TSC, check for excessive coolant tip wear.

´

Tool holder sticking in the spindle taper causes the ATC to be pulled up as the spindle head is travelling the distance specified in parameter 71; accompanied by a popping noise as the tool holder pops out of the spindle taper.

l l l l

Note: This problem may occur after loading a cold tool into a hot spindle (a result of thermal expansion of the tool holder inside the spindle taper. It may also occur in cuts with heavy vibration. If sticking occurs only during these circumstances, no service is necessary.If tool is pulled out of extractors due to a tool being stuck in the taper then the unclamp switch is not adjusted correctly or the switch could be bad.

Check the condition of the customer’s tooling, verifying the taper on the tool holder is ground and not turned. Look for damage to the taper caused by chips in the taper or rough handling. If the tooling is suspected, try to duplicate the symptoms with different tooling.

Check the condition of the spindle taper. Look for damage caused by chips or damaged tooling.

Also, look for damage such as deep gouges in the spindle taper caused by tool crashing. See «Spindle

Assembly» section for spindle cartridge replacement.

Duplicate the cutting conditions under which the deflection occurs, but do not execute an automatic tool change. Try instead to release the tool using the tool release button on the front of the spindle head. If sticking is observed, the deflection is not caused by improper ATC adjustment, but is a problem in the spindle or tool release piston. See the «Spindle Assembly» section in Mechanical

Sevice for spindle cartridge replacement.

Check air supply pressure it should be 85 psi (min). An air pressure drop of no more than 10 psi during tool release is acceptable. An air pressure drop greater than 10 psi is caused by a supply line restriction or an undersize supply line. Use of quick couplers (

1 /

4

«) can cause restriction. Directly connecting the air hose to a barb fitting can help.

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17

18

TROUBLESHOOTING

´

During a tool change, ATC appears to be pulled up; no popping noises.

l

Check the adjustment of the “Z” offset («Setting Parameter 64» section).

l

Note: If the offset is incorrect, a tool changer crash has occurred, and a thorough inspection of the ATC is necessary at this time.

Ensure the roller bolts on the shuttle of the ATC are tight against the V-guides on the ATC holding arm.If the lower right roller bolt is loose against the V-guide, the upper right bolt is probably bent.

See the following section («ATC Crashing») or «Roller Bolt Replacement», for roller bolt replacement.

June 1998

l l

Note: Bent roller bolts are a symptom of another problem with the ATC. Repair the bent roller bolt and then isolate the ATC problem.

Check Parameter 71 against the values that are in the documentation sent with the machine.

Ensure the balls on the drawbar move freely in the holes in the drawbar when the tool release button is pressed. If they do not move freely, the ATC will be pushed down about ¼” before the tool holder is seated in the taper, resulting in damage to the roller bolts on the ATC shuttle. Replace drawbar.

´

Tool holders twist against extractor fork during a tool change.

l

Check the alignment of the ATC in the X and Y axes («Automatic Tool Changer Alignment» section).

´

Tool holders spin at all pockets of the ATC when the ATC shuttle retracts.

l

ATC is misaligned in the “Y” axis. Realign ATC («Automatic Tool Changer Alignment» section).

Note: Observe the direction the tool holder rotates, as this will be the direction in which the “Y” axis of the ATC needs to be moved.

´

Tool holders spin only at certain pockets of the ATC when the ATC shuttle retracts.

l

Check all the extractor forks to ensure they are centered in the pocket of the ATC. Also, see above.

See «Extractor Fork Replacement» section, if necessary.

Note: If the ATC shows the problem as described here, each extractor fork must be checked and centered to eliminate the possibility of the ATC being aligned against an incorrectly-centered fork.

C

RASHING

Crashing of the ATC is usually a result of operator error. The most common ATC crashes are outlined as follows:

´

Shuttle crashes into spindle when a tool change is commanded (tool holder is in the pocket

l

facing the spindle head).

Rotate the carousel to an empty pocket. Refer to the Programming and Operation manual for correct operation.

Note: This crash is fairly common and is a result of operator error. If the ATC is stopped in the middle of tool change cycle, the operator must command the ATC to an empty pocket before the machine will operate correctly. Repeated crashes of this type can damage the I/O board, the slip clutch, and the shuttle motor in the ATC.

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TROUBLESHOOTING

´

During a tool change spindle crashes into top of the tool holder after a turret rotation.

When the spindle head moves down over the top of the tool holder during a tool change, the pull stud will bind inside the drawbar bore of the spindle, forcing the ATC down, bending the upper right roller bolt on the ATC shuttle or completely breaking it off. Tool holder is not held correctly in the extractor fork, possibly held only in one side of the extractor and at an odd angle.

l

Check all of the extractor forks on the ATC.

´

During a tool change spindle crashes into top of the tool holder after a turret rotation.

The balls in the drawbar do not move freely, causing the ATC to be forced down far enough to bend the upper right roller bolt or completely break it off.

l

Ensure the balls on the drawbar move freely in the holes in the drawbar when the tool release button is pressed. If this failure occurs, check all of the extractor forks on the ATC for damage and repair the spindle drawbar.

l

Check drawbar height and set according to the appropriate section, if necessary.

´

ATC properly deposits a tool holder in the spindle, but the tools are dropped onto the machine table when the shuttle retracts.

l

Inspect the balls and the Belleville springs in the drawbar. See appropriate section and replace drawbar.

´

The part or fixture on the mill table crashes into long tooling or into the ATC itself during a tool change.

l

Program the machine to move the part out of the way of the ATC. Inspect the pocket involved in the crash for damage and replace parts as necessary.

´

The part or fixture on the mill table crashes into long tooling or into the ATC itself when machining.

l

Either reposition the tools to remove the interference, or program the carousel to rotate long tooling out of the way of the part (USE THIS ONLY AS A LAST RESORT). CAUTION! If the carousel has to be programmed to rotate long tools clear of the part, the correct carousel position must be programmed back in before a tool change can be executed.

Note: If these crashes occur, thoroughly inspect the ATC for damage. Pay close attention to the extractor forks, the sliding covers on the ATC carousel, and the roller bolts on the ATC shuttle. See appropriate section for extractor fork replacement.

B

REAKAGE

Breakage of the ATC is caused by either very hard and repeated crashes or excessive TSC coolant tip wear.

´

ATC shuttle is broken off of the holding plate.

l

Carefully inspect the bosses on the shuttle casting (where the roller bolts mount) for damage to the threads or cracks. If any of the bosses are cracked, replace the casting. Realign the tool changer after repairing the machine.

´

ATC extractor forks are damaged after breakage.

l

Check the condition of the mounting holes in the carousel. If the threads are damaged, they must be repaired or the carousel replaced. See appropriate section for extractor fork replacement.

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19

20

TROUBLESHOOTING

N

OISY

O

PERATION

To isolate noise(s) in the ATC, carefully observe the ATC in operation and look for the following:

´

ATC makes noise as the shuttle moves.

l

Check the adjustment of the roller bolts on the ATC («Roller Bolt Replacement» section). Loose roller bolts can cause the ATC to make a clunking noise when the shuttle is commanded to move. Tight roller bolts can cause the shuttle motor to labor excessively, possibly damaging the motor or the

I/O board. In this case, the shuttle may also move too slowly.

l l l l l l

Check for damage to the trap door on the ATC cover. See appropriate section for trap door replacement.

Check for missing plastic riders on the ATC shutter. See «ATC Trap Door Replacement» for shutter replacement.

Ensure the guide pin mounted to the holding plate is not bent and does not scrape the ATC cover during movement. See «ATC Trap Door Replacement» for guide pin replacement.

Listen for damage to the gear train in the shuttle motor. If the motor is found to be the source of the noise, replace the motor («Shuttle Motor Removal» section). DO NOT try to repair the motor or to further isolate the noise in the motor. ATC makes noise during carousel rotation.

Check to ensure the Geneva driver on the turret motor is tight and properly adjusted («Shuttle

Motor Removal» section). If the Geneva driver is found to be loose, check for damage to the Geneva star. Any roughness in the slots will require that it be replaced («Geneva Star Replacement» section).

Check the adjustment of the Geneva driver in relation to the Geneva star («Geneva Star Replacement» section). If the adjustment is too loose, the carousel will vibrate heavily and make a loud clanking noise during carousel rotation. If the adjustment is too tight, the turret motor will labor excessively and the carousel may appear to move erratically.

June 1998

l l l

Note: If the turret motor adjustment is tight for extended periods, the turret motor,

Geneva star, and the I/O board may be damaged. If the adjustment of the Geneva star appears tight at some pockets and loose at others, the problem lies with the Geneva star. Check the concentricity of the star relative to the bearing housing on the carousel assembly. If the concentricity of the star is proven to within specification and the problem still persists, the Geneva star must be replaced («Geneva Star Replacement» section).

Ensure the screws holding the turret motor to the mounting plate are tight («Turret Motor Removal» section).

Ensure the screws attaching the motor mounting plate to the shuttle casting are tight.

Check for excessive noise in the gear train of the turret motor. See appropriate section for turret motor replacement.

Note: If the motor is found to be the source of noise, replace the motor assembly (motor, mounting plate, and Geneva driver).

DO NOT attempt to repair the motor or to further isolate the problem in the motor.

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TROUBLESHOOTING

S

PINDLE

O

RIENTATION

A switch is used to sense when the pin drops in to lock the spindle. When the pin drops the switch opens, indicating orientation is complete. The normally-closed side of this switch is wired to the spindle drive and commands it into the COAST STOP condition. This is done to make sure that the spindle motor is not powered when the pin is locking the spindle. If, during a tool change, the dogs on the spindle shaft do not align with the keys on the ATC carousel, the spindle orientation may be at fault.

The orientation of the spindle is as follows:

1) If the spindle is turning, it is commanded to stop,

2) Pause until spindle is stopped,

3) Spindle orientation speed is commanded forward,

4) Pause until spindle is at orientation speed,

5) Command spindle lock air solenoid active,

6) Pause until spindle locked status is active and stable,

7) If not locked after time-out time, alarm and stop.

´

ATC out of orientation with the spindle. Incorrect spindle orientation will cause the ATC

l

to crash as the shuttle moves. Alarm 113 will be generated.

Check the orientation of the machine.

´

ATC will not run.

l

In all cases where the tool changer will not run, an alarm is generated to indicate either a shuttle in/out problem or a turret rotation problem. These alarms will occur either on an attempt to change tools (ATC FWD) or ZERO RETURN the machine (AUTO ALL AXES). Use the appropriate alarm to select one of the problems following:

´

ATC shuttle will not move; shuttle is getting power (Command a tool change and feel for

l l

power being applied to the shuttle motor).

Disconnect the slip clutch arm from the ATC shuttle and ensure the shuttle can move freely. If not, appropriate section for shuttle adjustment.

Command a tool change with the shuttle disconnected.

Ø If the shuttle cycles, check the slip clutch on the ATC. See «Shuttle Installation» section for slip clutch replacement.

Note: The slip clutch should move the shuttle with a fair amount of force, but not so much that the shuttle cannot be made to slip when holding it back by hand. If the slip clutch is frozen, replace it. It cannot be rebuilt in the field.

Ø If the shuttle does not cycle, the motor has failed and must be replaced. Turn the motor by hand and feel for binding in the gear train in the motor.

Note: The motor uses a large amount of gear reduction and should be hard to turn by hand.

´

ATC shuttle will not move; shuttle is not getting power.

l l

Command a tool change feel for power being applied to the shuttle motor.

Check that the TC IN/TC OUT LED on the I/O PCB is illuminated when a tool change takes place.

Ø If the LED lights, check the fuse FU5 on the POWER PCB or FU1 on the I/O PCB. Otherwise, replace the I/O PCB («Electrical Service»).

Ø If the LED does not light, check cables I/O-P1-510 and I/O-P2-520.

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TROUBLESHOOTING

´

ATC turret will not rotate; turret motor is getting power.

l l

Command a tool change feel for power being applied to the turret motor.

If power is applied but the output shaft on the motor does not turn, check for binding between the turret motor assembly and the Geneva star («Automatic Tool Changer» section). Check for damage to the Geneva star or the Geneva driver. Check for a broken turret motor («Turret Motor Removal» section).

Note: Do not attempt to repair the motor or to further isolate the problem in the motor.

´

ATC turret will not rotate; turret motor is not getting power.

l l

Command a tool change feel for power being applied to the turret motor.

Check that the TC CW/ TC CCW LED on the I/O PCB is illuminated when a tool change takes place.

Ø If the LED lights, check the fuse FU5 on the POWER PCB or FU1 on the I/O PCB. Otherwise, replace the I/O PCB (Electrical Service).

Ø If the LED does not light, check cables I/O-P1-510 and I/O-P2-520.

June 1998

22

1.5 GEARBOX AND SPINDLE MOTOR

The gearbox cannot be serviced in the field and must be replaced as a unit. NEVER remove a motor from a VF-Series mill that has a gearbox, as this will damage the gearbox and void the warranty.

N

OISE

When investigating complaints of gearbox noise, also refer to «Spindle» troubleshooting section. Gearboxes can be damaged by failed air solenoids, gearshift cylinders, or bearings, resulting in noisy operation. While gearbox vibration can cause a poor finish on a workpiece, noisy gearbox operation may not.

´

Excessive or unusual noise coming from the gearbox and/or spindle motor.

Operate the machine in both high and lowgears. Monitor the gearbox for noise in both gear positions and if the pitch of the noise varies with the motor or the output shaft speed.

Ø If the noise only occurs in one gear throughout the entire RPM range of that gear position, the problem lies with the gearbox, and it must be replaced («Spindle Motor & Transmission» section).

Ø If the noise occurs in both gear positions, disconnect the drive belt and repeat the previous step.

If the noise persists, the gearbox is damaged and must be replaced, («Spindle Motor &

Transmission» section).

Ø With the drive belt disconnected, run the machine at 1000 RPM in high gear. Command a change of direction and listen for a banging noise in the gearbox as the machine slows to zero RPM and speeds back up to 1000 RPM in reverse. If the noise occurs, the motor has failed and the gearbox must be replaced.

G

EARS

W

ILL

N

OT

C

HANGE

´

Machine will not execute a gear change.

Note: Whenever a gear change problem occurs, an alarm will also occur. Refer

ALARMS section to diagnose each problem before working on the machine.

When a gear change is performed, the following sequence of events occurs:

1) If the spindle is turning, it is commanded to stop,

2) Pause until spindle is stopped,

3) Gear change spindle speed is commanded forward,

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TROUBLESHOOTING

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4) Pause until spindle is at speed,

5) Command high or low gear solenoid active,

6) Pause until in new gear or reversal time,

7) Alarm and stop if max gear change time elapsed,

If not in new gear, reverse spindle direction,

9) Turn off high and low gear solenoids.

l l l

Check air supply pressure. If pressure is too low, the gears will not change.

Check the air solenoid assembly on the solenoid bracket (rear of gearbox). If the solenoid operates properly and the limit switches on the gearbox operate properly, the problem lies with the gear change piston. Replace the gearbox («Spindle Motor & Transmission» section).

Check contactor CB4.

L

OW

P

RESSURE

A

LARM

´

Alarm 179 (Low Pressure Transmission Oil) has been triggered.

l l l l l l

Check for low oil supply in reservoir.

Check to see that pump motor is running.

Check for an air leak in the suction side of the pump.

Check for a bad pressure sensor.

Check for a broken or damaged cable.

Check for a worn pump head.

1.6 THROUGH THE SPINDLE COOLANT

C

OOLANT

O

VERFLOW

To begin troubleshooting, check the alarm history to determine the problem’s cause before any action is taken.

´

Coolant pouring out of spindle head covers.

l

Check the customer’s tooling for through holes in the pull stud, holder and tool.

l l l l l l

Check for seal failure. If failure is found, replace the seal housing (30-3286A). Refer to the appropriate steps in «TSC-Tool Release Piston Replacement» section for procedure.

Check that the TSC drain and purge lines are intact. If necessary, replace with 5/32″ O.D.

nylon tubing.

Check for coolant flowing from a failed fitting or check valve.

Check pre-charge pressure in accordance with TSC «Pressure Regulator Adjustment’ section and reset if necessary. Low pre-charge pressure can cause coolant to dump into the spindle head.

Ensure the coolant pump relief valve has not been tampered with (yellow paint band is intact).

Check the coolant pump pressure (should be 300 psi. for high pressure TSC , and 140 psi. for old system), with a standard (non-TSC) tool holder in spindle. If pump pressure is above 310 psi. (above

140 psi for old system), reset the pump relief valve in accordance with the «Setting TSC Pump Relief

Valve» section.

´

Excessive coolant flow out of drain line.

´

Pulsating flow through tool and drain line.

l l

Check pre-charge pressure in accordance with TSC «Pressure Regulator Adjustment» section. Reset precharge pressure if necessary. Low pre-charge pressure will cause heavy or pulsating flow from the drain line.

Ensure the coolant pump relief valve has not been tampered with (yellow paint band is intact). Check the coolant pump pressure (should be 300psi. for high pressure TSC, and 140 psi. for old system), with a standard (non-TSC) tool holder in spindle. If pump pressure is above 310 psi (above 140 psi.

for old system), reset pump relief valve in accordance with «Setting Pump Relief Valve» section.

23

24

TROUBLESHOOTING

L

OW

C

OOLANT

´

Alarm 151, «Low Thru Spindle Coolant»

l l l l l l l l l

Check coolant tank level.

Check for slow coolant drainage from machine enclosure.

Read the filter gauges and check the intake strainer to ensure there is no clogging. Read gauges with

TSC running with no tool in spindle. Check coolant lines for any clogging or kinking. Clean or replace as needed.

If received at start-up, check that the breaker hasn’t tripped and that the pump is turning. Check the electrical continuity of cables.

Check for overheating TSC motor. Single phase motors have a built in thermal cut out. Three phase

TSC motors have a thermal circuit that interrupts power to the relay coil.

For old TSC system, if the drawbar was replaced, check that the hole through the drawbar is 0.156

dia. not 0.190 dia. Replace if it is 0.190.

Check for pressure switch failure (refer to «Testing the Coolant Pressure Switch» section), and replace if necessary. Check «LO CLNT» bit in the diagnostics display (0 = pressure on, 1= pressure off). Leaking pressure switches can also give intermittent alarms.

Check the pump pressure with TSC running and no tool in the spindle. Normal pressure is 75-95

PSI. Replace the pump if pressure is 60 psi or less.

Another alarm generated during TSC operation can cause this alarm.

C

OOLANT

T

IP

W

EAR

The carbide coolant tip should last for the life of the machine. The old bronze coolant tip should be checked every 1000 hours of TSC operation.

´

Coolant tip is wearing quickly and needs frequent replacement.

l l l

Check the filtration system and that the coolant is not contaminated.

Check pre-charge pressure (refer to the TSC Pressure Regulator Adjustment» section). Heavy wear will occur if this pressure is too high.

Main air supply below 85 psi can cause excessive pre-charge pressure and heavy coolant tip wear.

Note: Abrasive swarf from grinding or ceramic machining operations will cause heavy wear of TSC coolant pump, coolant tip and drawbar. This is not covered by the warranty. Notify HAAS Service Dept. if machine is being used for this application.

P

RE

-C

HARGE

F

AILURE

´

Alarm 198, «Precharge Failure»

l l l l l l

Note: This alarm only applies to the TSC system. This alarm does not apply to 50 taper spindle machines. If this alarm is received on a 50 taper TSC machine, check that parameter 235 is set to zero. A non-zero value will cause the control to act as a 40 taper

TSC.

Check for broken or disconnected pre-charge air line, and replace if necessary.

Check if the «Tool Clamped» limit switch is sticking, and replace if necessary.

Check the «Tool Clamped» limit switch adjustment (refer to «Tool Clamp/Unclamp Switch

Adjustment»).

Check for low pre-charge pressure (refer to «Pressure Regulator Adjustment» section).

Check pre-charge solenoid for proper operation.

May be generated if another alarm occurs during TSC operation.

June 1998

96-8100

June 1998

TROUBLESHOOTING

1.7 CHIP CONVEYOR

´

Chip conveyor does not turn

l l l l

Check that Parameter 209 bit switch ENA CNVR is enabled.

Check that the front enclosure door is competely closed and door switches function properly.

Check that hub is connected to auger with bolt.

Check that all conveyor fuses are intact. [Single phase motor uses 2 fuses (VF-0,1/2 ; Three phase motor uses 3 fuse (VF-3,4,6,8)]

Check thermal reset button on conveyor motor body.

NOTE: Thermal reset indicates further problems: Ensure conveyor is not jammed, all necessary fuses are intact, check motor connector and I/O Board conveyor relays

´

Chip conveyor is moving in the wrong direction

l l

Toggle Parameter 209 bit switch REV CNVR to reverse direction of conveyor.

Check I/O Board conveyor relays.

´

Chip conveyor reverses, then shuts down

l l l

Check that the conveyor is free of obstruction.

Check that Parameters are at Default settings.

Check that Discrete Input CNVYR (conveyor overload) cycles from 0 — 1 or 1 — 0 (0 means overload condition)

NOTE: If it does cycle check the motor for burnout or binding. If it does not cycle check the I/O board.

96-8100

25

26

TROUBLESHOOTING

1.8 HYDRAULIC COUNTERBALANCE

M

ECHANICAL

D

IAGNOSIS

Important! Hydraulic counterbalance oil contains red dye for easier recognition.

´

Noise in the system

l l l l l

Slight moan or creaking at slow speeds is normal for rubber seals.

While Z-axis is in motion a whistle sound at tank location is normal fluid flow.

Verify cylinder is seated correctly in counterbore. If not then reseat the cylinder.

Bumping or grinding noise indicates a mechanical cylinder failure. Replace cylinder assembly.

Look for galling and wear on cylinder shaft. If so replace the cylinder assembly.

´

System is not holding pressure and/or has an E-STOP (Alarm 107) that cannot be reset.

l l l l

Check for accurate pressure readings. If low then the following items need to be checked:

Check for leaks at all cylinder fittings. If leaking then replace cylinder assembly.

Collapse the lower Z-axis waycover and look for any red oil pooled at the bottom of the base.

If so, then fittings or seals could be damaged. Replace cylinder assembly.

Remove cylinder vent fitting. If there is red oil inside the vent cavity then the cylinder assembly needs replacement.

Check for leaks at all hydraulic tank fittings. If leaking then tank assembly needs replacement.

´

Over Current alarms

l l l l l

Pressure is set too high.

Pressure is set too low.

Too much oil has been added. (Insufficient gas volume causes large pressure rise)

Hydraulic cylinder is binding or is misaligned. Replace cylinder assembly.

Length of replacement cylinder incorrect.

June 1998

96-8100

June 1998

TROUBLESHOOTING

1.9 LINEAR SCALES

Perform the «Linear Scale Alignment Check» if any of the linear scale alarms (279-290) are received.

L

INEAR

S

CALE

A

LIGNMENT

C

HECK

Note: This procedure is only accurate if the machine is square.

1. Remove the right side way cover for the X-axis to gain access to it’s linear scale. Remove the front way cover for the Y-axis to gain access to it’s linear scale.

2. Access to the Z-axis linear scale is from the top of the machine. Removal of the head cover may be necessary.

3. Tap the encoder head lightly and note any position change indicated by the control. If there is any change, ensure that the encoder head/encoder bracket fasteners are tight.

4. If problems persist, check for correct gaps at each end of travel by inserting tools T-1548 and T-1549 into their respective gaps, as shown in Figure 1-4. These tools must fit without having to force them. If the tool can be moved more than 0.003″, the fit is too loose.

96-8100

Figure 1-4. Linear scale alignment check tools.

If the tools can be inserted in accordance with the above instructions, the linear scale is correctly aligned.

5. Check for flatness and parallelism of the linear scale(s) (with respect to the linear guide path) with a magnetic base and indicator setup. It should be possible to insert the tools correctly at both ends of travel.

Runout specifications are:

Flatness: 0.005″ along full travel

Parallel: 0.005″ along full travel

6. Note results and contact Haas Automation for further instruction. DO NOT attempt to align the linear scales.

27

28

TROUBLESHOOTING

1.10 AUTOMATIC PALLET CHANGER

´

Checking pallet repeatability on to the receiver.

l l l l l

Maximum tolerance is .+/-0005.

Pallets are not considered repeatable from one to the other. Pallets should use seperate offsets.

If pallet is out of tolerance check the alignment pins on the receiver base and bushings on the bottom side of the clamp rails for damage.

Check the height of the alignment pins on the receiver base, the top of the pin should be

.450 to .490 above the receiver base.

If the alignment pins are out of the receiver body, check the depth of the hole. Depth should be .510 to .550.

´

Sticking Pallet.

l l

Check for chips around the alignment pins or pallet clamp rail bushings.

Check the torque on the bolts that fasten the clamp rails to the pallet. If the bolts are loose realign the pallet according to the instructions in the APC section of Mechanical Service.

´

APC not responding to controller commands.

l l

If the APC does not run but the mill does, check the APC control cable.

Make sure the E-Stop jumper is removed and that the APC control cable is plugged into the

5th axis port tightly

June 1998

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June 1998

´

Recovery from an E-Stop initiated during a pallet change

TROUBLESHOOTING

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29

TROUBLESHOOTING

June 1998

30

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June 1998

TROUBLESHOOTING

1.11 ELECTRICAL TROUBLESHOOTING

CAUTION! Before working on any electrical components, power off the machine and wait approximately 10 minutes. This will allow the high voltage power on the brushless amplifiers to be discharged.

E

LECTRICAL

A

LARMS

´

Axis Drive Fault Alarm

l l

Blown amplifier — indicated by a light at bottom of amplifier when power is on. Replace amplifier.

Amplifier or MOCON is noise sensitive. If this is the case, the alarm can be cleared and the axis will run normally for a while.

To check an amplifier, switch the motor leads and control cables between the amplifier and the one next to it. If the same problem occurs with the other axis, the amplifier must be replaced. If the problem stays on the same axis, either the MOCON or control cable. The problem could also be the axis motor itself, with leads either shorted to each other or to ground, which is very rare.

l

Amplifier faulting out for valid reason, such as overtemp, overvoltage, or +/-12 volt undervoltage condition. This usually results from running a servo intensive program, or unadjusted 12 volt power supply. Replace amplifier.

Overvoltage could occur if regen load is not coming on, but this does not usually happen. The problem could also be the axis motor itself, with leads either shorted to each other or to ground, which is very rare.

´

Axis Overload

l

The fuse function built into the MOCON has been overloaded, due to a lot of motor accel/decels, or hitting a hard stop with the axis. This safety function protects the amplifier and motor, so find the cause and correct it. If the current program is the cause, change the program. If the axis hits a hard stop, the travel limits may be set wrong.

´

Phasing Error

l

The MOCON did not receive the proper phasing information from the motors. DO NOT RESET the machine if this alarm occurs. Power the machine down and back up. If the problem persists, it is probably a broken wire or faulty MOCON connectors.

´

Servo Error Too Large

l

This alarms occurs when the difference between the commanded axis position and the actual position becomes larger the the maximum that is set in the parameter.

This condition occurs when the amplifier is blown, is not receiving the commands, or the 320 volt power source is dead. If the MOCON is not sending the correct commands to the amplifier, it is probably due to a broken wire, or a PHASING ERROR that was generated.

´

Axis Z Fault or Z Channel Missing

l

During a self-test, the number of encoder counts was found to be incorrect. This is usually caused by a noisy environment, and not a bad encoder. Check all shields and grounds on the encoder cables and the motor leads that come into the amplifiers. An alarm for one axis can be caused by a bad grounding on the motor leads of another axis.

96-8100

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32

TROUBLESHOOTING

´

Axis Cable Fault

l

During a self-test, the encoder cable signals were found to be invalid. This alarm is usually caused by a bad cable, or a bad connection on the motor encoder connectors. Check the cable for any breaks, and the encoder connectors at the motor controller board. Machine noise can also cause this alarm, although it is less common.

´

Alarm 101, «MOCON Comm. Failure»

l

During a self-test of communications between the MOCON and main processor, the main processor does not respond, and is suspected to be dead. This alarm is generated and the servos are stopped.

Check all ribbon cable connections, and all grounding. Machine noise can also cause this alarm, although it is less common.

´

Alarm 157, «MOCON Watchdog Fault»

l

The self-test of the MOCON has failed. Replace the MOCON.

1.12 P

ROCESSOR

S

TACK

D

IAGNOSTIC

(DISCONNECT CABLES FROM A NORMAL OPERATING SYSTEM)

´

Remove low voltage cable from the Video & Keyboard PCB

l l l

Processors LED’s are normal

Runs fine and the CRT is Normal

No keypad beep

´

Remove low voltage cable from the MOTIF PCB

l l

Processors LED’s are normal then RUN goes out

No screen

´

Remove the Data & or Address buss from the Video & Keyboard PCB

l

Processors LED’s Normal — then Run goes out

´

Remove the Data & or Address buss from the MOTIF PCB

l

Processors LED’s Normal — then Run goes out

´

Remove the Data & or Address buss from the Micro Processor PCB

l

Processors LED’s — CRT and Run are out

1.13 K

EYBOARD

D

IAGNOSTIC

June 1998

Note: Refer to the «Cable Locations» section of this manual for a drawing of the Keyboard Interface PCB.

96-8100

June 1998

TROUBLESHOOTING

96-8100

The following is an example of how to troubleshoot the keypad:

Note: Keypad Diodes 1-24 correspond to chart numbers 1-24

Example

1. Pressing the RESET button will cause diodes 1 and 17 to conduct.

l l

With the POWER OFF read across diode 1.

A typical reading is between .400-.700 ohms, note your reading.

2. Press and hold the RESET button. If the diode is conducting, the reading should drop about .03 ohms.

l

(If your reading was .486 and it dropped to .460, for a difference of .026; the diode is good) l l

The same will hold true for diode 17 in this example. If the reading stays the same or there is no change, the diode is not conducting. Pull P2 and read between pins 1 and 17.

Press and hold <RESET>. The meter should read a short (0 ohms) if not the keypad is bad.

33

TROUBLESHOOTING

June 1998

34

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ALARMS

96-8100

2. ALARMS

Any time an alarm is present, the lower right hand corner of the screen will have a blinking «ALARM». Push the ALARM display key to view the current alarm. All alarms are displayed with a reference number and a complete description.

If the RESET key is pressed, one alarm will be removed from the list of alarms. If there are more than 18 alarms, only the last 18 are displayed and the RESET must be used to see the rest. The presence of any alarm will prevent the operator from starting a program.

The ALARMS DISPLAY can be selected at any time by pressing the ALARM MESGS button. When there are no alarms, the display will show NO ALARM. If there are any alarms, they will be listed with the most recent alarm at the bottom of the list. The CURSOR and PAGE UP and PAGE DOWN buttons can be used to move through a large number of alarms.

The CURSOR right and left buttons can be used to turn on and off the ALARM history display.

The following alarm list shows the alarm numbers, the text displayed along with the alarm, and a detailed description of the alarm, what can cause it, when it can happen, and how to correct it.

Alarm number and text:

101 MOCON Comm. Failure

Possible causes:

During a self-test of communications between the MOCON and main processor, the main processor does not respond, and is suspected to be dead. Check cable connections and grounding.

102 Servos Off

103 X Servo Error

Too Large

Indicates that the servo motors are off, the tool changer is disabled, the coolant pump is off, and the spindle motor is stopped. Caused by EMER-

GENCY STOP, motor faults, tool changer problems, or power fail.

Too much load or speed on X-axis motor. The difference between the motor position and the commanded position has exceeded a parameter.

The motor may also be stalled, disconnected, or the driver failed. The servos will be turned off and a RESET must be done to restart. This alarm can be caused by problems with the driver, motor, or the slide being run into the mechanical stops.

104 Y Servo Error

Too Large

105 Z Servo Error

Too Large

106 A Servo Error

Too Large

107 Emergency Off same as 103.

same as 103.

same as 103.

108 X Servo Overload

EMERGENCY STOP button was pressed. Servos are also turned off. After the E-STOP is released, the RESET button must be pressed at least twice to correct this; once to clear the E-STOP alarm and once to clear the Servo Off alarm.

This alarm will also be generated if there is a low pressure condition in the hydraulic counterbalance system. In this case, the alarm will not reset until the condition has been corrected.

Excessive load on X-axis motor. This can occur if the load on the motor over a period of several seconds or even minutes is large enough to exceed the continuous rating of the motor. The servos will be turned off when this occurs. This can be caused by running into the mechanical stops but not much past them. It can also be caused by anything that causes a very high load on the motors.

35

36

ALARMS

109

110

111

112

113

114

115

Y Servo Overload

Z Servo Overload

A Servo Overload

No Interrupt

Shuttle In Fault

Shuttle Out Fault

Turret Rotate Fault

116 Spindle Orientation Fault

117

118

119

120

Spindle High Gear Fault

Spindle Low Gear Fault

Over Voltage

Low Air Pressure same as 108.

same as 108.

same as 108.

Electronics fault. Call your dealer.

Tool changer not completely to right. During a tool changer operation the tool in/out shuttle failed to get to the in position. Parameters 62 and

63 can adjust the time-out times. This alarm can be caused by anything that jams the motion of the slide or by the presence of a tool in the pocket facing the spindle. A loss of power to the tool changer can also cause this, so check CB4, relays K9-K12, and fuse F1.

Tool changer not completely to left. During a tool change operation the tool in/out shuttle failed to get to the out position. Parameters 62 and

63 can adjust the time-out times. This alarm can be caused by anything that jams the motion of the slide or by the presence of a tool in the pocket facing the spindle. A loss of power to the tool changer can also cause this, so check CB4, relays K9-K12, and fuse F1.

Tool carousel motor not in position. During a tool changer operation the tool turret failed to start moving or failed to stop at the right position.

Parameters 60 and 61 can adjust the time-out times. This alarm can be caused by anything that jams the rotation of the turret. A loss of power to the tool changer can also cause this, so check CB4, relays K9-K12, and fuse F1.

Spindle did not orient correctly. During a spindle orientation function, the spindle is rotated until the lock pin drops in; but the lock pin never dropped. Parameters 66, 70, 73, and 74 can adjust the time-out times.

This can be caused by a trip of circuit breaker CB4, a lack of air pressure, or too much friction with the orientation pin.

Gearbox did not shift into high gear. During a change to high gear, the spindle is rotated slowly while air pressure is used to move the gears but the high gear sensor was not detected in time. Parameters 67, 70 and 75 can adjust the time-out times. Check the air pressure, the solenoids circuit breaker CB4, and the spindle drive.

Gearbox did not shift into low gear. During a change to low gear, the spindle is rotated slowly while air pressure is used to move the gears but the low gear sensor was not detected in time. Parameters 67, 70 and 75 can adjust the time-out times. Check the air pressure, the solenoids circuit breaker

CB4, and the spindle drive.

Incoming line voltage is above maximum. The servos will be turned off and the spindle, tool changer, and coolant pump will stop. If this condition remains for 4.5 minutes, an automatic shutdown will begin.

Air pressure dropped below 80 PSI for a period defined by Parameter 76.

The «Low Air Pr» alarm will appear on the screen as soon as the pressure gets low, and this alarm appears after [Parameter 76] has elapsed. Check your incoming air pressure for at least 100 PSI and ensure that the regulator is set at 85 PSI.

June 1998

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June 1998

ALARMS

121

122

Low Lube or

Low Pressure

Regen Overheat

Way lube is low or empty or there is no lube pressure or too high a pressure.

Check tank at rear of mill and below control cabinet. Also check connector on the side of the control cabinet. Check that the lube lines are not blocked.

The control internal temperature is above 150 degrees F. This can be caused by almost anything in the control overheating. But is usually caused by overheat of the two regen resistors for servos and spindle drive. This alarm will also turn off the servos, spindle drive, coolant pump, and tool changer.

One common cause of this overheat condition is an input line voltage too high. If this condition remains for 4.5 minutes, an automatic shutdown will begin.

123 Spindle Drive Fault Overheat or failure of spindle drive or motor. The exact cause is indicated in the LED window of the spindle drive inside the control cabinet. This can be caused by a stalled motor, shorted motor, overvoltage, undervoltage, overcurrent, overheat of motor, or drive failure.

124 Low Battery Memory batteries need replacing within 30 days. This alarm is only generated at power on and indicates that the 3.3 volt Lithium battery is below 2.5 volts. If this is not corrected within about 30 days, you may lose your stored programs, parameters, offsets, and settings.

125 Shuttle fault

126 Gear Fault

Tool shuttle not initialized at power on, CYCLE START or spindle motion command.

This means that the tool shuttle was not fully retracted to the Out position.

Gearshifter is out of position when a command is given to rotate the spindle. This means that the two speed gear box is not in either high or low gear but is somewhere in between. Check the air pressure, the solenoids circuit breaker CB4, and the spindle drive.

127

129

No Turret Mark

M Fin Fault

Tool carousel motor not in position. The turret motor only stops in one position indicated by a switch and cam on the Geneva mechanism. This alarm is only generated at power-on. The AUTO ALL AXES button will correct this but be sure that the pocket facing the spindle afterwards does not contain a tool.

M-Fin was active at power on. Check the wiring to your M code interfaces. This test is only performed at power-on.

130 Tool Unclamped The tool appeared to be unclamped during spindle orientation, a gear change, a speed change, or TSC start-up. The alarm will also be generated if the tool release piston is energized during Power Up. This can be caused by a fault in the air solenoids, relays on the I/O assembly, the drawbar assembly, or in the wiring.

131 Tool Not Clamped When clamping or powering up the machine, the Tool Release Piston is not

HOME. This is a possible fault in the air solenoids, relays on the IO Assembly, the drawbar assembly, or wiring.

132 Power Down Failure Machine did not turn off when an automatic power-down was commanded. Check wiring to POWIF card on power supply assembly, relays on the IO assembly, and the main contactor K1.

96-8100

37

38

ALARMS

133

134

Spindle Locked

Tool Clamp Fault

Shot pin did not release. This is detected when spindle motion is commanded.

Check the solenoid that controls the air to the lock, relay 2-8, the wiring to the sense switch, and the switch.

When UNCLAMPING the tool did not release from spindle when commanded. Check air pressure and solenoid circuit breaker CB4. Can also be caused by misadjustment of drawbar assembly.

135 X Motor Over Heat Servo motor overheat. The temperature sensor in the motor indicates over 150 degrees F. This can be caused by an extended overload of the motor such as leaving the slide at the stops for several minutes.

136 Y Motor Over Heat same as 135.

137 Z Motor Over Heat same as 135.

138 A Motor Over Heat same as 135.

139 X Motor Z Fault Encoder marker pulse count failure. This alarm usually indicates that the encoder has been damaged and encoder position data is unreliable. This can also be caused by loose connectors at P1-P4.

140 Y Motor Z Fault

141 Z Motor Z Fault

142 A Motor Z Fault same as 139.

same as 139.

same as 139.

143 Spindle Not Locked Shot pin not fully engaged when a tool change operation is being performed.

Check air pressure and solenoid circuit breaker CB4. This can also be caused by a fault in the sense switch that detects the position of the lock pin.

Time allocated for use prior to payment exceeded. Call your dealer.

144 Time-out-

Call Your Dealer

145 X Limit Switch Axis hit limit switch or switch disconnected. This is not normally possible as the stored stroke limits will stop the slides before they hit the limit switches. Check the wiring to the limit switches and connector P5 at the side of the main cabinet. Can also be caused by a loose encoder shaft at the back of the motor or coupling of motor to the screw.

146

147

148

Y Limit Switch

Z Limit Switch

A Limit Switch

149 Spindle Turning same as 145 same as 145

Normally disabled for rotary axis.

150 Z and Tool

Interlocked

Spindle not at zero speed for tool change. A signal from spindle drive indicating that the spindle drive is stopped is not present while a tool change operation is going on.

Changer not at home and either the Z or A or B axis (or any combination) is not at zero. If RESET, E-STOP, or POWER OFF occurs during tool change, Z-axis motion and tool changer motion may not be safe. Check the position of the tool changer and remove the tool if possible. Re-initialize with the AUTO ALL AXES button but be sure that the pocket facing the spindle afterwards does not contain a tool.

June 1998

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June 1998

ALARMS

151

152

Low Thru Spindle

Coolant

Self Test Fail

For machines with Through the Spindle Coolant only. This alarm will shut off the spindle, feed, and pump all at once. It will turn on purge, wait for the amount of time specified in parameter 237 for the coolant to purge, and then turn off the purge. Check for low coolant tank level, any filter or intake strainer clogging, or for any kinked or clogged coolant lines. If no problems are found with any of these, and none of the coolant lines are clogged or kinked, call your dealer.

Control has detected an electronics fault. All motors and solenoids are shut down.

This is most likely caused by a fault of the processor board stack at the top left of the control. Call your dealer.

Broken wires or encoder contamination. All servos are turned off. This can also be caused by loose connectors at P1-P4.

153 X-axis Z

Ch Missing

154 Y-axis Z

Ch Missing

155 Z-axis Z

Ch Missing

156 A-axis Z

Ch Missing

162

163

164

Y-Axis Drive Fault

Z-Axis Drive Fault

A-Axis Drive Fault same as 153.

same as 153.

same as 153.

157 MOCON Watchdog The self-test of the MOCON has failed. Replace the MOCON.

Fault

158 Video/Keyboard

PCB Failure

Internal circuit board problem. The VIDEO PCB in the processor stack is tested at power-on. This could also be caused by a short in the front panel membrane keypad. Call your dealer.

159 Keyboard Failure

160 Low Voltage

Keyboard shorted or button pressed at power on. A power-on test of the membrane keypad has found a shorted button. It can also be caused by a short in the cable from the main cabinet or by holding a switch down during power-on.

The line voltage to control is too low. This alarm occurs when the AC line voltage drops below 190 when wired for 230 volts or drops below 165 when wired for 208 volts.

161 X-Axis Drive Fault Current in X servo motor beyond limit. Possibly caused by a stalled or overloaded motor. The servos are turned off. This can be caused by running a short distance into a mechanical stop. It can also be caused by a short in the motor or a short of one motor lead to ground.

same as 161.

same as 161.

same as 161.

165 X Zero Ret

Margin Too Small

This alarm will occur if the home/limit switches move or are misadjusted.

This alarm indicates that the zero return position may not be consistent from one zero return to the next. The encoder Z channel signal must occur between 1/8 and 7/8 revolution of where the home switch releases. This will not turn the servos off but will stop the zero return operation.

96-8100

39

40

ALARMS

166 Y Zero Ret

Margin Too Small

167 Z Zero Ret

Margin Too Small

168 A Zero Ret

Margin Too Small

169

170

Spindle Direction

Fault

Phase Loss

Same as 165.

Same as 165.

Not normally enabled for A-axis.

Problem with rigid tapping hardware. The spindle started turning in the wrong direction.

Problem with incoming line voltage between legs L1 and L2. This usually indicates that there was a transient loss of input power to the machine.

171 UNUSED

172 UNUSED

173

174

175

176

177

Spindle Ref

Signal Missing

Tool Load Exceeded

Ground Fault Detected

Over Heat Shutdown

Over Voltage Shutdown

The Z channel pulse from the spindle encoder is missing for hard tapping synchronization.

The tool load monitor option is selected and the maximum load for a tool was exceeded in a feed. This alarm can only occur if the tool load monitor function is installed in your machine.

A ground fault condition was detected in the 115V AC supply. This can be caused by a short to ground in any of the servo motors, the tool change motors, the fans, or the oil pump.

An overheat condition persisted for 4.5 minutes and caused an automatic shutdown.

An overvoltage condition persisted for 4.5 minutes and caused an automatic shutdown.

178 Divide by Zero

179 Low Pressure

Transmission Oil

180 Pallet Not Clamped

Software Error; Call your dealer.

Spindle coolant oil is low or low pressure condition in lines.

The APC pallet changer was not completed for some reason (pressing Estop, reset, or feedhold), and an attempt was made to run the spindle. Run

M50 pallet change to reset the machine.

Cable from X-axis encoder does not have valid differential signals.

182 X Cable Fault

183

184

185

Y Cable Fault

Z Cable Fault

A Cable Fault

Same as 182.

Same as 182.

Same as 182.

186 Spindle Not Turning Status from spindle drive indicates it is not at speed when expected.

187 B Servo Error Too Large Same as 103.

June 1998

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June 1998

188 B Servo Overload

189 B Motor Overheat

190 B Motor Z Fault

191 B Limit Switch

192 B Axis Z Ch Missing

193 B Axis Drive Fault

194 B Zero Ret Margin

Too Small

195

196

197

198

B Cable Fault

Coolant Spigot Failure

100 Hours Unpaid Bill

Precharge Failure

199 Negative RPM

201 Parameter CRC Error

202 Setting CRC Error

203 Lead Screw CRC Error

204 Offset CRC Error

205 Programs CRC Error

206 Internal Program Error

207 Queue Advance Error

208 Queue Allocation Error

209 Queue Cutter

Comp Error

210 Insufficient Memory

211 Odd Prog Block

212 Program Integrity Error

ALARMS

Same as 108.

Same as 135.

Same as 139.

Same as 148.

Same as 153.

Same as 161.

Same as 168.

Same as 182.

Spigot failed to achieve commanded location after two (2) attempts.

Call your dealer.

During TSC operation, the precharge failed for greater than 0.1 seconds.

It will shut off the feed, spindle and pump all at once. If received, check all air lines and the air supply pressure.

A negative spindle RPM was sensed.

Parameters lost maybe by low battery. Check for a low battery and low battery alarm.

Settings lost maybe by low battery. Check for a low battery and low battery alarm.

Lead screw compensation tables lost maybe by low battery. Check for

CRC Error low battery and low battery alarm.

Offsets lost maybe by low battery. Check for a low battery and low battery alarm.

Users program lost maybe by low battery. Check for a low battery and low battery alarm.

Possible corrupted program. Save all programs to floppy disk, delete all, then reload. Check for a low battery and low battery alarm.

Software Error; Call your dealer.

Software Error; Call your dealer.

Software Error; Call your dealer.

Not enough memory to store users program. Check the space available in the LIST PROG mode and possibly delete some programs.

Possible corrupted program. Save all programs to floppy disk, delete all, then reload.

Possible corrupted program. Save all programs to floppy disk, delete all, then reload. Check for a low battery and low battery alarm.

96-8100

41

42

ALARMS

213

215

217

Program RAM CRC Error

214 No. of Programs

Changed

Free Memory PTR

Changed

X Axis Phasing Error

218 Y Axis Phasing Error

219 Z Axis Phasing Error

220 A Axis Phasing Error

221 B Axis Phasing Error

222 C Axis Phasing Error

223 Door Lock Failure

224 X Transition Fault

225 Y Transition Fault

226 Z Transition Fault

227 A Transition Fault

228 B Transition Fault

229 C Transition Fault

231 Jog Handle Transition

Fault

232 Spindle Transition Fault

233 Jog Handle Cable Fault

234 Spindle Enc. Cable Fault

235 Spindle Z Fault

236 Spindle Motor Overload

237 Spindle Following Error

240 Empty Prog or No EOB

241 Invalid Code

242 No End

Electronics fault; Call your dealer.

Indicates that the number of programs disagrees with the internal variable that keeps count of the loaded programs. Call your dealer.

Indicates the amount of memory used by the programs counted in the system disagrees with the variable that points to free memory. Call your dealer.

Error occurred in phasing initialization of brushless motor. This can be caused by a bad encoder, or a cabling error.

Same as above.

Same as above.

Same as above.

Same as above.

Same as above.

In machines equipped with safety interlocks, this alarm occurs when the control senses the door is open but it is locked. Check the door lock circuit.

Illegal transition of count pulses in X axis. This alarm usually indicates that the encoder has been damaged and encoder position data is unreliable.

This can also be caused by loose connectors at the MOCON or MOTIF PCB.

Same as above.

Same as above.

Same as above.

Same as above.

Same as above.

Same as 224.

Same as 224.

Cable from jog handle encoder does not have valid differential signals.

Cable from spindle encoder does not have valid differential signals.

Same as 139.

This alarm is generated in machines equipped with a Haas vector drive, if the spindle motor becomes overloaded.

The error between the commanded spindle speed and the actual speed has exceeded the maximum allowable (as set in Parameter 184).

DNC program not found, or no end of program found.

RS-232 load bad. Data was stored as comment. Check the program being received.

Check input file for a number that has too many digits

June 1998

96-8100

June 1998

243

244

245

Bad Number

Missing )

Unknown Code

246 String Too Long

247 Cursor Data Base Error

248 Number Range Error

249 Prog Data

Begins Odd

250 Program Data Error

251 Prog Data Struct Error

252 Memory Overflow

253 Electronics Overheat

254 Spindle Overheat

257 Program Data Error

258 Invalid DPRNT Format

259 Bad Language Version

260 Bad Language CRC

261 Rotary CRC Error

262 Parameter CRC Missing

263 Lead Screw CRC Missing

264 Rotary CRC Missing

265 Macro Variable File

CRC Error

268 Door open @ M95 Start

270 C Servo Error Too Large

ALARMS

Data entered is not a number.

Comment must end with a » ) «.

Check input line or data from RS-232. This alarm can occur while editing data into a program or loading from RS-232.

Input line is too long. The data entry line must be shortened.

Software Error; Call your dealer.

Number entry is out of range.

Possible corrupted program. Save all programs to floppy disk, delete all, then reload.

Same as 249.

Same as 249.

Same as 249.

The control box temperature has exceeded 145 degrees F. This can be caused by an electronics problem, high room temperature, or clogged air filter.

This alarm is only generated in machines equipped with a Haas vector drive. The spindle temperature sensor sensed a high temperature for greater than 1.5 seconds.

Same as 249.

Macro DPRNT statement not structured properly.

Call your dealer.

Indicates FLASH memory has been corrupted or damaged.

Rotary table saved parameters (used by Settings 30, 78) have a CRC error.

Indicates a loss of memory — call your dealer.

RS-232 or floppy read of parameter had no CRC when loading from floppy or RS-232.

Lead screw compensation tables have no CRC when loading from floppy or

RS-232.

Rotary table parameters have no CRC when loading from floppy or RS-232.

Macro variable file has a CRC error. Indicates a loss of memory.

Call your dealer.

Generated whenever an M95 (Sleep Mode) is encountered and the door is open. The door must be closed in order to start sleep mode

Same as 103.

96-8100

43

44

ALARMS

271 C Servo Overload

272 C Motor Overheat

273 C Motor Z Fault

274 C Limit Switch

275 C Axis Z Ch Missing

276 C Axis Drive Fault

277 C Zero Ret Margin

Too Small

278 C Cable Fault

279 X Axis Linear Scale

Z Fault

280 Y Axis Linear Scale

Z Fault

281 Z Axis Linear Scale

Z Fault

282 A Axis Linear Scale

Z Fault

283 X Axis Linear Scale

Z Channel Missing

284 Y Axis Linear Scale

Z Channel Missing

285 Z Axis Linear Scale

Z Channel Missing

286 A Axis Linear Scale

Z Channel Missing

287 X Axis Linear Scale

Cable Fault

288 Y Axis Linear Scale

Cable Fault

289 Z Axis Linear Scale

Cable Fault

290 A Axis Linear Scale

Cable Fault

291 Low Air Volume/Pressure

During ATC

302 Invalid R In G02 or G03

June 1998

Same as 108.

Same as 135.

Same as 139.

Same as 145.

Same as 153.

Same as 161.

Same as 165.

Same as 182.

Encoder marker pulse count failure. This alarm usually indicates that the encoder has been damaged and encoder position data is unreliable. This can also be caused by loose connectors at P1-P4.

Same as alarm 279.

Same as alarm 279.

Same as alarm 279.

Broken wires or encoder contamination. All servos are turned off. This can also be caused by loose connectors at P1-P4.

Same as alarm 283.

Same as alarm 283.

Same as alarm 283.

Cable from X-axis encoder does not have valid differential signals.

Same as alarm 287.

Same as alarm 287.

Same as alarm 287.

An automatic tool change was not completed due to insufficient volume or pressure of compressed air. Check air supply line.

Check your geometry. R must be less than or equal to half the distance from start to end within an accuracy of 0.0010 inches.

96-8100

June 1998

ALARMS

96-8100

303 Invalid X, Y, or Z In

G02 or G03

304 Invalid I, J, or K In

G02 or G03

Check your geometry.

Check your geometry. Radius at start must match radius at end of arc within

0.0010 inches.

305 Invalid Q In

Canned Cycle

306 Invalid I, J, K, or Q In

Canned Cycle

Q in a canned cycle must be greater than zero.

I, J, K, and Q in a canned cycle must be greater than zero.

307 Subroutine

Nesting Too Deep

309

310

321

322

324

Exceeded Max Feed Rate

Invalid G Code

Auto Off Alarm

Sub Prog Without M99

Delay Time Range Error

Subprogram nesting is limited to nine levels. Simplify your program.

Use a lower feed rate.

G code not defined and is not a macro call.

311 Unknown Code

313 No P Code In M97,

M98, or G65

Possible corruption of memory by low battery. Call your dealer.

312 Program End of subroutine reached before M99. Need an M99 to return from subroutine.

Must put subprogram number in P code.

314 Subprogram or Macro

Not In Memory

315 Invalid P Code In

M97, M98 or M99

316 X Over Travel Range

317

318

Y Over Travel Range

Z Over Travel Range

319 A Over Travel Range

320 No Feed Rate Specified

Check that a subroutine is in memory or that a macro is defined.

The P code must be the name of a program stored in memory without a decimal point for M98 and must be a valid N number for M99.

X-axis will exceed stored stroke limits. This is a parameter in negative direction and is machine zero in the positive direction. This will only occur during the operation of a user’s program.

same as 316.

same as 316.

Not normally possible with A-axis.

Must have a valid F code for interpolation functions.

A fault turned off the servos automatically; occurs in debug mode only.

Add an M99 code to the end of program called as a subroutine.

P code in G04 is greater than or equal to 1000 seconds (over 999999 milliseconds).

325 Queue Full

326 G04 Without P Code

Control problem; call your dealer.

Put a Pn.n for seconds or a Pn for milliseconds.

45

46

331 Range Error

332 H and T

Not Matched

333 X-Axis Disabled

334 Y-Axis Disabled

335 Z-Axis Disabled

336 A-Axis Disabled

337 Line Referenced By

P, Not Found

338 Invalid IJK and XYZ in G02 or G03

339 Multiple Codes

340 Cutter Comp Begin

With G02 or G03

341 Cutter Comp End

With G02 or G03

342 Cutter Comp Path

Too Small

343 Display Queue

Record Full

344 Cutter Comp With

G18 and G19

345 Diff Step Ratio

On G17 Plane

346 Diff Step Ratio

On G18 Plane

ALARMS

327 No Loop For M

Code Except M97, M98

328 Invalid Tool Number

329 Undefined M Code

330 Undefined Macro Call

L code not used here. Remove L Code.

Tool number must be between 1 and the value in Parameter 65.

That M code is not defined and is not a macro call.

Macro name O90nn not in memory. A macro call definition is in parameters and was accessed by user program but that macro was not loaded into memory.

Number too large.

This alarm is generated when Setting 15 is turned ON and an H code number in a running program does not match the tool number in the spindle. Correct the Hn codes, select the right tool, or turn off Setting 15.

Parameters have disabled this axis. Not normally possible in VF Series

CNC Mill.

same as 333.

same as 333.

An attempt was made to program the A-axis while it was disabled

(DISABLED bit in Parameter 43 set to 1).

Subprogram is not in memory, or P code is incorrect.

There is a problem with circle definition; check your geometry.

Only one M, X, Y, Z, A, Q, etc. allowed in any block or two G codes in the same group.

Select cutter compensation earlier. Cutter comp. must begin on a linear move.

Disable cutter comp later.

Geometry not possible. Check your geometry.

A block exists that is too long for displaying queue. Shorten title block.

Cutter comp only allowed in XY plane (G17).

Parameters 5 and 19 must be same value.

Parameters 5 and 33 must be same value.

June 1998

96-8100

June 1998

347 Diff Step Ratio

On G19 Plane

348 Motion Not Allowed

In G93 Mode

349 Prog Stop W/O

Cancel Cutter Comp

350 Cutter Comp Look

Ahead Error

351 Invalid P Code

352 Aux Axis Power Off

353 Aux Axis No Home

354 Aux Axis

Disconnected

355 Aux Axis Position

Mismatch

356 Aux Axis Travel Limit

357 Aux Axis Disabled

358 Multiple Aux Axis

359 Invalid I, J, or K In G12 or G13

360 Tool Changer Disabled

361 Gear Change Disabled

362 Tool Usage Alarm

363 Coolant Locked Off

364 No Circ Interp

Aux Axis

367 Cutter Comp

Interference

368 Groove Too Small

ALARMS

Parameters 19 and 33 must be same value.

This alarm is generated if the mill is in Inverse Time Feed mode, and a

G12, G13, G70, G71, G72, G150, or any Group 9 motion command is issued.

Cutter compensation has been cancelled without an exit move. Potential damage to part.

There are too many non-movement blocks between motions when cutter comp is being used. Remove some intervening blocks.

In a block with G103 (Block Lookahead Limit), a value between 0 and 15 must be used for the P code.

Aux B, C, U, V, or W axis indicate servo off. Check auxiliary axes.

Status from control was OFF.

A ZERO RET has not been done yet on the aux axes. Check auxiliary axes. Status from control was LOSS.

Aux axes not responding. Check auxiliary axes and RS-232 connections.

Mismatch between machine and aux axes position. Check aux axes and interfaces. Make sure no manual inputs occur to aux axes.

Aux axes are attempting to travel past their limits.

Aux axes are disabled.

Can only move one auxiliary axis at a time.

Check your geometry.

Check Parameter 57. Not a normal condition for VF Series CNC Mill.

Check Parameter 57. Not a normal condition for VF Series CNC Mill.

Tool life limit was reached. To continue, reset the usage count in the

Current Commands display and press RESET.

Override is off and program tried to turn on coolant.

Only rapid or feed is allowed with aux axes.

G01 cannot be done with tool size.

Tool too big to enter cut.

96-8100

47

48

ALARMS

369 Tool Too Big

370 Pocket Definition

Error

371 Invalid I, J, K, OR Q

372 Tool Change In

Canned Cycle

373 Invalid Code in DNC

374 Missing XYZA in

G31 or G36

375 Missing Z or H in G37

376 No Cutter Comp In Skip

377 No Skip in Graph/Sim

378 Skip Signal Found

379 Skip Signal Not Found

380 X, Y, A, or G49

Not Allowed in G37

381 G43 or G44 Not

Allowed in G36 or G136

382 D Code Required in G35

383 Inch Is Not Selected

384 Metric Is Not Selected

385 Invalid L, P, or R

Code In G10

386 Invalid Address Format

387 Cutter Comp Not

Allowed With G103

388 Cutter Comp Not

Allowed With G10

389 G17, G18, G19

Illegal in G68

Use a smaller tool for cut.

Check geometry for G150.

Check G150.

Tool change not allowed while canned cycle is active.

A code found in a DNC program could not be interpreted because of restrictions to DNC.

G31 skip function requires an X, Y, Z, or A move.

G37 automatic tool length measurement function requires H code, Z value, and tool offset enabled. X, Y, and A values not allowed.

SkipG31 and G37 functions cannot be used with cutter compensation.

Graphics mode cannot simulate skip function.

Skip signal check code was included but skip was found when it was not expected.

Skip signal check code was included but skip was not found when it was expected.

G37 may only specify Z-axis and must have tool offset defined.

Auto work offset probing must be done without tool offset.

A Dnn code is required in G35 in order to store the measured tool diameter.

G20 was specified but settings have selected metric input.

G21 was specified but settings have selected inches.

G10 was used to changes offsets but L, P, or R code is missing or invalid.

An address A…Z was used improperly.

If block buffering has been limited, Cutter comp cannot be used.

Coordinates cannot be altered while cutter comp is active. Move G10 outside of cutter comp enablement.

Planes of rotation cannot be changed while rotation is enabled.

June 1998

96-8100

June 1998

390

391

392

394

397

No Spindle Speed

Feature Disabled

B Axis Disabled

393 Invalid Motion In

G74 or G84

B Over Travel Range

395 No G107 Rotary Axis

Specified

396 Invalid G107 Rotary

Axis Specified

Aux Axis In G93 Block

398 Aux Axis Servo Off

403 RS-232 Too Many Progs

404 RS-232 No Program

Name

405 RS-232 Illegal Prog

Name

406 RS-232 Missing Code

407 RS-232 Invalid Code

408 RS-232 Number Range

Error

409 RS-232 Invalid N Code

410 RS-232 Invalid V Code

411 RS-232 Empty Program

412 RS-232 Unexpected

End of Input

ALARMS

S code has not been encountered. Add an S code.

An attempt was made to use a control feature not enabled by a parameter bit. Set the parameter bit to 1.

Same as 336.

Rigid Tapping can only be in the Z minus G74 or G84 direction.

Make sure that the distance from the initial position to the commanded Z depth is in the minus direction.

Same as 316.

A rotary axis must be specified in order to perform cylindrical mapping

(G107).

The rotary axis specified is not a valid axis, or has been disabled.

This alarm is generated if a G-code block specifies any form of interpolated motion that involves BOTH one or more of the regular axes (X, Y, Z, A, B, etc…) AND one or more of the auxiliary axes (C, U, V, W).

Aux. axis servo shut off due to a fault.

Cannot have more than 200 programs in memory.

Need name in programs when receiving ALL; otherwise has no way to store them.

Check files being loaded. Program name must be Onnnn and must be at beginning of a block.

A receive found bad data. Check your program. The program will be stored but the bad data is turned into a comment.

Check your program. The program will be stored but the bad data is turned into a comment.

Check your program. The program will be stored but the bad data is turned into a comment.

Bad Parameter or Setting data. User was loading settings or parameters and something was wrong with the data.

Bad parameter or setting data. User was loading settings or parameters and something was wrong with the data.

Check your program. Between % and % there was no program found.

Check Your Program. An ASCII EOF code was found in the input data before program receive was complete. This is a decimal code 26.

96-8100

49

50

ALARMS

413 RS-232 Load

414

415

416

417

Insufficient Memory

RS-232 Buffer Overflow

RS-232 Overrun

RS-232 Parity Error

RS-232 Framing Error

418 RS-232 Break

419 Invalid Function

For DNC

420 Program Number

Mismatch

429 Flpy Dir Insufficient

Memory

430 Floppy Unexpected

End of Input

431 Floppy No Prog

Name

432 Floppy Illegal Prog

Name

433 Floppy Empty Prog

Name

434 Floppy Load Insufficient

Memory

435 Floppy Abort

436 Floppy File Not Found

501 Too Many Assignments

In One Block

502 [ Or = Not First Term

In Expressn

Program received doesn’t fit. Check the space available in the LIST PROG mode and possibly delete some programs.

Data sent too fast to CNC. This alarm is not normally possible as this control can keep up with even 38400 bits per second.

Data sent too fast to CNC. This alarm is not normally possible as this control can keep up with as much as 38400 bits per second.

Data received by CNC has bad parity. Check parity settings, number of data bits and speed. Also check your wiring.

Data received was garbled and proper framing bits were not found. One or more characters of the data will be lost. Check parity settings, number of data bits and speed.

Break condition while receiving. The sending device set the line to a break condition. This might also be caused by a simple break in the cable.

A code found on input of a DNC program could not be interpreted.

The O code in the program being loaded did not match the O code entered at the keyboard. Warning only.

Floppy memory was almost full when an attempt was made to read the floppy directory.

Check your program. An ASCII EOF code was found in the input data before program receive was complete. This is a decimal code 26.

Need name in programs when receiving ALL; otherwise has no way to store them.

Check files being loaded. Program must be Onnnn and must be at the beginning of a block.

Check your program. Between % and % there was no program found.

Program received doesn’t fit. Check the space available in the LIST

PROG mode and possibly delete some programs.

Could not read disk.

Could not find floppy file.

Only one assignment “=” is allowed per block. Divide block in error into multiple blocks.

An expression element was found where it was not preceded by “[“ or

“=”, that start expressions.

June 1998

96-8100

June 1998

503 Illegal Macro Variable

Reference

504 Unbalanced Paren. In

Expression

505 Value Stack Error

506 Operand Stack Error

507 Too Few Operands On

Stack

508 Division By Zero

509 Illegal Macro

Variable Use

510 Illegal Operator or

Function Use

511 Unbalanced Right

Brackets

512 Illegal Assignment Use

513 Var. Ref. Not Allowed

With N Or O

514 Illegal Macro Address

Reference

515 Too Many Conditionals

In a Block

516 Illegal Conditional

Or No Then

517 Exprsn. Not Allowed

With N Or O

518 Illegal Macro Exprsn

Reference

519 Term Expected

520 Operator Expected

521 Illegal Functional

Parameter

ALARMS

A macro variable number was used that is not supported by this control, use another variable.

Unbalanced brackets, “[“ or “]”, were found in an expression. Add or delete a bracket.

The macro expression value stack pointer is in error. Call your dealer.

The macro expression operand stack pointer is in error. Call your dealer.

An expression operand found too few operands on the expression stack.

Call your dealer.

A division in a macro expression attempted to divide by zero.

Re-configure expression.

See «Macros» section for valid variables.

See «Macros» section for valid operators.

Number of right brackets not equal to the number of left brackets.

Attempted to write to a read-only macro variable.

Alphabetic addresses N and O cannot be combined with macro variables.

Do not declare N#1, etc.

A macro variable was used incorrectly with an alpha address. Same as

513.

Only one conditional expression is allowed in any WHILE or IF-THEN block.

A conditional expression was found outside of an IF-THEN, WHILE, or M99 block.

A macro expression cannot be concatenated to N or O. Do not declare

O[#1], etc.

An alpha address with expression, such as A[#1+#2], evaluated incorrectly. Same as 517.

In the evaluation of a macro expression an operand was expected and not found.

In the evaluation of a macro expression an operator was expected and not found.

An illegal value was passed to a function, such as SQRT[ or ASIN[.

96-8100

51

52

ALARMS

522 Illegal Assignment

Var Or Value

523 Conditional Reqd

Prior To THEN

524 END Found With No

Matching DO

525 Var. Ref. Illegal

During Movement

526 Command Found On

DO/END Line

527 = Not Expected Or

THEN Required

528 Parameter Precedes

G65

529 Illegal G65 Parameter

530 Too Many I, J, or K’s

In G65

531 Macro Nesting Too

Deep

532 Unknown Code In

Pocket Pattern

533 Macro Variable

Undefined

534 DO Or END Already

In Use

535 Illegal DPRNT

Statement

536 Command Found On

DPRNT Line

537 RS-232 Abort

On DPRNT

538 Matching END Not

Found

539 Illegal Goto

A variable was referenced for writing. The variable referenced is read only.

THEN was encountered and a conditional statement was not processed in the same block.

An END was encountered without encountering a previous matching

DO. DO-END numbers must agree.

Variable cannot be read during axis movement.

A G-code command was found on a WHILE-DO or END macro block.

Move the G-code to a separate block.

Only one Assignment is allowed per block, or a THEN statement is missing.

On G65 lines all parameters must follow the G65 G-code. Place parameters after G65.

The addresses G, L, N, O, and P cannot be used to pass parameters.

Only 10 occurrences of I, J, or K can occur in a G65 subroutine call.

Reduce the I, J, or K count.

Only four levels of macro nesting can occur. Reduce the amount of nested G65 calls.

Macro syntax is not allowed in a pocket pattern subroutine.

A conditional expression evaluated to an UNDEFINED value, i.e. #0.

Return True or False.

Multiple use of a DO that has not been closed by and END in the same subroutine. Use another DO number.

A DPRNT statement has been formatted improperly, or DPRNT does not begin block.

A G-code was included on a DPRNT block. Make two separate blocks.

While a DPRNT statement was executing, the RS-232 communications failed.

A WHILE-DO statement does not contain a matching END statement.

Add the proper END statement.

Expression after «GOTO» not valid.

June 1998

96-8100

June 1998

ALARMS

540 Macro Syntax

Not Allowed

613 Command Not Allowed

In Cutter Comp.

A section of code was interpreted by the control where macro statement syntax is not permitted.

A command (M96, for example) in the highlighted block cannot be executed while cutter comp. is invoked.

End Of List

Note: Alarms 1000-1999 are user defined by macro programs.

1002 Unclamp Error The pallet did not unclamp in the amount of time allowed. This can be caused by a bad air solenoid, a blocked or cinked air line, or a mechanical problem.

1003 Clamp Error

1004 Mislocated Pallet @ APC

The pallet did not clamp in the amount of time allowed by the M50 macro. This alarm is most likely caused by the VMC table not being in the correct position. This can be adjusted using the macro variables for the X position (#500, 504) as described in the «Installation» section. If the pallet is in the correct position but not clamped, push the pallet against the hard stop and run an M18.

If the pallet is clamped, but not correctly, run an M17 to unclamp, push the pallet to the correct position, and run an M18 to clamp the pallet.

Less common causes could be that the slip clutch is slipping, the motor is at fault, an air solenoid is bad, or an air line is blocked or kinked.

A pallet is not in the proper place on the APC. The pallet must be pushed back against the hard stop by hand.

1005 Pal No Conflict Rec & Ch (Pallet Number Conflict Receiver and Pallet Changer)

The incorrect pallet number is entered in macro variable #510. Run an

M50 to reset this variable.

1006 Switch Missed Pal 1 Pallet #1 did not return from the receiver to the APC in the allowable amount of time. This can be caused by the chain switch block missing the limit switch, or from another mechanical problem, such as clutch slippage.

1007 Switch Missed Pal 2

1008 Door Not Open

Pallet #2 did not return from the receiver to the APC in the allowable amount of time. This can be caused by the chain switch block missing the limit switch, or another mechanical problem, such as clutch slip page.

The automatic door did not open (in the allowable time) when necessary to perform an APC function. This can be caused by a bad air solenoid, a blocked or kinked air line, or a mechanical problem.

1009 Door Not Closed The automatic door did not close (in the allowable time) when necessary after an APC function has been performed. This can be caused by a bad air solenoid, a blocked or kinked air line, or a mechanical problem.

96-8100

53

54

ALARMS

1010 Missing Pallet @ Receiver Pallet change sequence was halted because receiver switch was not activated. Pallet is either unclamped or not on the receiver. Ensure the pallet is correctly located on receiver (against hardstop) then run M18 to clamp the pallet.

1011 Unknown Chain Location Neither Chain Location switch is tripped, so the control cannot locate the chain position. This can occur if a pallet change is interrupted for any reason, such as an alarm or an E-STOP. To correct this problem, the pallets and chain must be moved back into a recognized position, such as both pallets home or one pallet home and one on the receiver. The chain position adjustment tool must be used to rotate the chain into position. The pallets must be pushed into place by hand.

WARNING! Do not move the limit switches for any reason.

June 1998

CAUTION! The pallets weigh 300 lbs. each, and can cause serious injury. Use extreme

caution when moving them.

1012 Incorrect Chain Location Chain not in position to load or unload pallets when necessary. To correct this, the mislocated pallet must be moved back into the proper position by hand.

CAUTION! The pallets weigh 300 lbs. each, and can cause serious injury. Use extreme caution when moving them.

96-8100

January 1998

MECHANICAL SERVICE

MECHANICAL SERVICE

RECOMMENDED TORQUE VALUES FOR MACHINE FASTENERS

The following chart should be used as a reference guide for torquing machine fasteners where specified.

DIAMETER

1/4 — 20

5/16 — 18

3/8 — 16

M10 — 100

M12 — 65

1/2 — 13

3/4 — 10

1 — 8

TORQUE

15 ft. lb.

30 ft. lb.

50 ft. lb.*

50 ft. lb.

100 ft. lb.

80 ft. lb.

275 ft. lb.

450 ft. lb.

* 3/8-16 SHCS used on tool release piston torqued to 35 ft. lb.

1. HEAD COVERS REMOVAL / INSTALLATION

Please read this section in its entirety before attempting to remove or replace covers.

REMOVAL —

Note: This procedure is for the VF-3/4. However, the procedure varies only slightly for other models.

1. Power on the Vertical Machining Center (VMC).

2. Zero return (ZERO RET) all axes, then HANDLE JOG to center X- and Y-axes under spindle.

3. Protect table surface with a piece of cardboard.

4. Loosen the four SHCS that attach top cover to side covers, and remove.

5. Loosen the six SHCS that attach rear cover to side covers, and remove.

6. Loosen the eight SHCS that attach front cover to side covers, then carefully remove front cover from the bottom until you can disconnect the tool release cable (quick disconnect).

7. Loosen the seven SHCS that attach each side cover, and remove from the top side. Jog Z-axis as necessary to make screw removal easier.

CAUTION! Be careful not to run head covers into the enclosure.

96-8100

5 5

MECHANICAL SERVICE

January 1998

5 6

Figure 1-1. View of VF-3/4 head covers.

INSTALLATION —

1. Protect table surface with a piece of cardboard.

2. Replace each side cover from the top side with seven SHCS. Jog Z-axis as necessary to make access to screws easier.

CAUTION! Be careful not to run the head covers into the enclosure.

3. Reconnect tool release cable, if equipped, then replace front cover from the bottom and attach with eight

SHCS.

4. Replace rear cover, and attach to side covers with six SHCS.

5. Replace top cover, and attach to side covers with four SHCS.

96-8100

January 1998

MECHANICAL SERVICE

2. TOOL RELEASE PISTON (TRP) ASSEMBLY

Please read this section in its entirety before attempting to replace tool release piston assembly.

2.1 TRP R

EMOVAL

Note: This procedure applies to machines with 40 taper spindles only. Refer to the following sections for 50 taper TRP replacement instructions.

1. If machine is equipped with Through the Spindle Coolant (TSC), place a tool holder in the spindle.

2. Remove cover panels from the headstock area in accordance with «Head Covers Removal and Installation».

3. Remove the four 3/8-16 x 1¾» SHCS holding the tool release piston assembly to the head casting.

4. Disconnect the air line at the lube/air panel.

5. Disconnect the clamp/unclamp cables (quick disconnect) and the assembly’s solenoid wiring located on the solenoid bracket.

6. Remove the tool release air hose and precharge hose at the fitting shown in Fig. 2-1. If machine is equipped with TSC, also remove the coolant hose (wrench required).

7. Remove entire tool release piston assembly.

Note: Steps 8 and 9 apply only to machines with TSC.

8. Remove the drain and purge lines from the seal housing.

9. Remove the seal housing from the TRP.

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Figure 2-1. Tool Release Piston with Optional TSC fitting.

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MECHANICAL SERVICE

January 1998

5 8

Figure 2-2. Mounting location for tool release piston assembly

2.2 TRP I

NSTALLATION

1. Ensure drive belt has been properly replaced as described in «Belt Assembly» section.

2. Verify spindle sweep adjustment is correct (as shown in «Spindle Assembly» section) before proceeding.

If not correct, re-shim as necessary.

3. Reinstall tool release piston assembly loosely if the machine is equipped with TSC. Otherwise tighten the four mounting bolts securely.

4. Reconnect the air hoses at the applicable fittings on the tool release piston assembly.

5. Reconnect the clamp/unclamp cables to the sides of the solenoid bracket.

Note: Steps 7 and 8 apply only to machines with TSC.

6. Connect the 5/32″ drain line and 5/32″ purge line to the seal housing and install the seal housing on the

TRP (use Loctite on the screws). The drain line connector should point toward the rear of the machine.

Note: The drain line must run straight through the cable clamp guide on the transmission, and must not interfere with the pulley or belts. On VF-O/OE machines, the drain line must go straight down through the cable clamp on the bracket.

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MECHANICAL SERVICE

7. Apply precharge pressure several times to allow the seal to center itself with the drawbar. While holding down precharge, tighten the bolts.

8. Install the coolant hose. A wrench must be used, tighten snug. Do not overtighten!!

9. Adjust the clamp/unclamp switches in accordance with the appropriate section.

10. Replace the head covers.

2.3 S

ETTING

P

RE

-C

HARGE

Note: This procedure does not apply to machines equipped with a 50 taper spindle.

Note: Do not perform this procedure on machines equipped with Through the Spindle

Coolant (TSC). It will damage the machine. Refer to the «Precharge Regulator Adjustment» section (section 16.1) and perform those adjustments.

1. Remove the cover panels in accordance with «Head Covers Removal and Installation». It will not be necessary to remove the rear or left side panels for this operation.

2. Turn the air pressure regulator down to zero (0). The knob must be pulled out to unlock before adjusting.

Note: At «0» pressure on the pre-charge regulator, the adjustment knob is out as far as it will turn.

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Figure 2-3. Air pressure regulator adjustment knob.

3. Ensure Parameter 149, PRE-CHARGE DELAY, is set to 300. If not, set it at this time.

4. Execute a tool change. A banging noise will be heard as the tool release piston contacts the drawbar.

5. Turn the air pressure regulator ½ turn in. Execute a tool change and listen for the noise described previously. If it is heard, repeat this step until no noise is heard. There should be no noise with or without a tool in the spindle.

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MECHANICAL SERVICE

CAUTION! Only increase the pressure to the point where tool changes become obviously quiet. Any further pressure increases are not beneficial. Excessive pressure to the pre-charge system will cause damage to the tool changer and tooling in the machine.

January 1998

2.4 TRP R

EMOVAL

— 50 T

APER

1. For TSC equipped machines, place a tool holder in the spindle.

2. Remove cover panels from the headstock area in accordance with «Head Covers Removal and Installation».

3. For TSC equipped machines the rotary union and extension tube must be removed before proceeding. They

both have left handed threads.

4. Disconnect the air line at the lube/air panel.

5. Disconnect the clamp/unclamp cables (quick disconnect) and the assembly’s solenoid wiring located on the solenoid bracket.

6. Remove the three tool release air hoses.

7. Remove the four shoulder screws holding the tool release piston assembly to the head casting. Make sure to keep all the washers and shims.

8. Remove entire tool release piston assembly, by sliding it forward then lifting it upward. The assembly is heavy so use great care when removing it.

2.5 TRP I

NSTALLATION

— 50 T

APER

6 0

Figure 2-4. Shim and spacer location diagram.

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January 1998

1. Install Nominal Shims in Fork and on TRP Spacers.

Fork:

Part No.

(45-0014)

(45-0015)

TRP Spacers: (45-0019)

(45-0017)

(45-0018)

Description

0.010 Shim Washer

0.018 Shim Washer

0.093 Nylon Washer

0.010 Shim Washer

0.015 Shim Washer

30-0013A (NEW)

1 ea.

7 ea.

(Note: TRP Spacers: the nylon washer goes on top of the shims.)

2. Installation is the reverse order of removal.

3. Set the main air regulator to 85 psi.

1 ea.

2 ea.

3 ea.

MECHANICAL SERVICE

30-0013 (OLD STYLE)

None

5 ea.

1 ea.

2 ea.

2 ea.

Note: The following two steps must be completed.

2.6 T

OOL

P

USH

O

UT

A

DJUSTMENT

1. Put tool holder in spindle.

2. Place machined aluminim block onto machine table. Place a clean sheet of paper under the block to protect the table.

Figure 2-5. Pushout Adjustment.

3. Jog Z-Axis down until tool holder is about 0.030 above the aluminum block. Switch to 0.001

increments. Jog down one increment at a time until no movement can be felt in the block. This is our zero point. Do not press the tool release button now, this can cause a Z-Axis overload!!

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January 1998

6 2

Figure 2-6. Fork shim location.

4. The Tool Push-out adjustment is 0.060 +/-0.010. Add or remove shims from the tool release fork to make adjustments. The shims come in 0.010 and 0.018 thicknesses.

Jog upward 0.060. Press and hold the tool release button, and feel for movement in the aluminum block.

— If the block is tight when the button is pressed, shims may have to be ADDED to the tool release fork.

— If the block is loose when the button is pressed, shims may have to be REMOVED from the tool release fork.

(This is the opposite of 40 taper adjustment.)

— If the alumimum block is tight at 0.060, release the button and jog the Z-Axis up 0.001 and press the tool release button again. Feel for movement in the aluminum block. Repeat this until movement is felt. Note the last position where the block was tight. If the position is 0.070

or more, add shims to the tool release fork.

— If the aluminum block is loose at 0.060, jog the Z-Axis downward 0.001 at a time and check for movement in the aluminum block. If the the position where the block becomes tight is 0.050

or less, remove shims from the tool release fork.

5. If shims were added to the TRP fork, add half that amount to the TRP spacers supporting the

TRP. This will keep the two clearance gaps between the TRP and the rotating Spindle equal (approximately 0.095 each). If shims were removed from the TRP fork, remove half that number of shims from the TRP spacers.

6. Apply red grease to the shoulder bolts used to mount the TRP when the shim adjustments are complete. Use blue Loctite on the threads.

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MECHANICAL SERVICE

2.7 S

ETTING

TRP S

WITCHES

Figure 2-7. TRP shim location

Figure 2-8. Tool Clamp / Unclamp Switches.

1. Setting the upper switch (Tool Clamped). Push the switch in slowly until it trips, then push it a little farther. Lock down the screws. Double-Check the switch by turning on the TRP a few times. The bit in the Diagnostics Page should always turn on (1) when the TRP is completely retracted.

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MECHANICAL SERVICE

2. Setting the lower switch (Tool Unclamped). Use the air pressure regulator on the back of the machine or an extra regulator placed in line.

a) Jog the Z-Axis to 0.030 above the aluminum block.

b) Put a jumper across the air switch to prevent a low pressure alarm.

c) Back off the air pressure to around 65 psi (75 psi for old style TRP’s).

d) Press the tool release and check for movement in the aluminum block. Adjust the air pressure until the block is loose at 0.030 +/-0.005.

e) While holding the Tool Release Button push the switch in until it just trips (the bit on the

Diagnostics Page should change to “1”). Lock down the screws. Double-check the switch by turning the TRP on and off a few times.

f) Back off the air pressure until the block is loose at 0.020 +/-0.005. Press the tool release button, the Tool Unclamped bit in Diagnostics should remain “0”. If not, repeat the above steps.

January 1998

3. BELT ASSEMBLY

Please read this section in its entirety before attempting to replace the drive belt.

3.1 B

ELT

R

EMOVAL

Note: FOR EASIER REMOVAL, PLACE TRANSMISSION IN HIGH GEAR BEFORE

BEGINNING.

1. Remove cover panels from headstock area in accordance with «Head Covers Removal and Installation».

6 4

Figure 3-1. Spindle head casting disconnect points.

2. Remove tool release piston assembly in accordance with «Tool Release Piston Assembly Removal».

3. For all VMC’s except VF-0, remove the six SHCS holding the transmission to the head casting and pull the transmission forward enough (½» to ¾» max.) to allow the drive belt to be pulled upward over the spindle pulley.

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MECHANICAL SERVICE

4. For the VF-0, remove the four SHCS holding the mounting plate to the spindle head casting. Slide the assembly forward enough to allow the drive belt to be pulled up over the spindle pulley.

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Figure 3-2. Head casting area showing belt location.

5. Remove the inspection cover from the bottom of the spindle head casting and carefully slide the drive belt between the sump tank and the web in the casting.

6. First, pull the belt up over the spindle pulley, then push the other end down to clear the shifter and pull out.

Note: DO NOT bend or kink the belt in any way; damage to the fibers in the belt may result, and the belt will fail soon after installation.

3.2 B

ELT

I

NSTALLATION

1. For all VMC’s except VF-0, slide the replacement belt(s) under the sump tank and onto the pulley.

Note: DO NOT wrap the belts over the pulley. The pulley can be rather sharp, and may cut the belts. DO NOT bend or kink the belt in any way; damage to the fibers in the belt may result, and the belt will fail soon after installation.

2. Ensuring the belt is properly seated, push the transmission back, tightening the belt. Pull belt forward from rear of head casting. Pull belt over spindle pulley.

3. Tighten the drive belt in accordance with the following section.

4. Set the spindle orientation in accordance with appropriate section.

Note: The following step is necessary only if the spindle or transmission was exchanged prior to belt replacement.

5. Double-check the spindle sweep to assure that nothing has moved during the previous steps. If sweep is

6 5

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MECHANICAL SERVICE

within tolerance, continue; if not, sweep must be readjusted.

January 1998

Note: Drive belt tension must be adjusted after every installation.

3.3 T

ENSION

A

DJUSTMENT

Note: The drive belt’s tension should be adjusted after every service on the transmission or spindle of the machine.

1. Turn the machine ON. Jog the spindle head down to a level that will allow you to work on the drive belt comfortably.

2. Remove the cover panels from the head stock area as shown in «Head Covers Removal» section.

3. Remove the tool release piston assembly in accordance with appropriate section.

FOR THE VF-1 THROUGH 9

4. Loosen the six SHCS holding the transmission to the spindle head casting.

Note: Ensure the transmission is broken free by moving it slightly by hand.

5. Set the belt tension tool in place as shown in Figure 3-3. Mount it to the head casting by inserting the two SHCS into the two front TRP mounting holes. Tighten the SHCS finger tight.

6. Turn the handle until the tool is flat against the transmission casting.

Note: Ensure the transmission is straight, and not cocked, before tensioning belt.

7. Turn the handle until the edge of the tool’s plunger and the outer tube are flush (see Figure 3-3). This will set the belt at the proper tension.

Note: A belt that is correctly tensioned will whine slightly, and requires approximately 12 hours of break-in time.

8. Check if the belt is too loose or too tight. If the belt is set too tight, the belt will whine excessively when the assembly is at speed; and if it is set too loose, it will vibrate during accelerations and decelerations.

9. With the tool still in place, tighten the six SHCS holding the transmission to the spindle head casting.

10. Loosen the two SHCS and remove the belt tension tool.

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MECHANICAL SERVICE

96-8100

Figure 3-3. Belt tension tool.

FOR THE VF-0:

4. Loosen the four SHCS holding the motor mounting plate to the head casting.

Note: Ensure the motor is broken free by moving it slightly by hand.

5. Set the belt tension tool in place as shown in Figure 3-3. Mount it to the head casting by inserting the two SHCS into the two front TRP mounting holes. Tighten the SHCS finger tight.

6. Turn the handle until the tool is flat against the motor mounting plate.

Note: Ensure the motor is straight, and not cocked, before tensioning belt.

7. Turn the handle until the edge of the tool’s plunger and the outer tube are flush (see Figure 3-3), and then

1/2 turn more. This will set the belt at the proper tension.

Note: A belt that is correctly tensioned will whine slightly, and requires approximately 12 hours of break-in time.

8. Check if the belt is too loose or too tight. If the belt is set too tight, the belt will whine excessively when the assembly is at speed; and if it is set too loose, it will vibrate during accelerations and decelerations.

9. With the tool still in place, tighten the four SHCS holding the mounting plate to the head casting.

10. Loosen the two SHCS and remove the belt tension tool.

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MECHANICAL SERVICE

January 1998

4. SPINDLE ASSEMBLY

Please read this section in its entirety before attempting to replace spindle.

IMPORTANT! The current pulley is shrink-fitted onto the spindle and is not field-serviceable.

It is identified by two threaded holes on top of the spindle pulley. Should any attempt to remove the pulley damage the spindle or its components, the service warranty will be voided.

Note: The drive belt’s tension should be adjusted after every service on the transmission or spindle of the machine.

4.1 S

PINDLE

C

ARTRIDGE

R

EMOVAL

1. Ensure the VMC is ON. You will need to raise and lower the head stock to remove the spindle. Place the cardboard on the mill table to protect the surface.

2. Remove cover panels from head stock area as described in «Head Covers Removal» section.

3. Remove the tool release piston assembly in accordance with appropriate section.

4. Remove the spindle drive belt from the spindle pulley as shown in previous section. It is not possible to completely remove the belt at this time.

5. First disconnect the oil line from the fitting at the oil injection cover, then remove the brass fitting.

Note: When replacing a new design spindle in any vertical machine, it is important to note that the cavity between the housing and the spindle cartridge will be filled with either oil or grease. An oil filled spindle is identified by the oil fill hole to the left side of the spindle head near the spindle bore as viewed from the top.

6. Ensure oil plug is inserted into oil injection port of spindle before removing spindle or oil may spill into the spindle cartridge.

7. With the 5/16″ hex wrench, loosen approximately two turns the six SHCS holding the spindle to the underside of the head casting.

8. Place the block of wood (minimum 6″ thick) on the table directly under the spindle.

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MECHANICAL SERVICE

Figure 4-1. Position wood block under spindle.

9. At the panel, go to the JOG mode and choose Z-axis. Slowly jog in the negative (-) direction until the spindle rests on the block, then remove the screws that were previously loosened (step 7).

10. Jog Z-axis in the positive (+) direction until spindle is half way out of the head casting.

11. Grasp spindle with one hand and continue to jog in Z in the positive (+) direction until it is completely free of the casting.

4.2 S

PINDLE

C

ARTRIDGE

I

NSTALLATION

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Figure 4-2. Spindle cartridge.

1. Thoroughly clean all mating surfaces of both the cartridge and the head casting, lightly stone if necessary

6 9

MECHANICAL SERVICE

January 1998

to remove burrs or high spots.

2. Place spindle on wood block making sure both spindle dogs contact the block. Align the two 10-32 holes located on the spindle lock so they are approximately 90 degrees from the front of the spindle on the right side.

7 0

Figure 4-3. Underside view of spindle cartridge.

3. Slowly jog the Z-axis in the negative (-) direction until the top portion of spindle is inside of head casting.

At this point, align spindle to spindle bore. While performing this operation, you must make sure the spindle cartridge is straight to the spindle bore.

4. If the spindle moves to one side, use a rubber mallet and/or jog in the X or Y directions to straighten it.

The spindle must go in easy. If it does not, check your alignment. Do not force it!

5. Install the six SHCS and tighten down completely.

6. Reattach the brass fitting to the oil injection cover and connect the oil line to the fitting. CAUTION! Do not overtighten the fittings when replacing on the oil injection cover. Overtightening may result in damage to the spindle cartridge.

Note: If replacing copper tubing to spindle, thoroughly clean out with filtered air.

7. Fill the cavity between the housing and the spindle cartridge with oil. The oil fill hole is to the left side of the spindle head near the spindle bore, as viewed from the top. WARNING! Never pour oil into the spindle housing.

8. Reinstall the drive belt and adjust the tension as needed.

9. Reinstall the tool release piston assembly.

10. Check the spindle sweep, as described later in this section. Check the clamp/unclamp switch adjustment.

Note: Refer to the appropriate sections and check the spindle orientation and ATC alignment.

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January 1998

MECHANICAL SERVICE

4.3 D

RAWBAR

R

EPLACEMENT

REMOVAL —

1. Place a tool holder with no cutter in the spindle.

2. Remove head cover panels as shown in «Head Covers Removal’.

3. Remove the tool release piston in accordance with appropriate section.

4. Remove the snap ring from the top of the spindle shaft.

5. Reinstall the tool release piston.

6. Remove the tool holder from the spindle.

7. Remove the spindle, as described earlier in this section.

8. Remove the drawbar from the spindle assembly.

INSTALLATION —

9. Thoroughly coat the replacement drawbar with grease, including the end of the shaft where the four holding balls are located.

10. If machine is equipped with Through the Spindle Coolant option, grease the O-rings.

11. Insert four new balls in the replacement drawbar and insert into the spindle shaft. Be sure that as the shaft is installed, the balls do not fall out of the bores in the drawbar.

CAUTION! Insert the drawbar gently so the O-rings are not damaged. DO NOT use a hammer to force it.

Note: Carefully inspect the spindle shaft for galling or burrs inside the spindle shaft where the end of the drawbar rides. If it is damaged, the spindle must be replaced.

12. Refer to appropriate section, and install the spindle cartridge. The tool release piston will have to be reinstalled at this time.

13. Install a tool holder with no cutter into the spindle taper.

14. Remove the tool release piston.

15. Install the snap ring on the spindle shaft.

16. Reinstall the tool release piston.

17. Finish installation of the spindle, beginning with «Spindle sweep adjustment».

18. Set the drawbar height, and clamp and unclamp switches as described in the following section.

CAUTION! Step 19 must be followed or damage to the ATC will result.

19. Refer to «Spindle Orientation» and set the spindle orientation.

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January 1998

20. Reinstall the head covers.

21. Test-run the machine and perform the necessary ATC adjustments in the «Automatic Tool Changer» section.

4.4 S

PINDLE

S

WEEP

A

DJUSTMENT

Note: The machine must be properly leveled for the spindle sweep adjustment to be accurate.

1. To check spindle sweep, place a .0005 indicator on a suitable holder, place on spindle nose and jog the

Z-axis in the negative (-) direction enough so that you can adjust the indicator to sweep a 5″ radius from the center of X and Y axes’ travels. Slowly jog Z-axis in the negative (-) direction to zero out indicator.

2. Establish reference zero at rear of the table. Sweep the three remaining points (left, front, and right) and record the reading.

7 2

Figure 4-4. Spindle sweep area.

3. Shim the spindle if necessary to correct the spindle sweep to specifications.

4. Recheck sweep. It must be within .0005 in both X/Z and Y/Z planes, as stated in the inspection report supplied with the VMC.

5. Replace the Tool Release Piston Assembly in accordance with the «Tool Release Piston Assembly

Installation» and «Setting Pre-Charge» sections.

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MECHANICAL SERVICE

5. TOOL CLAMP/UNCLAMP SWITCH ADJUSTMENT

Please read this section in its entirety before adjusting clamp/unclamp switches or setting drawbar height.

TOOLS REQUIRED

ü

ü

ü

Machined aluminum block (2″ x 4″ x 4″)

6″ flexible ruler or .020″ shim

1″ diameter pipe (approx. 1′ long)

Note: If machine is equipped with a 50 Taper spindle, skip to Section 5.5.

5.1 T

OOL

C

LAMP

/U

NCLAMP

S

WITCH

A

DJUSTMENT

— I

NITIAL

P

REPARATION

1. Remove cover panels, as described in «Head Covers Removal».

2. Place a sheet of paper under the spindle for table protection, then place a machined block of aluminum

(approximately 2″ x 4″ x 4″) on the paper.

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Figure 5-1. Placement of aluminum block under spindle.

3. Power on the VMC.

4. Insert a tool holder WITHOUT ANY TYPE OF CUTTER into the spindle taper.

5. Go to the HANDLE JOG mode. Choose Z-axis and set jog increments to .01.

6. Jog Z-axis in the negative (-) direction until the tool holder is approximately .03 from the block. At this point, stop jogging the spindle and push the TOOL RELEASE button (top left). You will notice that the tool holder comes out of the taper.

Note: The clearance from the tool holder to the block should be zero (0).

7. To accomplish this, set the jog increments to .001 and jog in the negative (-) Z direction a few increments

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MECHANICAL SERVICE

January 1998

of the hand wheel at a time. Between these moves, push the tool release button and feel for movement by placing your finger between the tool holder and the spindle. Do this until no movement is felt. You are now at zero (0).

CAUTION! Do not jog too far in the negative (-) direction or else it will cause an overcurrent in the Z-axis.

5.2 S

ETTING

D

RAWBAR

H

EIGHT

1. Press MDI and turn hand wheel to zero (0).

2. Press HANDLE JOG button and set increments to .01. Jog the Z-axis in the positive (+) direction 0.100″.

3. Press and hold the TOOL RELEASE button, grasp the block and try to move it. The block should be tight at .100 and loose at .110. If block moves at .100, jog the Z-axis in the negative (-) direction one increment at a time. Press the TOOL RELEASE button and check for movement between increments until block is tight.

Note: The increments jogged in the Z negative (-) direction are the amount of shim washers that must be added to the tool release bolt (or coolant tip for TSC). Refer to

«Shim Washers» section.

4. If the block is tight at .110, move the Z-axis in the positive (+) direction one increment at a time. Press the TOOL RELEASE button and check movement between increments until block is loose.

The increments jogged in the Z positive (+) direction are the amount of shim washers that must be removed.

(Refer to «Shim Washers» section).

5.3 S

HIM

W

ASHERS

1. To add or subtract shim washers, remove tool release piston assembly («Tool Release Piston» section) from head casting.

Note: Shims may need to be added or removed when spindle cartridge, tool release piston assembly, or drawbar is replaced. If none have been replaced, skip this section.

7 4

Figure 5-2. Tool release piston assembly (TSC shown).

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January 1998

MECHANICAL SERVICE

2. Remove tool release bolt. If machine is equipped with TSC, loosen the three set screws and remove the

TSC coolant tip.

3. Add or subtract required shim washers (See previous section for correct amount to add or remove).

4. Before installing tool release bolt, put a drop of serviceable (blue) Loctite® on the threads and install. If replacing TSC coolant tip, put a drop of Loctite® on the threads of the three set screws before installing.

5. Install tool release piston assembly in accordance with the «Tool Release Piston — Installation» section and recheck settings. If within specifications, continue; if not, readjust.

5.4 A

DJUSTMENT OF

S

WITCHES

LOWER (UNCLAMP) SWITCH —

1. Push the PARAM/DGNOS button (top center) twice. You are now in diagnostics mode. Look at the bottom left corner of the page and you should see DB OPN 0 (tool unclamped) and directly under that, DB CLS 1 (tool clamped). If not, push PAGE DOWN until you do. A «1» means that particular switch is being tripped. A «0» means it is not being tripped.

2. With the tool holder resting on the block and set at zero («Setting Drawbar Height» section), jog Z-axis in the positive (+) direction .06.

3. Press the tool release button and hold it. DB OPN should change from a «0» to a «1». If it does not, slightly loosen the two ¼-20 x ½» SHCS holding the unclamp switch bracket (switch on right) to the tool release assembly.

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Figure 5-3. Tool release piston assembly.

4. While activating tool release, tap unclamp switch assembly towards spring retainer until it just trips.

Switch must trip at .060 +/- .010.

THIS ADJUSTMENT IS VERY IMPORTANT FOR PROPER TOOL CHANGER OPERATION, AND MUST

BE PROPERLY SET!

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MECHANICAL SERVICE

January 1998

5. Check the adjustment by setting the jog handle at .06 and activating the tool release. The DB OPN signal should be a «1».

If the adjustment is not correct, adjust until it is within specifications. You may have to readjust the switch several times.

UPPER (CLAMP) SWITCH —

CAUTION! Remove the tool holder from the spindle before performing the upper (CLAMP) switch adjustment. Failure to remove it could result in damage to the tool holder, the mill table, or cause severe personal injury.

6. Place a shim (approximately .020 thick), or the flexible ruler, between the tool release piston adjustment bolt and the drawbar.

7 6

Figure 5-4. Placement of shim before checking switch adjustment.

7. Move the tool release piston down so the shim is pressed against the drawbar. This can be done in one of the two following ways:

Ø Using the pipe as a lever, push down on the piston until it contacts the drawbar and the shim is held in place. For the VF-0: wedge a large, flat-tip screwdriver under the cooling fins of the motor and push the piston down.

IMPORTANT! Use extreme care when performing this procedure on TSC equipped machines, or the pipe fitting will break off the top of the TRP shaft.

Ø If machine is equipped with the «macros» option: set macro variable #1120 to 1. This will energize the pre-charge solenoid, bringing the TRP in contact with the drawbar (no prying is necessary). Press RESET to de-energize the solenoid.

8. While the tool release piston is down, move the switch bracket all the way in and check for «Tool Unclmp» status on the CRT (DB OPN=0, DB CLS=0), and tighten the bracket bolts. If not, move the switch out until

«Tool Unclmp» status appears on the CRT and then tighten the bolts.

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January 1998

MECHANICAL SERVICE

9. Check the switch several times. This is done by by moving the piston up and down to ensure that the «Tool

Unclmp» status appears when the piston makes contact with the shim and drawbar, and does not appear when it is in the retracted position. «Tool Unclmp» status appears on the CRT display as (DB OPN=0, DB CLS=0).

Figure 5-5. Push piston down to hold shim in place.

5.5 A

DJUSTMENT OF

S

WITCHES

— 50 T

APER

O

PTION

See section 2.5 TRP Installation — 50 Taper, Setting TRP Switches.

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MECHANICAL SERVICE

January 1998

6. SPINDLE ORIENTATION

Please read this section in its entirety before attempting to orient the spindle.

Note: If machine is equipped with a vector drive, skip to the next section.

6.1 O

RIENTATION

— S

PINDLE

D

RIVE WITH

S

HOT

P

IN

O

RIENTATION

1. Remove cover panels from the head stock area («Head Covers Removal»), and tool changer front cover.

2. In MDI mode, press the ORIENT SPINDLE button.

3. Loosen the four 1/4″-20 bolts on the orientation ring. Remove two of these bolts and insert them into the two threaded holes on the ring. Evenly tighten these two bolts until the taper lock is broken.

4. Remove the two 1/4″-20 bolts and place them into their original holes. Tighten them finger tight, then

1/2 of a turn more. Ensure that the orientation ring is snug, but not tight.

Note: If replacing the orientation ring, clean the shaft and the ring bore thoroughly with alcohol. They must be free of grease and oil.

5. Set up a magnetic base with a 0.0005″ indicator on the table. Zero the indicator on the spindle dog in the

X- plane.

6. Jog the indicator across the spindle dogs and note the indicator reading. The spindle dogs should be parallel to the X axis within 0.030″.

7 8

Figure 6-1. Top view of spindle orientation components.

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MECHANICAL SERVICE

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Figure 6-2. VF-0 motor with orient ring location.

7. There is a 0.015″-0.030″ backlash in the spindle system when it is oriented. Be certain to compensate for this backlash when performing the adjustment.

8. Using a 5/8″ open end wrench, rotate the spindle until the appropriate alignment is attained. If the spindle is very difficult to rotate, STOP and return to Step 4.

9. Disconnect the main air line to the machine.

10. Manually turn the orientation ring and push the shot pin until it drops into the orient ring detent.

11. Tighten the orient screws (evenly) to 15 ft-lbs. Verify that spindle alignment has not changed.

Note: It is vital that the orient screws be tightened evenly. If not, the top of the orientation ring will run out and the ring will slip.

Note: Ensure the orientation ring has an adequate layer of grease around the circumference before starting operation.

12. Make at least 50 tool changes to test the spindle orientation.

6.2 O

RIENTATION

— V

ECTOR

D

RIVE

1. Place the machine in low gear.

2. Adjust Parameter 257, «SPINDL ORIENT OFSET», until the spindle dogs are parallel to the X-axis. Ensure that the dogs are within 0.030″ using a dial indicator.

3. If the machine is equipped with a 50 taper spindle, add 5 degrees of offset (111 encoder steps) to

Parameter 257 to match the tool changer arm offset.

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MECHANICAL SERVICE

January 1998

7. SETTING PARAMETER 64 (TOOL CHANGE OFFSET)

Please read this section in its entirety before attempting to set Parameter 64.

Note: Setting 7 must be «unlocked» before setting Parameter 64.

1. WITHOUT a tool in the spindle taper, initiate a tool change and stop the tool changer using the

EMERGENCY STOP button (when the Z-axis moves above the carousel, but before the carousel rotates).

Insert a tool holder into the pocket facing the spindle.

2. Using a .0005 indicator and suitable 18″ mag base, zero off of bottom left edge “A” of tool holder (looking directly into pocket). Move indicator to bottom right edge “B” of tool holder. Any difference between these edges should be equally divided. For example: if a difference of .002 from left side to right side edge, adjust indicator dial so that indicator reads .001 when it is on either edge. This gives you the tool offset reference.

8 0

Figure 7-1. Checking tool offset reference.

3. Carefully (so as not to disturb relative position) move the indicator to one side. Remove tool from the tool changer and place it in the spindle.

4. Press Z SIGL AXIS to zero return the Z-axis only.

5. Carefully (so as not to disturb relative position) place indicator under spindle and indicate on bottom left edge of the tool holder.

If spindle head is too far in the negative (-) or the positive (+) direction, go to JOG mode and choose Z-axis.

Jog Z-axis in the necessary direction until it reads zero (0).

6. Push the help button twice. This will put the machine in the calculator mode.

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Figure 7-2. Screen showing calculator.

7. Take the number in the Z-axis machine display (center left of page) and multiply it by Parameter 33, which is Z RATIO (STEPS/UNIT).

If Z-axis work display is negative (-), add the number to the number that you calculated to Parameter 64. If the number is positive (+), subtract it from Parameter 64.

8. To insert the calculated new number, place the cursor at Parameter 64, type in new number and push

WRITE key. ZERO RET Z-axis to initialize the new Parameter 64.

9. Recheck the offset with the indicator (Steps 1-5).

10. Insert tool holder in spindle in spindle taper and initiate a tool change.

Note: When the Parameter 64 is changed, the tool offsets must be reset.

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MECHANICAL SERVICE

3.8 SPINDLE MOTOR & TRANSMISSION

Please read this section in its entirety before attempting to remove or replace transmission.

NOTE: The drive belt’s tension should be adjusted after every service on the transmission or spindle.

M

OTOR

R

EMOVAL

(VF-0)

1. Ensure the VMC is ON. You will need to raise and lower the head stock to remove the transmission. At this time, raise the Z-axis to the full up position.

2. Remove the cover panels from head stock area («Head Stock Removal» section).

3. Remove the tool release piston assembly («Tool Release Piston Assembly» section).

4. Press the POWER OFF button on the control panel and turn the main breaker off. If there is an external breaker box, turn it off and lock it out.

5. Disconnect the air supply from the back panel of the machine.

6. Disconnect all of the electrical and pneumatic lines from the solenoid bracket on top of the spindle motor assembly. Mark any connections that have not been previously labeled for reassembly.

7. Remove the two SHCS holding the cable carrier to the solenoid bracket and position the cable carrier so as to not interfere with removal of the motor. It may be necessary to tie the cable carrier back to the Z-axis motor to keep it in place.

8. If machine is equipped with Through the Spindle Coolant option, remove the pressure regulator and bracket from the old transmission and install them on the new transmission.

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82

Figure 3-26. VF-0 with lifting eyeholes.

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MECHANICAL SERVICE

9. Remove the four SHCS and carefully lift the spindle motor assembly off the spindle head. Take care to not damage the drive pulley during removal.

NOTE: It is recommended that the HAAS Transmission Hoist be used in this operation

(Refer to «Hoist Pre-Assembly», later in this section, for assembly and setup).

I

NSTALLATION

(VF-0)

1. Carefully lower the motor assembly down to just above the spindle head casting, taking care not to damage the drive pulley or pinch the drive belt.

2. Place the drive belt on the motor’s drive pulley and lower the motor down onto the spindle head casting.

3. Insert and tighten down the four SHCS attaching the motor to the spindle head casting. Adjust the drive belt as noted in «Belt Assembly» before tightening down completely.

4. Refer to the appropriate section and set the spindle orientation.

5. Check for proper orientation of the machine and be aware of any unusual noises or vibration that may occur because of incorrect belt tension.

6. Reattach the cable carrier to the solenoid bracket and reconnect all electrical and fluid lines. Replace any leaking or damaged lines at this time, if necessary.

NOTE: Ensure the orient ring has an adequate layer of grease around the circumference before starting operation.

H

OIST

P

RE

-A

SSEMBLY

1. Attach the mast support to the support base, using the four 3/8-16 x 1¼» SHCS, four 3/8″ flat washers, four split washers, and the four 3/8-16 hex nuts. Ensure the bolts are securely tightened.

2. Attach the boom modification plates to the mast using the three ½-13 x 4½» HHB, three ½» split washers, three ½-13 hex nuts, and the three spacers.

96-8100

Figure 3-27. Support base/mast support assembly.

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MECHANICAL SERVICE

June 1998

Figure 3-28. Exploded view of boom modification plate components.

3. Assemble the boom assembly as follows:

A. Lubricate the components of the assembly:

1) Using a grease brush, apply grease to the through-hole and the side surface of the pulley wheel.

2) Wipe a thin coat of oil on the entire cable.

3) Lubricate all clevis pins with a thin layer of grease.

4) Oil all bearings on the winch and apply grease to the gear teeth.

B. Place the pulley wheel inside the cable guide and place this subassembly into the end of the boom. Ensure the clevis pin through-hole is toward the top of the boom and the rounded end of the cable guide is toward the outside. Slide the clevis pin through the hole and fasten with the

1/8″ x 1″ cotter pin.

C. Attach the winch base to the boom with the two 3/8-16×1″ SHCS, two 3/8″ lock washers, and the two 3/8″ hex nuts. See owner’s manual for mounting for left-or right-handed operation.

D. Feed the free end of the cable (without hook) between the pulley and cable guide and through the inside of the boom.

84

Figure 3-29. Mounting cable guide and pulley wheel to boom.

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MECHANICAL SERVICE

E. Attach the cable to the winch as follows:

1) FOR LEFT-HAND OPERATION —

Pass the cable under the winch drum and through the hole in the drum flange.

Form a loop of cable and securely anchor it in place using the tie-down clasp, carriage bolt, and hex nut. The cable must be underwound on the winch drum.

2) FOR RIGHT-HAND OPERATION —

Pass the cable between the frame rod and the countershaft of the winch, over the winch drum, and through the hole in the drum flange. Form a loop of cable and securely anchor it in place using the tie-down clasp, carriage bolt, and hex nut.

The cable must be overwound on the winch drum.

F. Ensure all hex nuts and cap nuts are securely tightened and all cotter pins are properly bent to secure them in place. Make sure all pivots and rotation points are well-lubricated and refer to the winch owner’s manual for proper lubrication before operating.

4. Place the transmission lift fixture on top of the transmission, with the rod at each end in the two lifting eyeholes of the transmission. Tighten the fixture onto the transmission by turning the handle at the end. Do

not overtighten.

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Figure 3-30. View of transmission lift fixture.

T

RANSMISSION

R

EMOVAL

NOTE: This procedure is not for VF-O.

1. Ensure the VMC is ON. You will need to raise and lower the head stock to remove the transmission. At this time, raise the Z-axis to the full up position.

2. Remove the cover panels from head stock area («Head Covers Removal» section).

3. If machine is equipped with the Through the Spindle Coolant option, remove the pressure regulator, check valve assembly, and bracket from the old transmission, so they can be installed later on new transmission.

4. Remove the tool release piston assembly («Tool Release Piston» section).

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MECHANICAL SERVICE

5. Remove the six SHCS holding the transmission to the head casting. Slide the transmission forward enough to release the drive belt from the transmission and spindle pulleys.

6. Press the POWER OFF button on the control panel and turn the main breaker off. If there is an external breaker box, turn it off and lock it up.

7. Disconnect all electrical lines and air lines from the transmission solenoid bracket. Disconnect the electrical and oil lines from the oil pump. Plug the oil lines to prevent contamination. Most of the lines should be marked and identified. If not marked, do so as it is removed.

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86

Figure 3-31. Solenoid bracket with all lines connected.

8. Remove the two SHCS holding the cable carrier to the solenoid bracket and position the cable carrier so as to not interfere with the transmission removal. It may be necessary to tie the cable carrier back to the Zaxis motor to keep it in place.

9. Remove the protective cardboard from the mill table and install the support base assembly on the table, using the four SHCS, four ½» flat washers, and the four T-nuts.

CAUTION! Ensure the protective rubber pads on the bottom of the mounting base are in place and in good condition, or damage to the mill table may result.

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MECHANICAL SERVICE

Figure 3-32. Support base/mast support assembly location.

10. With the boom modification plate in place, insert the mast into the mast support. Using the two clevis pins, attach the boom to the mast.

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Figure 3-33. Mounting boom assembly to mast.

11. Place the hoist directly over the transmission and attach the hook to the cradle’s eye bolt.

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Figure 3-34. Fully assembled hoist in position

12. Raise the transmission, ensuring the hoist is being lifted in the locking position, clearing the enclosures.

Swing the boom toward the front of the machine and lower onto the wood blocks.

88

Figure 3-35. Lifting position for VF-1 through 4.

13. For VF-1-4: Place the hoist hook in the bar’s lifting eye and place the two hooks on either end of the bar into diagonally opposite lifting holes in the motor shroud. Lift just enough to ensure the hooks are seated properly, then carefully lift the motor and transmission assembly up enough to clear the VMC. Swing the boom toward the front of the machine and lower onto the wood blocks.

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MECHANICAL SERVICE

T

RANSMISSION

I

NSTALLATION

1. If machine is equipped with Through the Spindle Coolant option, reinstall the pressure regulator, check valve assembly, and bracket. Install two cable ties on the replacement transmission as follows:

Ø Place one cable tie around the limit switch cable.

Ø Place the second cable tie through the first one, forming a loop.

Ø Tighten the first cable tie. NOTE: The loop of the second cable tie must allow the drain line to slip through.

2. Place cradle under new transmission and lift just enough to put tension on the cables.

3. Ensure new transmission is seated securely and lift. Only lift high enough to clear the enclosure and to swing into place.

4. Slowly swing boom around to center the cradle and transmission over the spindle head.

NOTE: Inspect the gearbox isolators to ensure the spacer is flush with the bushing on the underside of the housing.

5. Lower the transmission carefully to just above the spindle head. Place the drive belt onto the transmission pulley.

6. Lower the transmission into the spindle head, taking care not to crush or bind the drive belt as you lower.

7. Insert and tighten down the six SHCS attaching the transmission to the spindle head. If these screws include gearbox isolators, ensure the 3/8″ fender washer is NOT touching the gearbox housing.

96-8100

Figure 3-36. Gearbox isolators.

Adjust the drive belt tension as noted in «Belt Assembly» section before tightening screws down completely.

8. Reattach the cable carrier to the solenoid bracket and reconnect all electrical and fluid lines. Replace any leaking lines at this time, if necessary.

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MECHANICAL SERVICE

NOTE: The hoist must be disassembled before removing from the mill table. Break down the hoist by removing the boom assembly, then the mast. It will not be necessary to completely break down the hoist after the first assembly.

NOTE: Ensure the positioning ring has an adequate layer of grease around the circumference before starting operation.

3.9 AXIS MOTOR REMOVAL / INSTALLATION

Please read this section in its entirety before attempting to remove or replace the motors.

ü

Z-Axis: Cylinder shaft stop (P/N 99-7562 — VF-0 through 4, P/N 93-9962 — VF-6 through 10)

X-A

XIS

M

OTOR

R

EMOVAL

1. Turn the VMC ON. ZERO RETURN all axes and put the machine in HANDLE JOG mode.

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90

Figure 3-37. X-axis motor and components.

2. Move the table to the far left position. Loosen the SHCS and remove the right way cover.

3. Move the table to the far right position. Loosen the SHCS and remove the left way cover.

4. Remove the side enclosure panels.

5. On the motor housing, remove the four BHCS and remove the cover plate.

6. Loosen the SHCS on the motor coupling at the lead screw.

7. Turn the machine power OFF.

8. On the motor housing, loosen the four SHCS and remove the motor from the housing.

9. Disconnect all wiring from the motor.

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MECHANICAL SERVICE

INSTALLATION —

1. Slide motor into motor housing, inserting the end of the lead screw in the motor coupling.

96-8100

Figure 3-38. Motor coupling components.

2. Reinstall and tighten down the four SHCS that hold the motor to the housing.

3. Visually inspect the coupler flex plates to ensure they are parallel to the coupling halves.

NOTE: The slot in the locking collar must be positioned 45 degrees between the bolt hole pattern of the coupler. If improperly aligned, the coupler will not have enough clamping force on the leadscrew or motor shaft.

Tighten the SHCS on the motor coupling at the lead screw. (Place a drop of blue Loctite® on the screw before inserting.)

4. Replace the cover plate and fasten with the four BHCS.

5. Move the table to the far right position. Replace the left way cover with the SHCS.

6. Move the table to the far left position. Replace the right way cover with the SHCS.

7. Reinstall the side enclosures.

8. Check for backlash in the X-axis lead screw (Troubleshooting section) or noisy operation.

Y-A

XIS

M

OTOR

R

EMOVAL

1. Turn the machine power ON. ZERO RETURN all axes and put the machine in HANDLE JOG mode.

2. Move the table to the farthest forward position. Using a 5/32″ hex wrench, remove the SHCS on the way cover at the rear of the saddle.

3. Slide the way cover back against the machine. Remove the two roller brackets from the base. Pull the way cover forward and off of the base.

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MECHANICAL SERVICE

4. If the bearings are to be serviced, move the table to the rear of its travel and remove the SHCS holding the front way covers to the saddle. Slide the way cover to the forward position.

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92

Figure 3-39. Y-axis motor and components.

REMOVING LUBE / AIR PANEL —

5. Turn the machine off and disconnect all air lines to panel.

6. Disconnect the spindle air/lube line.

7. Using a 3/8″ open-end hex wrench, disconnect the oil line connecting the base to the lubrication system panel.

8. Disconnect the two air lines from the panel (quick-disconnect fittings) by hand.

9. Disconnect the three connections labeled ‘limit switches’ and remove the cords from the panel.

10. Disconnect the limit switch connection and the Y-axis connection at the side of the control panel.

11. While holding the lube/air panel assembly at the bottom edge, loosen the two SHCS and remove the panel assembly.

CAUTION! On machines with only two SHCS, remove one screw at a time. Replace the screw to hold the cabinet in place before removing the other screw. Failure to do this will result in damage to the cabinet.

12. On the motor housing, remove the four and remove the cover plate.

13. Loosen the SHCS on the motor coupling at the lead screw.

14. On the motor housing, loosen the SHCS and remove the motor from the housing.

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MECHANICAL SERVICE

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Figure 3-40. Lube/Air Panel.

INSTALLATION —

1. Slide motor into motor housing, inserting the end of the lead screw in the motor coupling.

2. Replace and tighten down the four SHCS that hold the motor to the housing.

3. Visually inspect the flex plates to ensure they are parallel to the coupling halves.

NOTE: The slot in the locking collar must be positioned 45 degrees between the bolt hole pattern of the coupler. If improperly aligned, the coupler will not have enough clamping force on the leads screw or motor shaft.

Tighten the SHCS on the motor coupling at the lead screw. (Place a drop of blue Loctite® on the screw before inserting.)

4. Replace the cover plate and fasten with the four BHCS.

5. Replace the lube system panel with the two SHCS that mount it.

6. Plug in the limit switch connection and Y-axis connection at the side of the control panel.

7. Reconnect the three connections labeled «limit switches» to the panel.

8. Reconnect the two air lines to the panel, and the solenoid to the front of the panel.

9. Reconnect the oil line that connects the lube system panel to the base.

10. If the front way cover was removed, slide it back into position, and replace the SHCS that holds it to the

saddle.

11. Move the table to the fully forward position. Replace the rear way cover.

12. Replace the two roller brackets onto the base.

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MECHANICAL SERVICE

13. Slide the way cover back into place, and attach to the saddle with the SHCS.

14. Check for backlash in the Y-axis lead screw (Troubleshooting section) or noisy operation.

Z-A

XIS

M

OTOR

R

EMOVAL

CAUTION! ALWAYS BLOCK THE HYDRAULIC CYLINDER WITH SHAFT STOP BLOCK

BEFORE SERVICING ANY Z-AXIS COMPONENTS.

1. Turn the machine power ON. Zero return (ZERO RET) all axes and put the machine in HANDLE JOG mode.

2. Loosen the six SHCS that attach the rear cover to the side covers, and remove from the spindle head.

NOTE: If machine is equipped with a hydraulic counterbalance, remove entire spindle head cover for VF-0/OE/1/2, VCE 500/550/700/750, or right side spindle head cover for

VF-3/4, VCE 1000/1250.

3. If the bearings are to be serviced, remove the three SHCS attaching the Z-axis way cover to the spindle head and slide the cover to the bottom position.

4. Lower the spindle head to its lowest position.

5. If the machine is equipped with a hydraulic counterbalance, install cylinder shaft stop (See Fig. 9-6).

HANDLE JOG Z-axis up until shaft stop blocks axis.

6. Disconnect the electrical power.

7. On the motor housing, loosen the four BHCS and remove the cover plate.

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94

Figure 3-41. Z-axis motor and components.

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MECHANICAL SERVICE

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Figure 3-42. Z-axis motor and components for machines equipped with hydraulic counterbalance.

8. Loosen the SHCS on the motor coupling at the lead screw.

9. On the motor housing, loosen the four SHCS and remove the motor from the housing.

10. Disconnect the Z-axis connection from the control panel.

INSTALLATION —

1. Slide motor into motor housing, inserting the end of the lead screw in the motor coupling.

2. Replace and tighten down the four 5/16-18 x 1¼» SHCS that hold the motor to the housing.

3. Visually inspect the flex plates to ensure they are parallel to the coupling halves.

NOTE: The slot in the locking collar must be positioned 45 degrees between the bolt hole pattern of the coupler. If improperly aligned, the coupler will not have enough clamping force on the leads screw or motor shaft.

Tighten the SHCS on the motor coupling at the lead screw. (Place a drop of blue Loctite® on the screw before inserting.)

4. Replace the cover plate and fasten with the four BHCS.

5. Reconnect electrical power.

6. Remove shaft stop, if necessary.

7. If the front way cover was removed, slide it back into position, and replace the 10-32×3/8″ SHCS that holds

it to the saddle.

8. Move the table to the fully forward position. Replace the rear way cover.

9. Replace the two roller brackets onto the base.

95

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MECHANICAL SERVICE

10. Slide the way cover back into place, and attach to the saddle with the 10-32×3/8″ SHCS.

11. Check for backlash in Z-axis lead screw (Troubleshooting section), or noisy operation.

C

OUPLER

R

EPLACEMENT

1. Remove the axis motor in accordance with «Axis Motor Removal/Installation» section.

NOTE: It will not be necessary at this time to completely remove the motor. Do not disconnect the electrical components.

2. Completely loosen the 10-32 x ½» SHCS on the two coupling rings and remove the coupling.

3. For installation: Visually inspect the flex plates to ensure they are parallel to the coupling halves. Slide the new coupling onto the motor shaft until the coupling half is flush to the end of the shaft.

NOTE: The slot in the locking collar must be positioned 45 degrees between the bolt hole pattern of the coupler. If improperly aligned, the coupler will not have enough clamping force on the leads screw or motor shaft.

Tighten the SHCS on the motor coupling at the lead screw. (Place a drop of blue Loctite® on the screw before inserting.)

5. Reinstall the axis motor.

June 1998

Figure 3-43. Motor coupling.

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MECHANICAL SERVICE

3.10 LEAD SCREW REMOVAL AND INSTALLATION

Please read this section in its entirety before attempting to remove or replace the lead screws.

TOOLS REQUIRED

ü

ü

ü

Spanner wrench (32 mm or 40/50 mm)

ü

2″ x 4″ wood block (21″-23

Torque tester

1

/

2

» long)

Shaft lock (32 mm or 40/50 mm)

ü

Z-Axis: Cylinder shaft stop (P/N 99-7562 — VF-0 through 4, P/N 93-9962 — VF-6 through 10)

NOTE: Certain steps in the following procedures apply only to 40 and 50 mm lead screws.

X-A

XIS

L

EAD

S

CREW

R

EMOVAL

1. Turn the machine ON. ZERO RETURN all axes and put the machine in HANDLE JOG mode.

2. Remove the side enclosures.

3. Loosen the SHCS and remove the chip tray from the mill table.

4. Jog the table to the far right position. Loosen the SHCS and remove the right way cover.

5. Jog the table to the far left position. Loosen the SHCS and remove the left way cover.

6. If applicable, remove the hard stop from the bearing housing on the lead screw.

96-8100

Figure 3-44. X-axis lead screw and components.

7. Disconnect the oil line from the ball nut.

8. Loosen the 10-32 x ½» SHCS and remove the clamp nut on the lead screw support bearing end.

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MECHANICAL SERVICE

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98

Figure 3-45. Lead screw assembly.

9. Remove the axis motor in accordance with «X-Axis Motor Removal».

NOTE: The motor’s electrical connections do not need to be removed for this operation.

After removing motor from the housing, set it to one side.

10. Loosen the 10-32 x ½» SHCS and remove the clamp nut on the lead screw in the motor housing.

11. For 32 mm lead screws:

Ø

Loosen the six ¼-20 x 1″ SHCS and remove the bearing sleeve from the motor housing. Push on

Ø the mill table or the opposite end of the lead screw to loosen.

Push the mill table towards the motor end until the lead screw clears the bearing support.

Remove the SHCS from the ball nut and remove the lead screw by pulling from the bearing support end.

CAUTION! DO NOT PRY THE BEARING SLEEVE AWAY FROM THE HOUSING. DAMAGE

TO THE SLEEVE, BEARING, OR LEAD SCREW WILL RESULT.

Ø

Ø

For 40 and 50 mm lead screws:

Loosen the SHCS that mount the bearing support to the saddle, and remove. Remove the pull pins from the bearing support.

Loosen the five SHCS in the ball nut and remove the lead screw by pulling from the bearing support end.

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MECHANICAL SERVICE

THIS PROCEDURE ASSUMES THAT THE NUT AND MOTOR HOUSING WILL NOT BE REMOVED.

INSTALLATION —

1. Center the mill table on the saddle.

2. Ensure all mating surfaces on the bearing sleeve, motor housing, nut housing, and ball nut are free of dirt, burrs, grease, or other contaminants.

CAUTION! MATING SURFACES MUST BE CLEAN OR MISALIGNMENT MAY OCCUR,

SERIOUSLY AFFECTING THE PROPER OPERATION OF THE MACHINE.

3. Insert the lead screw through the nut housing and motor housing (See Fig. 10-3), taking care not to make contact with the screw threads, which will cause possible damage.

96-8100

Figure 3-46. Install lead screw from right side.

4. If 40 or 50 mm lead screw:

Ø Mount the bearing support to the saddle with six SHCS, but do not tighten completely. Replace the pull pins in the bearing support.

Ø Install the spacer ring on the motor end of the lead screw.

Ø Insert the 5/16-18 x 3/4″ (or M10 x 25 mm) SHCS, attaching the ball nut to the nut housing, but do not tighten completely. (Place a drop of blue Loctite

®

on each of the SHCS before inserting.).

Ø Skip to Step 8.

5. Place the bearing sleeve in the motor housing as shown. (It may be necessary to align the bearings in the sleeve to facilitate mounting on the lead screw.)

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MECHANICAL SERVICE

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100

Figure 3-47. Bearing sleeve mounting location.

6. Insert the six ¼-20 x 1″ SHCS attaching the bearing sleeve to the motor housing. (Place a drop of blue

Loctite® on each of the SHCS before inserting.) Tighten to torque specification.

CAUTION! Do not use more than one drop of Loctite®. An excessive amount will cause a film between the sleeve and housing, which could result in backlash.

7. Move mill table as far right as possible. Insert, but DO NOT TIGHTEN, the five ¼-20 x 1″ (or ¼-20 x ¾»)

SHCS attaching the ball nut to the nut housing. (Place a drop of blue Loctite

®

on each of the SHCS before inserting.)

CAUTION! Do not run mill table pads past the end of the linear guides! If this occurs, cease all operations and contact the manufacturer at once.

8. The following sequence is important to ensure proper installation of the lead screw:

Ø Tighten the clamp nut, hand tight, on the motor end.

Ø Install and tighten clamp nut on bearing support.Ensure the nut does not touch the support bearing.

Ø Install the shaft lock onto the bearing support end of the lead screw. This will keep the lead screw from turning while torquing the clamp nut.

Ø Place a spanner wrench on the clamp nut at the motor end of the assembly.

Ø Torque the clamp nut to 15 FT-LBS.

NOTE: The 40/50 mm leadscrew clamp nut should be torqued to 50 FT-LBS.

Ø Tighten the clamp nut screw and mark with yellow paint on motor support end.

Ø Remove the shaft lock.

Ø Torque support mounting bolts to proper specifications.

Ø Loosen the clamp nut screw and clamp nut at the bearing support end and tighten to 4 IN-LBS against the bearing. Retighten the clamp screw.

9. For 40 and 50 mm lead screws only:

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MECHANICAL SERVICE

Ø Move the table all the way to the right. Tighten down completely the SHCS that mount the bearing support to the saddle.

Ø Loosen the clamp nut on the bearing support end. Adjust the nut until it seats on the bearing.

Retighten the clamp nut hand-tight, then 1/8 turn more (If you have a torque screwdriver, torque the clamp nut to 4 in-lbs).

10. Reinstall the motor according to «Axis Motor Removal and Installation».

11. Check lead screw torque at bearing support end with torque tester. Jog the table all the way to the right.

Check the lead screw torque again. It should be the same as the previous reading.

12. Reinstall the way covers and chip tray. If applicable, replace the hard stop.

13. Check for backlash in the lead screw («Accuracy/Backlash» section) or noisy operation.

Y-A

XIS

L

EAD

S

CREW

R

EMOVAL

1. Turn the machine ON. ZERO RETURN all axes and put the machine in HANDLE JOG mode.

2. If applicable, remove the hard stop from the lead screw support bearing end of the lead screw.

3. Disconnect the oil line at the ball nut.

4. Loosen the 10-32 x ½» SHCS and remove the clamp nut on the lead screw bearing support end.

96-8100

Figure 3-48. Y-axis lead screw and components.

5. Remove the motor in accordance with «Y-Axis Motor Removal».

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MECHANICAL SERVICE

NOTE: The motor’s electrical connections do not need to be removed for this operation.

After removing motor from the housing, set it to one side.

6. Loosen the 10-32 x 1/2″ SHCS and remove the clamp nut on the lead screw in the motor housing.

7. For 32 mm lead screws:

Ø

Loosen the six ¼-20 x 1″ SHCS and remove the bearing sleeve from the motor housing. Push on the mill table or the opposite end of the lead screw to loosen.

CAUTION! DO NOT PRY THE BEARING SLEEVE AWAY FROM THE HOUSING. DAMAGE

TO THE SLEEVE, BEARING, OR LEAD SCREW WILL RESULT.

Ø

Ø

Ø

Remove the five SHCS attaching the ball nut to the nut housing.

Hand-turn the lead screw toward the rear of the machine until the front end of the lead screw clears the bearing by approximately six inches (6″).

Carefully pull the lead screw forward, to the right of the support bearing, under the front way cover until the rear of the lead screw clears the nut housing. Shift the rear end of the lead screw to the right side of the nut housing and move the lead screw to the rear of the machine until it clears the front way cover. Remove lead screw from the machine.

For 40 and 50 mm lead screws:

Ø

Loosen the SHCS that mount the bearing support to the saddle, and remove. Remove the pull

Ø pins from the bearing support.

Loosen the five SHCS in the ball nut and remove the lead screw by pulling from the bearing support end.

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102

Figure 3-49. Pull lead screw forward around bearing support,…

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MECHANICAL SERVICE

96-8100

…push back into the machine, then pull out forward.

THIS PROCEDURE ASSUMES THAT THE NUT AND MOTOR HOUSING WILL NOT BE REMOVED.

INSTALLATION —

1. Ensure all mating surfaces on the bearing sleeve, motor housing, nut housing, and ball nut are free of dirt, burrs, grease, or other contaminants.

CAUTION! MATING SURFACES MUST BE CLEAN OR MISALIGNMENT MAY OCCUR,

SERIOUSLY AFFECTING THE PROPER OPERATION OF THE MACHINE.

2. Slide the motor end of the lead screw under the saddle, taking care not to damage the screw threads.

Position the lead screw to the right side of the nut housing and slide toward the rear of the machine as far as it will go.

3. Pull the lead screw forward until it is against the front way covers. Place the motor end of the lead screw through the nut housing and push the lead screw toward the back of the machine until the ball nut is seated in the nut housing.

4. If 40 or 50 mm lead screw:

Ø Mount the bearing support to the saddle with six SHCS, but do not tighten completely. Replace the pull pins in the bearing support.

Ø Install the spacer ring on the motor end of the lead screw.

Ø Insert the 5/16-18 x 3/4″ (or M10 x 25 mm) SHCS, attaching the ball nut to the nut housing, but do not tighten completely. (Place a drop of blue Loctite

®

on each of the SHCS before inserting.).

Ø Skip to Step 8.

5. Place the bearing sleeve in the motor housing as shown. (It may be necessary to align the bearings in the sleeve to facilitate mounting on the lead screw.)

103

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MECHANICAL SERVICE

6. Insert the six ¼-20 x 1″ SHCS attaching the bearing sleeve to the motor housing. (Place a drop of blue

Loctite® on each of the SHCS before inserting.) Tighten to torque specifications.

June 1998

CAUTION! Do not use more than one drop of Loctite®. An excessive amount will cause a film between the sleeve and housing, which could result in backlash.

7. Move mill table as far forward as possible. Insert, but DO NOT TIGHTEN, the five 1/4-20 x 1″ (or 1/4-20 x 3/4″) SHCS attaching the ball nut to the nut housing. (Place a drop of blue Loctite® on each of the SHCS before inserting.)

CAUTION! Do not run mill table pads past the end of the linear guides! If this occurs, cease all operations and contact the manufacturer at once.

8. The following sequence is important to ensure proper installation of the lead screw:

Ø Tighten the clamp nut, hand tight, on the motor end.

Ø Install and tighten clamp nut on bearing support. Ensure the nut does not touch the support bearing.

Ø Install the shaft lock onto the bearing support end of the lead screw. This will keep the lead screw from turning while torquing the clamp nut.

Ø Place a spanner wrench on the clamp nut at the motor end of the assembly.

Ø Torque the clamp nut to 15 FT-LBS.

NOTE: The 40/50 mm leadscrew clamp nut should be torqued to 50 FT-LBS.

Ø Tighten the clamp nut screw and mark with yellow paint.

Ø Remove the shaft lock.

Ø Torque support mounting bolts to proper specifications.

Ø Loosen the clamp nut screw and clamp nut at the bearing support end and tighten to 4 IN-LBS.

against the bearing. Retighten the clamp screw.

9. Move the mill table to the far back position (motor end). Tighten down completely the five SHCS attaching the ball nut to the nut housing.

10. For 40 and 50 mm lead screws only:

Ø Move the table all the way forward. Tighten down completely the SHCS that mount the bearing support to the base.

Ø Loosen the clamp nut on the bearing support end. Adjust the nut until it seats on the bearing.

Retighten the clamp nut hand-tight, then 1/8 turn more (If you have a torque screwdriver, torque the clamp nut to 4 in-lbs).

11. Reinstall the motor according to «Axis Motor Removal and Installation». If applicable, replace the hard stop from the lead screw support bearing end of the lead screw.

12. Check lead screw torque at bearing support end with torque tester. Jog the table all the way to the front.

Check the lead screw torque again. It should be the same as the previous reading.

13. Check for backlash in the lead screw («Accuracy/Backlash» section) or noisy operation.

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June 1998

Z-A

XIS

L

EAD

S

CREW

R

EMOVAL

MECHANICAL SERVICE

WARNING! ALWAYS BLOCK THE HYDRAULIC CYLINDER WITH THE SHAFT STOP

BLOCK. DO NOT MOVE THE SPINDLE DURING LEAD SCREW SERVICE.

1. Turn the machine ON. ZERO RETURN all axes and put the machine in HANDLE JOG mode.

2. Loosen the six SHCS that attach the rear cover to the side covers, and remove from the spindle head.

Remove the three SHCS attaching the Z-axis way cover to the spindle head and slide the cover to the bottom position.

3. Lower the spindle head to it’s lowest position. Install cylinder shaft stop. Handle jog Z-axis up until the shaft stop blocks the axis.

4. Disconnect electrical power.

5. If applicable, remove the hard stop from the bearing housing on the lead screw.

6. Disconnect the oil line at the ball nut.

7. Loosen the 10-32 x ½» SHCS and remove the clamp nut on the lead screw support bearing end.

8. Remove the axis motor in accordance with «Z-Axis Motor Removal».

NOTE: The motor’s electrical connections do not need to be removed for this operation.

After removing motor from the housing, set it to one side.

9. Loosen the 10-32 x ½» SHCS and remove the clamp nut on the lead screw in the motor housing.

10. For 32 mm lead screws:

Ø

Loosen the six ¼-20 x 1″ SHCS and remove the bearing sleeve from the motor housing. Push on the opposite end of the lead screw to loosen.

CAUTION! DO NOT PRY THE BEARING SLEEVE AWAY FROM THE HOUSING. DAMAGE

TO THE SLEEVE, BEARING, OR LEAD SCREW WILL RESULT.

Ø

Ø

Hand-turn the lead screw to move the screw up until the bottom end clears the support bearing by approximately six inches (6″).

Remove the SHCS from the ball nut and lower the lead screw down and to the right of the support bearing, past the Z-axis way cover. For the VF-6, remove the lead screw from top of column.

USE EXTREME CAUTION! DO NOT DAMAGE THE THREADS ON THE LEAD SCREW.

Ø

Ø

For 40 and 50 mm lead screws:

Loosen the SHCS that mount the bearing support to the column, and remove. Remove the pull pins from the bearing support.

Loosen the five SHCS in the ball nut and remove the lead screw by pulling from the bearing support end.

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MECHANICAL SERVICE

June 1998

106

Figure 3-50. Z-axis lead screw and components.

INSTALLATION —

WARNING! ALWAYS BLOCK THE HYDRAULIC CYLINDER WITH SHAFT STOP BLOCK.

DO NOT MOVE THE SPINDLE DURING LEAD SCREW SERVICE.

1. Ensure all mating surfaces on the bearing sleeve, motor housing, nut housing, and ball nut are free of dirt, burrs, grease, or other contaminants.

CAUTION: MATING SURFACES MUST BE CLEAN OR MISALIGNMENT MAY OCCUR,

SERIOUSLY AFFECTING THE PROPER OPERATION OF THE MACHINE.

2. If 40 or 50 mm lead screw:

Ø Insert the lead screw into the bearing support. Screw the clamp nut on a few turns.

Ø Insert the lead screw, with the bearing support attached, into place on the column. Ensure the lead screw goes through the ball nut housing and the bearing sleeve.

Ø Mount the bearing support to the column with SHCS, but do not tighten completely. Replace the pull pins in the bearing support.

Ø Install the spacer ring on the motor end of the lead screw.

Ø Hand-turn the ball nut until it comes into contact with the nut housing mounting surface. If necessary, turn the leadscrew to correctly position lube fitting of the ball nut. Insert, but DO NOT

TIGHTEN, the 5/16-18 x 3/4″ (or M10 x 25 mm) SHCS, attaching the ball nut to the nut housing.

(Place a drop of blue Loctite

Ø Skip to Step 7.

®

on each of the SHCS before inserting.)

3. Slide the lead screw up into the nut housing and gently lower it until it is resting in the support bearing.

96-8100

June 1998

MECHANICAL SERVICE

96-8100

Figure 3-51. Reinstalling the lead screw.

4. Place the bearing sleeve in the motor housing as shown. (It may be necessary to align the bearings in the sleeve to facilitate mounting on the lead screw.)

5. Insert the six ¼-20 x 1″ SHCS attaching the bearing sleeve to the motor housing. (Place a drop of blue

Loctite® on each of the SHCS before inserting.) Tighten down completely.

CAUTION! Do not use more than one drop of Loctite®. An excessive amount will cause a film between the sleeve and housing, which could result in backlash.

6. Hand-turn the ball nut until it comes into contact with the nut housing mounting surface. If necessary, turn the leadscrew to correctly position lube fitting of the ball nut. Insert, but DO NOT TIGHTEN, the five ¼-

20 x 1″ (or ¼-20 x ¾») SHCS attaching the ball nut to the nut housing. (Place a drop of blue Loctite of the SHCS before inserting.)

®

on each

7. The following sequence is important to ensure proper installation of the lead screw:

Ø Tighten the clamp nut, hand tight, on the motor end.

Ø Install and tighten clamp nut on bearing support. Ensure the nut does not touch the support bearing. It will be used to hold the lead screw while the other end is tightened.

Ø Install the shaft lock onto the bearing support end of the lead screw. This will keep the lead screw from turning while torquing the clamp nut.

Ø Place a spanner wrench on the clamp nut at the motor end of the assembly.

Ø Torque the clamp nut to 15 FT-LBS.

NOTE: The 40/50 mm leadscrew clamp nut should be torqued to 50 FT-LBS.

Ø Tighten the clamp nut screw and mark with yellow paint.

Ø Remove the shaft lock.

Ø Torque support mounting bolts to proper specifications.

Ø Loosen the clamp nut screw and clamp nut at the bearing support end and tighten to 4 IN-LBS against the bearing. Retighten the clamp screw.

8. Tighten down completely the five SHCS attaching the ball nut to the nut housing.

107

108

MECHANICAL SERVICE

9. Reinstall the motor according to «Z-Axis Motor Removal and Installation». Reinstall the hard stop at the support bearing end of the lead screw.

10. Reconnect electrical power.

11. Jog the spindle down and remove the cylinder shaft stop.

12. For 40 and 50 mm lead screws only:

Ø Jog the spindle head towards the bearing support end.

Ø Tighten down completely the SHCS that mount the bearing support to the column.

Ø Loosen the clamp nut on the bearing support end. Adjust the nut until it seats on the bearing.

Retighten the clamp nut hand-tight, then 1/8 turn more (If you have a torque screwdriver, torque the clamp nut to 4 in-lbs).

13. Check lead screw torque at bearing support end with torque tester. Jog the the spindle head to it’s highest position. Check the lead screw torque again. It should be the same as the previous reading.

14. Check for backlash in the lead screw («Accuracy/Backlash» section) or noisy operation.

June 1998

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June 1998

MECHANICAL SERVICE

3.11 BEARING SLEEVE REMOVAL AND INSTALLATION

Please read this section in its entirety before attempting to remove or replace the bearing sleeve.

TOOLS REQUIRED

ü

ü

ü

Spanner wrench

Wood block (16″ long)

ü

Pre-load fixture

Z-Axis: Cylinder shaft stop (P/N 99-7562 — VF-0 through 4, P/N 93-9962 — VF-6 through 10)

Note: For machines equipped with 40 or 50 mm lead screws, the lead screw must be removed in order to remove the bearing sleeve. Refer to the «Lead Screw Removal/

Installation» section for instructions.

X-A

XIS

B

EARING

S

LEEVE

R

EMOVAL

1. Turn the VMC ON. ZERO RETURN all axes and put the machine in HANDLE JOG mode.

96-8100

Figure 3-52. X-axis lead screw and components.

2. Loosen the SHCS and remove the chip tray from the mill table.

3. Remove the axis motor in accordance with «X-Axis Motor Removal».

Note: The motor’s electrical connections do not need to be removed for this operation.

After removing from the motor housing, set it to one side.

4. Loosen the 10-32 x ½» SHCS and remove the clamp nut on the lead screw in the motor housing.

5. Loosen the six ¼-20 x 1″ SHCS and remove the bearing sleeve from the motor housing. Push on the mill table or the opposite end of the lead screw to loosen.

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MECHANICAL SERVICE

CAUTION! DO NOT PRY THE BEARING SLEEVE AWAY FROM THE HOUSING. DAMAGE

TO THE SLEEVE, BEARING, OR LEAD SCREW WILL RESULT.

INSTALLATION —

1. Ensure all mating surfaces on the bearing sleeve, motor housing, nut housing, and ball nut are free of dirt, burrs, grease, or other contaminants.

CAUTION! MATING SURFACES MUST BE CLEAN OR MISALIGNMENT MAY OCCUR,

SERIOUSLY AFFECTING THE PROPER OPERATION OF THE MACHINE.

2. Move mill table to the far right.

3. Place the bearing sleeve in the motor housing as shown. (It may be necessary to align the bearings in the sleeve to facilitate mounting.)

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110

Figure 3-53. Lead screw assembly.

4. Insert the six ¼-20 x 1″ SHCS, attaching the bearing sleeve to the motor housing. (Place a drop of blue

Loctite® on each of the SHCS before inserting.) Tighten down completely.

CAUTION! Do not use more than one drop of Loctite®. An excessive amount will cause a film between the sleeve and housing, which could result in backlash.

5. Start the clamp nuts on both ends of the lead screw. Do not tighten.

6. Hand-turn the mill table to the far left position.

7. Loosen the six ¼-20 x 1″ SHCS attaching the bearing sleeve to the motor housing and retighten completely.

DO NOT SKIP THIS STEP. It ensures the lead screw is installed and runs parallel and flat to the linear guides and the saddle.

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June 1998

MECHANICAL SERVICE

Note: For the angular contact design bearing, no pre-load is necessary. Do the following:

Ø

Tighten the clamp nut on the motor housing to 15 foot-pounds.

Ø

Tighten the SHCS on the clamp nut.

Ø

Tighten the clamp nut on the support bearing end of the lead screw until it contacts the bearing, then tighten further approximately 1/8 of a turn.

Ø

Tighten the SHCS on the clamp nut.

8. Reinstall the axis motor in accordance with «X-Axis Motor Removal».

9. Reinstall the way covers and chip tray.

10. Check for backlash in the X-axis lead screw (Troubleshooting section) or noisy operation.

Y-A

XIS

B

EARING

S

LEEVE

R

EMOVAL

1. Turn the VMC ON. ZERO RETURN all axes and put the machine in HANDLE JOG mode.

2. Remove the axis motor in accordance with «Y-Axis Motor Removal».

3. Remove the hard stop from the bearing housing on the lead screw.

4. Loosen the 10-32 x ½» SHCS and remove the clamp nut from the bearing support end of the lead screw.

5. Loosen the six ¼-20 x 1″ SHCS and remove the bearing sleeve from the motor housing. Push on the mill table or the opposite end of the lead screw to loosen.

CAUTION: DO NOT PRY THE BEARING SLEEVE AWAY FROM THE MOTOR HOUSING.

DAMAGE TO THE SLEEVE, BEARING, OR THE LEAD SCREW WILL RESULT.

INSTALLATION —

1. Ensure all mating surfaces on the bearing sleeve, motor housing, nut housing, and ball nut are free of dirt, burrs, grease, or other contaminants.

96-8100

CAUTION! MATING SURFACES MUST BE CLEAN OR MISALIGNMENT MAY OCCUR,

SERIOUSLY AFFECTING THE PROPER OPERATION OF THE MACHINE.

2. Slide the bearing sleeve into the motor housing and start all six ¼-20 x 1″ SHCS into the motor housing.

(Place a drop of blue Loctite® on each of the SHCS before inserting.)

CAUTION! Do not use more than one drop of Loctite®. An excessive amount will cause a film between the sleeve and housing, which could result in backlash.

3. Move the table to the rear of its travel.

4. Tighten the six ¼-20 x 1″ SHCS that attach the bearing sleeve to the motor housing.

5. Loosely install the clamp nut on the lead screw at the motor housing end.

Note: For the angular contact design bearing, no pre-load is necessary (follow the procedure in «X-axis bearing sleeve» section).

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MECHANICAL SERVICE

6. Reinstall the axis motor.

7. Check for backlash in the Y-axis lead screw (Troubleshooting section) or noisy operation.

Z-A

XIS

B

EARING

S

LEEVE

R

EMOVAL

WARNING! ALWAYS BLOCK THE HYDRAULIC CYLINDER WITH SHAFT STOP BLOCK

BEFORE SERVICING ANY Z-AXIS COMPONENTS.

1. Turn the machine power ON. Zero return (ZERO RET) all axes and put the machine in HANDLE JOG mode.

2. Loosen the six SHCS that attach the rear cover to the side covers, and remove from the spindle head.

Note: If machine is equipped with a hydraulic counterbalance, remove entire spindle head cover for VF-0/OE/1/2, VCE 500/550/700/750, or right side spindle head cover for

VF-3/4, VCE 1000/1250.

3. If the bearings are to be serviced, remove the three SHCS attaching the Z-axis way cover to the spindle head and slide the cover to the bottom position.

4. Remove the hard stop from the bearing housing on the lead screw.

5. Loosen the 10-32 x ½» SHCS and remove the clamp nut from the bearing support end of the lead screw.

6. Raise the spindle head until the bottom edge is approximately sixteen inches (16″) above the mill table.

7. Install cylinder shaft stop. HANDLE JOG Z-axis up until shaft stop block axis.

8. Place the wood block beneath the spindle head and lower the spindle head until it is resting on the block.

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112

Figure 3-54. Z-axis bearing sleeve.

9. Perform Steps 6-10 of «Z-Axis Motor Removal».

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June 1998

MECHANICAL SERVICE

Note: The motor’s electrical connections do not need to be removed for this operation.

After removing from motor housing, set it to one side.

10. Loosen the 10-32 x ½» SHCS and remove the clamp nut from the motor housing end of the lead screw.

11. Loosen the six ¼-20 x 1″ SHCS and remove the bearing sleeve from the motor housing. Hand-turn the lead screw in an upward direction to push the bearing sleeve out of the motor housing.

CAUTION! DO NOT PRY THE BEARING SLEEVE AWAY FROM THE MOTOR HOUSING.

DAMAGE TO THE SLEEVE, BEARING, OR THE LEAD SCREW WILL RESULT.

INSTALLATION —

1. Ensure all mating surfaces on the bearing sleeve, motor housing, nut housing, and ball nut are free of dirt, burrs, grease, or other contaminants.

CAUTION! MATING SURFACES MUST BE CLEAN OR MISALIGNMENT MAY OCCUR,

SERIOUSLY AFFECTING THE PROPER OPERATION OF THE MACHINE.

2. Slide the bearing sleeve into the motor housing and start all six ¼-20 x 1″ SHCS into the motor housing.

(Place a drop of blue Loctite® on each of the SHCS before inserting.)

CAUTION! Do not use more than one drop of Loctite®. An excessive amount will cause a film between the sleeve and housing, which could result in backlash.

3. Tighten the six ¼-20 x 1″ SHCS that attach the bearing sleeve to the motor housing.

4. Loosely install the clamp nut on the lead screw at the motor housing end.

5. Reinstall the hard stop on the bearing housing end of the lead screw.

Note: For the angular contact design bearing, no pre-load is necessary. Follow the procedures as outlined in «X-Axis Bearing Sleeve» section.

6. Reinstall the axis motor in accordance with «Z-Axis Motor-Installation».

7. Remove shaft stop.

8. Check for backlash in the Z-axis lead screw (Troubleshooting section) or noisy operation.

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113

114

MECHANICAL SERVICE

3.12 AUTOMATIC TOOL CHANGER

TOOLS REQUIRED

ü

Two-jaw puller

ü

1-2-3 Block

ü

ü

Hydraulic jack

Cardboard

C

ARRIAGE

C

ASTING

R

EPLACEMENT

Note: If the carriage casting is damaged in a crash, it must be replaced. Look specifically for broken bosses where the roller bolts mount to the casting. If the carriage casting is broken off of the holding plate but not damaged, only the roller bolts need be replaced.

1. Turn the machine power off.

2. Remove the left side enclosure panel of the machine.

3. Disconnect all cables from the carriage casting and remove any bolts holding the ATC to the holding plate.

Note: If the carriage casting has been damaged, replacement is necessary; move the

ATC to a bench and remove all components from the damaged carriage casting and place in the new casting. Skip to Step 6 for replacement.

4. Place a piece of cardboard over the machine’s table, and carefully lower the carriage casting (with carousel) onto the machine table.

5. If the carriage casting has crashed and/or has been broken off of the holding plate, it should be inspected for damage before going any further.

6. Remove any damaged roller bolts from the carriage casting. Replace with new bolts.

7. With a lifting device, carefully lift the ATC assembly up and onto the holding plate.

Note: Ensure the cam follower on the slip clutch engages the slot on the carriage casting.

8. With the ATC assembly securely supported, install the lower roller bolts and adjust in accordance with

«Roller Bolt Replacement».

9. Repair or replace any cables damaged and adjust the ATC. Align the ATC assembly in accordance with the following sections, and set Parameter 64 in accordance with «Spindle Motor and Transmission» section.

R

OLLER

B

OLT

R

EPLACEMENT

1. Remove the shuttle motor cover from the back of the machine (VF-0, VF-1, VF-2).

2. Place a support under the center of the carousel.

3. Loosen the eccentric locks on the bottom roller bolts.

CAUTION! Ensure the ATC is securely supported, otherwise it may fall when an upper roller bolt is removed.

4. Carefully remove the damaged roller bolt from the ATC shuttle and replace with a new bolt.

June 1998

96-8100

June 1998

MECHANICAL SERVICE

Note: REPLACE ONLY ONE ROLLER BOLT AT A TIME. Carefully inspect the v-groove rollers for roughness or damage, and replace if necessary.

5. Tighten the eccentric locks on the bottom rollers until there is no play between the rollers and the V-guide on the ATC holding plate.

6. Set the tool change offset (Parameter 64) in accordance with «Setting Parameter 64» section.

7. Verify the ATC alignment in accordance with the following section.

8. Reinstall the shuttle motor cover (VF-0, VF-1, VF-2).

A

UTOMATIC

T

OOL

C

HANGER

(ATC) A

LIGNMENT

1. Verify that the spindle orientation is correct (Refer to appropriate section).

2. Command an automatic tool change, and press EMERGENCY STOP when the shuttle is in the full in position.

3. Verify that the spindle dog lines up to the alignment key in the ATC, in the Y plane.

Note: If the spindle dog and alignment key do not line up, loosen the four HHB that hold the ATC holding arm to the column.

96-8100

Figure 3-55. Underside showing centering measurements.

4. Move the entire tool changer until the tool alignment key lines up with the spindle dog. Tighten the four

HHB.

Note: Parameter 64 must be checked, and adjusted if necessary, when the ATC is aligned.

5. Make at least 50 tool changes after the alignment is complete. Verify that the tools are being picked up squarely.

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MECHANICAL SERVICE

S

HUTTLE

S

TROKE

A

DJUSTMENT

6. Move the ATC away from the spindle and loosen the four HHBs in the ATC holding arm in the X-axis plane.

7. Push the cam follower to its full upward stroke, then push the entire ATC assembly in by pushing on the tool changer holding plate until ATC is fully engaged on the tool holder.

8. Ensure the extractor is making full contact on the tool flange.

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116

Figure 3-56. Automatic Tool Changer — Mechanical Assembly (Side View)

E

XTRACTOR

F

ORK

R

EPLACEMENT

Note: Extractor forks that do not hold the tool holders firmly, or forks that are bent, must be replaced. Damage to the ATC will result if not replaced.

1. With no tool holders in the spindle or in the ATC, command «ATC FWD» until the extractor fork needing replacement is facing the spindle.

2. Command «ATC FWD» again, but press the EMERGENCY STOP after the spindle head lifts up off the carousel

Note: At this point, the shuttle should be in and the spindle should be about 4½» above the carousel.

3. Loosen the SHCS that attach the damaged extractor fork to the ATC carousel.

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June 1998

MECHANICAL SERVICE

96-8100

Figure 3-57. Automatic Tool Changer — Mechanical Assembly (Top View)

4. With the extractor fork removed, inspect the alignment key mounted under the extractor. If it is damaged due to improper spindle orientation, replace it and correct the orientation (Refer to appropriate section) after the extractor fork has been replaced.

5. Put a drop of blue Loctite on each of the SHCS and attach the new extractor fork to the ATC with the SHCS.

DO NOT OVER-TORQUE! Ensure the distance from the edge of the extractor fork to the edge of the pocket in the carousel is the same on both sides in accordance with the following section.

6. Test run the ATC to ensure proper operation.

S

LIDING

C

OVER

R

EPLACEMENT

Note: If any of the sliding covers on the ATC do not slide freely or are bent in a crash, they must be replaced.

1. Loosen the four screws that attach the sliding panel cover to the carousel. Be careful to not lose the spring that holds the sliding cover closed or the number plate on the ATC carousel.

2. Inspect the cover for any galling or damage. Inspect the spring for damage.

3. Loosely install the two innermost screws that attach the number plate and the cover to the carousel and slide the spring into position in the slot in the ATC carousel.

4. Put the replacement sliding panel in place, making certain that the tongue on the panel pushes on the end of the spring.

5. Tighten the two rear screws completely and install the two front screws.

6. Ensure the sliding panel moves freely.

Note: If the sliding door is bent, determine the cause before resuming normal operation.

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MECHANICAL SERVICE

S

HUTTLE

M

OTOR

R

EMOVAL

1. Turn the VMC off.

2. Remove the cover from the tool carriage casting.

3. Remove the hex bolt that attaches the cam follower to the slip clutch (see Fig. 3-56).

4. Push the tool changer in as far as it will go.

5. Loosen the set screw that secures the slip clutch assembly to the shuttle motor (see Fig. 3-57).

6. Using a small two-jaw puller, pull the slip clutch assembly (see Fig. 3-57) off the shuttle motor shaft.

7. Remove the SHCS attaching the cover to the holding arm casting on the tool changer.

8. Remove the cover from the wire channel inside the holding arm casting and unplug the shuttle motor from the wiring harness.

June 1998

118

Figure 3-58. Wiring harness for shuttle motor.

9. Remove the four FHCS attaching the shuttle motor to the holding plate on the tool changer. The FHCS are visible from the front of the VMC. Do not remove the HHB’s holding the shuttle motor gear box together.

S

HUTTLE

M

OTOR

I

NSTALLATION

1. Install the new motor on the tool changer holding plate using the four 10-32 x ¾» FHCS. Before inserting the FHCS, place a drop of blue Loctite® on each screw.

2. Reattach the shuttle motor connection to the wiring harness in the holding arm casting.

3. Replace the cover on the holding arm casting.

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MECHANICAL SERVICE

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Figure 3-59. Front view of holding plate showing FHCS location.

4. Reattach the slip clutch assembly to the shuttle motor shaft. Before placing on the shaft, put two or three drops of red Loctite

®

on the slip clutch hub.

5. Insert and tighten down the set screw holding the slip clutch assembly to the shuttle motor shaft.

Before inserting the set screw, put a drop of blue Loctite

®

on the set screw.

6. Ensure the actuating arm on the slip clutch assembly contacts the shuttle IN and OUT limit switches.

7. Ensure the hub of the slip clutch assembly does not interfere with the face plate on the shuttle motor.

8. Start the VMC and go through a performance check consisting of at least 30 tool changes, assuring correct operation.

T

URRET

M

OTOR

R

EMOVAL

1. Power on the VMC and put it in MDI mode.

2. Zero Return all axes (ZERO RET — AUTO ALL AXES).

3. Press ATC FWD then the EMERGENCY STOP after the spindle head has moved during the tool change cycle.

At this time, the tool changer should be at the full in position and the spindle head should be above the tool changer.

4. Turn the VMC power OFF.

5. Remove the 10-32 SHCS from the carriage casting cover and remove the cover.

6. Tag both limit switch connections for reassembly, then unplug the limit switches’ and the power’s connections at the carriage casting.

7. Remove the four SHCS attaching the turret motor and mounting plate to the tool carriage casting.

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MECHANICAL SERVICE

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Figure 3-60. Carriage casting with cover removed.

8. Carefully lift the turret motor assembly off of the tool carriage casting.

Note: The gear motor should never be disassembled and is not field-serviceable. All gear motors should be returned to Haas for evaluation and rebuilding.

INSTALLATION —

1. Grease the locking element and drive pin on the Geneva driver. Also, grease the teeth on the Geneva star on the ATC.

2. Rotate the Geneva driver until the cam depresses the limit switch on the turret motor assembly.

3. Place a narrow strip of paper around the locking element of the Geneva driver and install the turret motor assembly onto the casting. Be certain that the locking element of the Geneva driver is seated against the star with the paper strip acting as a shim.

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Figure 3-61. Required spacing for Geneva driver.

4. Attach the turret motor assembly to the carriage casting with the four SHCS.

5. Reconnect the power and limit switch lines to the turret motor.

6. Power on the VMC and ZERO RETURN all axes (ZERO RET — AUTO ALL AXES).

7. Go to MDI mode and press «T — 1 — ATC FWD».

Note: The machine may alarm at this time (Alarm 115 or 127). If this occurs, ZERO

RETURN the Z-axis (ZERO RET — SINGL AXIS) and repeat step 8. This step may need to be repeated two times to clear all possible alarms.

8. Press «T — 9 — ATC FWD». The tool changer should go to tool nine. If the tool changer travels to tool seven, the turret motor is wired backwards. Reverse motor leads and repeat steps 7-10. Also, the turret should run quietly with no strain in the motor, banging, or vibration.

9. Reinstall the tool carriage casting cover.

10. Test the tool changer for proper operation.

G

ENEVA

S

TAR

R

EPLACEMENT

Note: If the ATC Geneva star is damaged or worn in its driven slots, it must be replaced.

1. Turn the machine power off.

2. Remove the cover from the front of the ATC shuttle.

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MECHANICAL SERVICE

3. Remove the turret motor assembly (Refer to previous section).

4. Place a support for the ATC under the center of the carousel.

5. Loosen the nut inside the carriage casting that attaches the ATC carousel assembly to the casting. There is a socket head in the top of the shaft to hold it stationary while loosening the nut.

6. Place the cardboard over the mill table and carefully lower the carousel until it rests on the table.

7. Remove the six SHCS that attach the Geneva star to the bearing housing on the ATC carousel.

8. Install the Tool #1 standoff on the replacement Geneva star.

9. Install the replacement Geneva star. Check the concentricity of the star to the shaft on the carousel assembly; it must be within 0.005″. If the star is not within tolerance, loosen the SHCS and adjust the alignment until it is acceptable.

10. Installation is reverse of removal. Be certain to grease the perimeter of the star before installation and readjust the ATC in accordance with «Alignment Preparation» and «Shuttle Stroke Adjustment», if necessary.

ATC T

RAP

D

OOR

R

EPLACEMENT

Note: If the ATC trap door is damaged in a crash, it must be replaced.

1. Turn the machine power off.

2. Remove the turret motor assembly in accordance with the previous section.

3. Place a support for the ATC under the center of the carousel.

4. Loosen the nut inside the carriage casting that attaches the ATC carousel assembly to the casting. There is a socket head in the top of the shaft to hold it stationary while loosening the nut.

5. Place the cardboard over the mill table and carefully lower the carousel until it rests on the table.

6. Remove the two SHCS that attach the guide pin for the ATC trap door to the ATC holding plate and remove the guide pin.

7. Slide the trap door from between the carousel cover and the shuttle casting. Be careful to not lose the two nylon washers that sandwich the trap door between the carousel cover and the shuttle casting.

8. Installation is reverse of removal. When installing the guide pin, ensure the mounting slot is approximately central to the mounting screws and be certain the pin does not interfere with the top of the ATC carousel cover.

Grease the carousel cover where the plastic standoffs ride, the slot in the ATC shutter, the guide pin, and the nylon washers where the shutter pivots. The position of the ATC may need to be readjusted after installation.

June 1998

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MECHANICAL SERVICE

3.13 GRID OFFSET CALCULATION

Please read this section in its entirety before attempting to set the grid offset.

GUIDELINES —

The encoder Z channel signal must occur between 1/8 and 7/8 revolution from where the home switch is released. If DISTANCE TO GO is less than 1/8 (.0295) or greater than 7/8 (.2065) of a revolution, it will alarm to “Zero Return Margin Too Small”.

In ZERO RETURN mode, the DISTANCE TO GO is the amount the encoder rotated from when the switch was released until it found the Z channel signal. The ideal amount for the DISTANCE TO GO is .118 (This equals

½ of a revolution of the encoder).

SETTING THE OFFSET —

1. Set the grid offset to zero. (Parameter 125,126, 127, 128, or 170, depending on the axis being set.) Setting

#7 (PARAMETER LOCK) must be OFF to reset grid offset.

2. Press ZERO RET and ZERO SINGL AXIS the axis you are setting (X, Y, Z, A, or B).

3. Calculate the grid offset using the following formula, and write the result in Parameter 125,126, 127, 128, or 170 (depending on the axis being set).

(DISTANCE TO GO — .118) x Ratio = Grid Offset

The Ratio (steps/unit) for the X, Y, Z, A, and B axes are the values in Parameters 5, 19, 33, 47, and 155, respectively.

4. ZERO RET the axis again to use this offset.

Note: If Z-axis grid offset is reset, Parameter 64 should be checked and adjusted accordingly.

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MECHANICAL SERVICE

3.14 ENCLOSURE REPLACEMENT

Please read this section in its entirety before attempting to replace the doors or windows.

TOOLS REQUIRED

ü

Trim installation tool (dull-edged knife or caulking spatula)

D

OOR

R

EPLACEMENT

CAUTION! If possible, have two people performing this operation, as the weight of the doors may be a factor in removal.

REMOVAL —

1. Turn the machine power off.

2. Slide the doors to the full open position.

3. Remove the tension springs (2) connecting the two swivel roller brackets at the top and bottom of the door.

4. Slide the door to the fully closed position. Loosen the two upper roller hex nuts, and disengage the upper swivel roller brackets from the top roller guide.

5. Lift the door from the bottom roller guide and remove.

INSTALLATION —

6. Ensure that the lower roller hex fasteners are wrench tight and the upper roller fasteners are finger tight in the middle of their adjusting slots. Place the door into the enclosure, and position with the lower rollers resting on the lower roller guide.

7. Rotate the door to the upright position, and engage the top rollers onto the top roller guide.

8. Replace the tension springs onto the upper and lower roller swivel brackets. Tighten the upper roller fasteners.

9. Verify that the door travels smoothly. If it does not:

Ø Check that all roller wheels are seated and roll on their tracks.

Ø If all roller wheels are seated on their tracks, it will be necessary to adjust the door travel by loosening the upper and lower roller hex fasteners.

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MECHANICAL SERVICE

Figure 3-62. Roller/roller guide assembly.

DOOR ADJUSTMENTS —

10. Close both doors and check that the vertical gap between them is uniform. If it is not:

Ø Determine which door must be adjusted.

Ø Loosen the door’s outer lower roller attachment and pivot the door on the inner lower roller wheel.

Ø When the door is in the desired position (the vertical gap is uniform), tighten the lower outer roller fastener.

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Figure 3-63. View of vertical gap between front doors.

11. Check the gap between the door and the front panel flange, and verify it is 5/8″ throughout the travel of the door. If it is not:

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MECHANICAL SERVICE

Ø Loosen the door’s upper roller fasteners and tilt the door forward or back, as necessary, to adjust door position.

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126

Figure 3-64. View of gap between front of door and front panel flange.

SWITCH ADJUSTMENT —

12. Move the door to the fully closed position. Go to the «Diagnostics» page on the control panel, and ensure

«DOOR S» reads «0». Move the door to the open position, and ensure «DOOR S» reads «1». If either reading is incorrect:

Ø Loosen the SHCS that mounts the switch actuator bracket to the top of the door. (Note: It is possible to access this bracket from the side window.)

Ø Move the bracket in its slot to the proper position and tighten the SHCS.

W

INDOW

R

EPLACEMENT

REMOVAL —

1. Turn the machine power off.

2. Move the door to the fully closed position so the window is accessible. Use a trim installation tool to pull the locking tab out of the inside of the window seal (the tab is a part of the seal).

3. Remove the window panel from the seal. The tool can be placed between the window panel and the seal to aid in removing the window panel.

4. Remove the seal from the enclosure’s cutout.

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MECHANICAL SERVICE

Figure 3-65. Cross-section of window seal.

INSTALLATION —

5. Replace the seal around the enclosure’s cutout, with the locking tab facing the inside of the machine.

6. Replace the window panel into the seal. The tool can be placed between the window panel and the seal to aid in replacing the window panel into the seal.

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MECHANICAL SERVICE

3.15 HYDRAULIC COUNTERBALANCE

TOOLS REQUIRED

ü

ü

(1) 4 x 4 x 14″ head support block

Hydraulic counterbalance service kit, consists of:

l l

Pressure tank with manifold assembly, prefilled with (2) quarts DTE-25 hydraulic oil

Hydraulic cylinder with hose attached (if necessary)

H

YDRAULIC

T

ANK

R

EPLACEMENT

REMOVAL —

CAUTION! While performing this procedure, the spindle head may drop if the control loses power or alarms.

1. Raise spindle head by HANDLE JOG up to 14.5″ above table. Insert wood block and lower head casting onto it. EMERGENCY STOP the machine. Head should rest securely on table block. Power OFF VMC.

Note: DO NOT LOWER SPINDLE ONTO BLOCK.

2. Disconnect the two-pin end of the pressure sensor cable(s) to the pressure sensor(s), if tank is equipped with sensor.

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128

Figure 3-66. Hydraulic counterbalance charge/discharge kit (shown in place to discharge system).

3. Remove cap to Schrader filler valve.

4. Ensure T-handle of the gas chuck is turned completely counterclockwise. Attach charge/discharge kit by tightening gas chuck to the Schrader valve finger tight, then wrench lightly to tighten (see Figure 3-66).

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MECHANICAL SERVICE

5. Place the CGA 580 end of charge/discharge kit into a bucket to the contain the hydraulic oil while discharging the system.

6. Slowly turn the T-handle clockwise until the system begins to discharge. Complete discharge may take up to 10 minutes. Verify tank gauge reads 0 psi.

7. Turn the T-handle completely counterclockwise and remove the charge/discharge kit from the Schrader valve.

8. Disconnect the hydraulic hose from the tank assembly.

9. Remove the tank assembly from the column by removing the four SHCS from the tank mount.

INSTALLATION —

10. Connect the hose to the tank before mounting the tank in the inverted position. This prevents hydraulic oil from spilling.

Note: For a positive seal, ensure the hose-to-tank connection is straight, and not skewed.)

11. Mount the tank assembly to the column with the tank mount and four SHCS. Ensure the hydraulic hose is not twisted.

12. Connect the two-pin end of the pressure sensor cable(s) to the pressure sensor(s).

13. Use cable ties to secure the cable to the hydraulic hose.

Note: For this step, use regulated dry nitrogen gas (welding grade acceptable) that accepts a right-hand thread CGA 580 fitting.

14. Attach the CGA 580 fitting end of the charge/discharge kit to the source pressure. Ensure T-handle of the gas chuck is turned completely counterclockwise. Attach charge/discharge kit by tightening gas chuck to the Schrader valve finger tight, then wrench lightly to tighten. Pressurize the system to required pressure as listed in Figure 3-67.

Note: For VF-6/8 follow installation procedure for each hydraulic tank.

Note:

Ø Do not use compressed air, oxygen or flammable gas.

Ø Refer to the table below and verify pressure according to machine and spindle head position.

Ø Verify cylinder is seated in counterbore.

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Figure 3-67. Tank pressure requirements.

15. Power on the machine and zero return (ZERO RET) Z-axis only. Check for any leaks or abnormal noises.

Verify tank pressure at top of travel. Remove charging system and replace valve cap.

Note: If there is an E-stop alarm that will not reset, check for correct system pressure and the correct tank assembly.

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MECHANICAL SERVICE

H

YDRAULIC

C

YLINDER

R

EPLACEMENT

REMOVAL-

1. Remove the hydraulic tank as described in previous section.

2. To gain access to the cylinder rod, remove the three SHCS holding the Z-axis way cover to the spindle head.

3. Remove the cotter pin and lock nuts from the threaded end of the cylinder rod.

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130

Figure 3-68. Hydraulic Cylinder Rod Installation for VF-0 through 4 and (VF-6/8).

Note: For VF-6/8 loosen jam nut from clevis then remove the cotter pin, clevis pin, clevis and jam nut.

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MECHANICAL SERVICE

4. Remove the band clamp that holds the cylinder to the stabilizer bracket. Loosen the two SHCS that attach the bracket to the column.

5. Remove the hydraulic cylinder from the top of the column.

Figure 3-69. VF-Series hydraulic counterbalance — right side view.

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Fig. 3-70 VF-Series hydraulic counterbalance view — left side view.

Note: Do not disassemble unit. Keep the hose attached to the cylinder.

131

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MECHANICAL SERVICE

6. Return complete assembly to HAAS Automation.

INSTALLATION-

7. Install cylinder with cylinder rod extended from top of column.

Note: Cylinder rod should pass through column bracket and spindle head bracket.

Cylinder body must rest in column bracket counterbore.

8. Orient cylinder body with hydraulic hose facing away from lead screw.

Note: For VF-6/8 orient cylinder bodies with hydraulic hose facing the lead screw.

9. Install lock nuts, at threaded end of cylinder rod, wrench tight. Install safety cotter pin.

Note: For VF-6/8 install jam nut and clevis at end of cylinder rod then attach to spindle head bracket with clevis pin. Install safety cotter pin and lock the clevis by tightening jam nut.

10. Install the hydraulic tank as described in the previous section, but DO NOT power up the machine.

11. Power on the machine and zero return (ZERO RET) Z-axis only. Observe cylinder body for motion or abnormal noises. Check for fluid at manifold, cylinder hose connection and cylinder rod. Verify tank pressure at top of travel. Remove charging system and replace valve cap.

12. Install the band clamp and tighten the two SHCS that attach the stabilizer bracket to the column.

13. Zero return (ZERO RET) machine. HANDLE JOG Z-axis in 0.1 increments. Verify full Z travel.

14. Cycle Z-axis, using the following program, for five minutes and check for oil leaking at top of cylinder and cylinder rod.

G28, G54, Z-14.

M99

50% Rapid

15. If Z-axis overcurrents alarm during travel, verify and correct system pressure.

Note:

Ø If Z-axis overcurrent alarm at top or bottom of travel, call HAAS Automation Service

Department immediately for assistance.

Ø If fluid leaks from hydraulic fittings, check that fittings are tight.

Ø If leaking continues, call HAAS Automation Service Department for assistance.

16. Reinstall Z-axis way cover with three SHCS that hold it to the spindle head.

June 1998

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MECHANICAL SERVICE

3.16 THROUGH THE SPINDLE COOLANT SYSTEM — ADJUSTMENTS

TOOLS REQUIRED

ü

ü

Tool holder with small TSC drill or restrictor (with a small orifice #T-1461)

TSC Gauge Kit (P/N 93-9011), includes:

l l

0-15 PSI Precharge pressure gauge

0-160 PSI Purge pressure gauge (Not used on newer TSC machines)

l l

0-600 Coolant pressure gauge

Ball valve

P

RECHARGE

R

EGULATOR

A

DJUSTMENT

1. CAUTION! Extreme care must be taken in making this delicate adjustment. Insert a short piece of 1/4″ plastic tubing into the 0-15 psi pressure gauge. Insert the short tube into the precharge pressure regulator

(located on top of the transmission) and connect the plastic precharge tube (leading to the TRP) to the pressure gauge.

2. Manually turn on the precharge air by pushing the plunger on the precharge solenoid valve.

3. Hold down the precharge solenoid valve for at least 20 seconds to allow the pressure reading to stabilize, then set the precharge pressure to 4.0 psi (±0.4 psi). Release the solenoid and hold it down again for 20 seconds and re-check the precharge pressure. Repeat this a few times to ensure the pressure setting remains stable. Be sure the regulator adjustment knob is securely locked in place.

4. Remove the pressure gauge and short 1/4″ hose. Reattach the precharge tube to the regulator.

P

RIMING THE

TSC S

YSTEM

Note: When machine is ready to operate, with coolant in the coolant tank, prime the

Through the Spindle Coolant (TSC) system according to the following procedure. This procedure should also be performed whenever the pump has sucked in air (e.g. low coolant).

50 Taper TSC (old system)

1. With no tool in the spindle, switch to MDI mode.

2. Close the programmable coolant (p-Cool) and lock line shut-off valves.

3. Press the COOLNT key to turn on the main coolant pump; this will prime the TSC pump.

4. Wait 20-30 seconds for the TSC pump to fill.

5. Press the AUX CLNT key to turn on the TSC. Wait for coolant to flow from the spindle at full force.

6. Press the reset key to shut off the system. The TSC system will continue to hold it’s prime after this.

High pressure TSC 40 and 50 taper

1. With no tool in the spindle, switch to MDI mode.

2. Press the AUX CLNT button to turn on TSC. Wait for coolant to flow from the spindle.

3. Allow coolant to flow for at least one minute.

4. Press the AUX CLNT button again to turn off TSC.

C

HECKING

P

UMP

P

RESSURE

Note: If the coolant pressure with no tool in the spindle is 60 psi or less, replace the pump assembly (30-3281A). Old Tsc system uses pump head (93-3280B).

1. Insert the 0-600 psi coolant pressure gauge into the coolant line between the coolant filters and the TSC pump hose. Use wrenches to tighten the fittings snug. DO NOT OVERTIGHTEN !!

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MECHANICAL SERVICE

2. With no tool in the spindle, prime the TSC system as described above.

3. Insert a standard (no through hole in pull stud) tool holder into the spindle.

4. Turn on TSC.

5. Check for leaks while TSC is still running. Shut off TSC.

6. Remove pressure gauge and reconnect the pump to the machine.

If the pump relief valve has been changed, adjust the relief valve in the following manner:

1. Remove the sealing cap from the pump relief valve. Loosen the lock nut.

2. Start with the pressure below 300 psi. Adjust the pressure relief valve until the pressure on the gauge rises

to 300 psi. Tighten the lock nut, and replace the sealing cap. Setting range is 280-300psi.

3. Mark across the pump and sealing cap with a paint marker. This will indicate any future tampering.

T

ESTING THE

C

OOLANT

P

RESSURE

S

WITCH

1. Insert the ball valve and pressure gauge into the TSC pump outlet. The ball valve must be between the pump and pressure gauge. Connect the other end to the machine. For high pressure TSC, the connectors must be tightened snug with wrenches. DO NOT OVERTIGHTEN.

2. Run TSC system for one minute to purge air

3. Insert a TSC type tool holder (with a small TSC drill or restrictor) in the spindle. CAUTION! Changing tools after running TSC can cause coolant to spray out. Wear safety glasses.

June 1998

WARNING! Do not put your hands in the high pressure coolant stream as coolant and particles can be blown into your skin.

4. Set Parameter 236 to 100.

5. Turn on TSC. Test low coolant pressure switch by slowly shutting off the ball valve in the coolant line

(pump should shut off at 40 psi +/- 5 psi). If the switch is outside this range, replace the switch.

Note: Test the electrical continuity of the pressure switch cable and the control function by shorting the leads of the cable. The «LO CLNT» bit on the Diagnostics page should change from «1» to «0». Check this before replacing the pressure switch.

5. Reset Parameter 236 to 1000.

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3.17 AIR / OIL LINE DIAGRAM

MECHANICAL SERVICE

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MECHANICAL SERVICE

THROUGH THE SPINDLE COOLANT

SYSTEM FLOW DIAGRAM

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136

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THROUGH THE SPINDLE COOLANT

SYSTEM FLOW DIAGRAM

50 TAPER SPINDLE

MECHANICAL SERVICE

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138

MECHANICAL SERVICE

3.18 AUTOMATIC PALLET CHANGER (APC)

P

ALLET

R

EPLACEMENT

TOOLS REQUIRED:

ü

Hoist

ü

Eyebolts (2)

ü

Straps or Chains

CAUTION! Be careful when changing out pallets, each pallet weighs approx. 300lbs.

Note: Pallets that have been replaced must be re-aligned to the receiver. Pallets shipped with the VMC from the factory have been machined perpendicular to the spindle. It is recommended that replacement pallets be machined after aligning them to the reciever.

1. Remove the old pallet from the APC using the supplied eyebolts and a hoist.

2. Set the new pallet on the APC, aligning the roller grooves on the bottom of the pallet with the rollers on the APC.

3. Loosen the clamp rail bolts on the new pallet (the bolts should be snug and not overtight).

4. Run new pallet into the receiver. Clamp and unclamp the pallet a few times (this will allow the pallet to center on the guide pins). Torque the clamp rail bolts to 50 FT-LB while the pallet is clamped to the receiver.

June 1998

Figure 3-71 Pallet Replacement

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June 1998

IMPORTANT! New pallets should be machined on the VMC in order for them to be perpendicular to spindle.

P

ALLET

C

LAMP

R

AIL

R

EPLACEMENT

TOOLS REQUIRED:

ü

ü

Hoist

Eyebolts (2)

ü

Straps or Chains

Note: This procedure must be performed with the pallets on the APC.

1. Loosen the clamp rail bolts.

2. Screw the eyebolts into place and lift the pallet carefully.

3. Remove the clamp rails from the pallets.

MECHANICAL SERVICE

96-8100

Figure 3-72

4. Verify the condition of the wipers and determine if they need replacing.

5. Re-install the new rails leaving the bolts loose.

6. Carefully place the pallet back onto the APC using the hoist.

7. Position the pallet back onto the receiver and clamp/unclamp the pallet several times to allow the rails to center themselves on to the guide pins.

8. Finish torquing the clamp rail bolts.

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MECHANICAL SERVICE

A

LIGNMENT

P

IN

R

EPLACEMENT

TOOLS REQUIRED:

ü

ü

Hoist

Eyebolts (2)

ü

Straps or Chains

CAUTION! Be careful when changing out pallets, each weighs approx. 300lbs.

Note: The receiver must removed in order to access the alignment pins.

1. Both pallets must be on the APC in order to access the receiver.

2. Position the receiver to the front of the machine.

3. Disconnect the air from the machine.

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140

Figure 18-3 Alignment Pin Removal

3. Remove the six (6) receiver mounting bolts.

4. Use a hoist and the two eyebolts supplied with the APC, lift the receiver off the table.

5. Use a punch to remove the alignment pins.

6. Install the new pins using a brass hammer. The pins should bottom out in the holes.

Pin height from the base of the receiver to the top of the pin should be within .450 to .490.

7. Position the receiver back onto the table.

8. Install the six mounting bolts.

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June 1998

MECHANICAL SERVICE

9. Reconnect the air to the machine.

10. Postion a pallet onto thte receiver and clamp/unclamp the pallet to the receiver several times. Check for the pallets sticking during this process. If the pallets are sticking, loosen the clamp rail bolts and clamp/ unclamp the pallet several times to center the alignment pin to the rails.

Note: Because the receiver was been removed from the VMC, any tooling on the pallets must be re-aligned.

D

RIVE

P

IN

R

EPLACEMENT

Note: If the drive pin assembly is damaged due to a crash or from excessive wear, all components should be checked for damage and replaced.

Note: The chain must be loosene in order to remove the entire drive pin assembly.

1. Power off the machine.

2. Remove the drive pin retaining clip.

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Figure 3-73 Drive Pin Assembly

3. Remove 1/4″ washer.

4. The cam follower is lightly pressed onto the pin. The spacer should slide off easily.

L

OOSENING THE CHAIN

.

5. Remove the two screws that mount the coverplate over the sprocket located at the far end of the APC as shown.

141

142

MECHANICAL SERVICE

Figure 3-74 Loosening Chain Sprocket

6. Loosen the 4 bolts that mount the sprocket bracket to the casting.

7. Loosen the chain sprocket tensioner screw slightly.

8. At this point there should be enough slack in the chain to slide the drive pin out.

9. Re-assemble the drive pin assembly according to the assembly drawing below.

10. Re-tension the chain in the reverse order.

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ELECTRICAL SERVICE

4. ELECTRICAL SERVICE

4.1 SOLENOIDS

Please read this section in its entirety before attempting to replace any solenoid assemblies.

5.

6.

2.

3.

4.

A

IR

S

OLENOID

A

SSEMBLY

REMOVAL —

1.

Turn machine power on and raise spindle head to uppermost position. Turn power off.

Remove spindle head covers (Mechanical Service).

Remove air supply from machine.

Disconnect all air lines going to and from the air solenoid assembly on the bottom rear of the solenoid bracket. Do not remove the fittings — remove the lines from the fittings.

Disconnect the two leads to the low air pressure sensor.

Unplug the wiring leading to the plug marked on the solenoid bracket as «880 FROM I/O PCB TO

SOLENOID VALVES» and the plug marked «SPARE».

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7.

Figure 4-1. Air solenoid assembly.

Remove the SHCS holding the assembly to the bracket and remove the assembly.

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ELECTRICAL SERVICE

INSTALLATION:

8.

Replace the air solenoid assembly and attach to the bracket with the SHCS previously removed.

Tighten securely.

9.

Reconnect all air lines at this time, ensuring that all connections are tight and do not leak.

10.

Reconnect the two leads to the low air pressure sensor.

11.

Reconnect the wiring to the plugs on the solenoid bracket (see Step 6).

12.

Reconnect air supply to the machine.

4.

5.

2.

3.

T

OOL

R

ELEASE

P

ISTON

A

SSEMBLY

A

IR

S

OLENOID

1.

Turn machine power on and raise spindle head to uppermost position. Turn power off.

Remove spindle head covers (Mechanical Service).

Remove air supply from machine.

6.

Remove the tool release piston assembly (Mechanical Service).

Unscrew the air solenoid assembly from the tool release piston assembly, taking care to not disturb the position of the clamp/unclamp switches.

Unscrew the air solenoid from the air solenoid assembly.

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144

7.

8.

9.

Figure 4-2. Tool release piston assembly with air solenoid assembly.

Install the new air solenoid on the air solenoid assembly. Reinstall the air solenoid assembly onto the tool release piston assembly. Take care to not disturb the position of the clamp/unclamp switches.

Reinstall the tool release piston assembly (Mechanical Service).

Ensure all air lines are reconnected to their proper fitting!

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June 1998

S

PINDLE

L

UBE

A

IR

S

OLENOID

1.

Turn the machine power off and remove the air supply from the machine.

ELECTRICAL SERVICE

2.

3.

Figure 4-3. Front side of lube/air panel.

Disconnect the air lines from the spindle lube air solenoid assembly.

Unplug the electrical leads at the quick-disconnect. You will have to slide the wiring channel cover back to disconnect the leads.

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Figure 4-4. Top view of spindle lube/air solenoid assembly.

145

ELECTRICAL SERVICE

4.

Unscrew the assembly from the T-fitting.

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146

5.

6.

7.

8.

Figure 4-5. Top view of spindle lube/air solenoid assembly.

Replace the assembly, ensuring it is approximately horizontal to the floor, and tighten fittings securely.

Reconnect all air lines.

Reconnect wiring leads at the quick-disconnect in the wiring channel. Slide cover back into place.

Restore air supply to the machine.

4.2 LINE VOLTAGE ADJUSTMENTS

Please read this section in its entirety before attempting to adjust the line voltage.

TOOLS REQUIRED

ü

ü

Large flat tip screwdriver

Digital voltmeter

ADJUSTING VOLTAGE —

Note: The machine must have air pressure at the air gauge or an interlock will prevent it from powering up.

CAUTION! Working with the electrical services required for the VMC can be extremely hazardous. The electrical power must be off and steps must be taken to ensure that it will not be turned on while you are working with it. In most cases this means turning off a circuit breaker in a panel and then locking the panel door. However, if your connection is different or you are not sure how to do this, check with the appropriate personnel in your organization or otherwise obtain the necessary help BEFORE you continue.

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WARNING! The electrical panel should be closed and the three screws on the door should be secured at all times except during installation and service. At those times, only qualified electricians should have access to the panel. When the main circuit breaker is on, there is high voltage throughout the electrical panel (including the circuit boards and logic circuits) and some components operate at high temperatures. Therefore extreme caution is required.

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1.

Figure 4-6. Control cabinet general overview.

Hook up the three power lines to the terminal on top of the main switch at upper right of electrical panel and the separate ground line to the ground bus to the left of the terminals.

WARNING! Through the Spindle Coolant (TSC) pump is a three phase pump and MUST BE

PHASED CORRECTLY! Improper phasing will cause damage to the TSC pump and void the warranty. Refer to the TSC start up section.

147

ELECTRICAL SERVICE

227 to 243 left c

244 to 260 left s

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2.

Figure 4-7. Power lines; hookup location.

Note: Make sure that the service wires actually go into the terminal-block clamps. [It is easy to miss the clamp and tighten the screw. The connection looks fine but the machine runs intermittently or has other problems, such as servo overloads.] To check, simply pull on the wires after the screws are tightened.

After the line voltage is connected to the machine, make sure that main circuit breaker (at top-right of rear cabinet) is off (rotate the shaft that connects to the breaker counterclockwise until it snaps off). Turn on the power at the source. Using an accurate digital voltmeter and appropriate safety procedures, measure the voltage between all three pair phases at the main circuit breaker and write down the readings. The voltage must be between 195 and 260 volts.

Note: wide voltage fluctuations are common in many industrial areas; you need to know the minimum and maximum voltage which will be supplied to the machine while it is in operation. U.S. National Electrical Code specifies that machines should operate with a variation of +5% to -5% around an average supply voltage. If problems with the line voltage occur, or low line voltage is suspected, an external transformer may be required.

If you suspect voltage problems, the voltage should be checked every hour or two during a typical day to make sure that it does not fluctuate more than +5% or -5% from an average.

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3.

Figure 4-8. Transformer connections.

CAUTION! Make sure that the main breaker is set to OFF and the power is off at your supply panel BEFORE you change the transformer connections. Make sure that all three black wires are moved to the correct terminal block and that they are tight.

Check the connections on the transformer at the bottom-right corner of the rear cabinet. The three black wires labeled 74, 75, and 76 must be moved to the terminal block triple which corresponds to the average voltage measured in Step 2 above. There are four positions for the input power to this transformer. The input voltage range for each terminal block is as follows:

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ELECTRICAL SERVICE

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4.

Figure 4-9a. Transformer with 354-488V Figure 4-9b Transformer with 195-260V range

Set the main switch to on (rotate the shaft that engages the handle on the panel door clockwise until it snaps into the on position). Check for evidence of problems, such as the smell of overheating components or smoke. If such problems are indicated, set the main switch to off immediately and call the factory before proceeding.

5.

After the power is on, measure the voltage across the upper terminals on the contactor K1 (located below the main circuit breaker. It should be the same as the measurements where the input power connects to the main breaker. If there are any.

150

Figure 4-10. Measure voltage here. problems, call the factory.

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6.

7.

ELECTRICAL SERVICE

Check the DC voltage displayed in the second page of Diagnostic data on the CRT. It is labeled DC BUS.

This voltage must be between 150 and 175 volts. If the voltage is outside these limits, turn off the power and recheck the incoming power and the transformer wiring (repeat steps 2 and 3). If the voltage is still incorrect, turn off the power and call the factory.

Turn off the power (rotate the shaft that engages the handle on the panel door counterclockwise until it snaps into the off position). Also, set the main switch handle on the panel door to off. (Both the handle and the switch must be set to off before the door can be closed). Close the door, screw the screws into place, and turn the power back on.

4.3 FUSE REPLACEMENT

Please read this section in its entirety before attempting to replace any fuses.

O

VERVOLTAGE

F

USES

WARNING! The electrical panel will have residual voltage, even after power has been shut off and/or disconnected . Never work inside this cabinet until the small red CHARGE light on the servo drive assembly goes out. The servo drive assembly is on the left side of the main control cabinet and about halfway down. This light is at the top of the circuit card at the center of the assembly. Until this light goes out, there are dangerous voltages in the assembly EVEN

WHEN POWER IS SHUT OFF.

1. Turn machine power off.

2. Turn the main switch (upper right of electrical cabinet) to the off position.

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3.

Figure 4-11. Unscrew the three screws to open the cabinet door. (Control cabinets may require a key)

Using a large flat tip screwdriver, loosen the three screws on the cabinet door and then open the door enough to safely work on the electrical panel. Wait until at least the red CHARGE light on the servo drive assembly goes out before beginning any work inside the electrical cabinet.

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ELECTRICAL SERVICE

4.

5.

On the POWER SUPPLY board there are three fuses located in a row at the upper right of the board; these are the overvoltage fuses. An orange light will be on to indicate the blown fuse(s).

Using a flat tip screwdriver, turn the fuse(s) counterclockwise to remove and replace the blown fuse(s) with ones having the same type and rating (½ amp, type AGC, 250V).

June 1998

CAUTION! When the left fuse is blown, it is still possible to operate the machine, thereby making an overvoltage situation possible. VERIFY absolute voltage to the machine does not exceed 260 volts.

O

PERATOR

‘

S

L

AMP

F

USE

1.

Turn the main switch (upper right of electrical cabinet) to the off position.

2.

3.

Using a large flat tip screwdriver, loosen the three screws on the cabinet door and then open the door enough to safely work on the electrical panel. Wait until at least the red CHARGE light on the servo drive assembly goes out before beginning any work inside the electrical cabinet.

The Operator’s Lamp Fuse is located at the lower left of the Power Supply Board. An orange light will be on to indicate the blown fuse.

152

4.

Figure 4-12. Power supply board; fuse locations.

Using a flat tip screwdriver, turn the fuse counterclockwise to remove and replace the blown fuse with ones having the same type and rating (operator’s lamp:½ amp, type AGC, 250V).

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ELECTRICAL SERVICE

S

ERVO

D

RIVER

& SDIST F

USES

1.

Turn the main switch (upper right of electrical cabinet) to the off position.

2.

3.

Using a large flat tip screwdriver, loosen the three screws on the cabinet door and then open the door enough to safely work on the electrical panel. Wait until at least the red CHARGE light on the servo drive assembly goes out before beginning any work inside the electrical cabinet.

On the SERVO DRIVE ASSEMBLY, there are three fuses on the SDIST panel, and three individual fuses on each of the SERVO DRIVE boards (See Fig. 4-13; the F3 fuses are not shown).

4.

5.

On the SDIST panel, use a flat tip screwdriver to turn the fuse(s) counterclockwise to remove. Replace the blown fuse(s) with ones having the same type and rating (FU1, FU2: ½ amp, type AGC, 250V; FU3:

5 amp, type ABC, 250V).

On each of the SERVO DRIVER boards, the fuses (F1, F2, F3) may be replaced by simply pulling out the fuses by hand and replacing with fuses of the same type and rating (F1, F2: 20 amp, type ABC,

250V; F3: 10 amp, type ABC, 250V).

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Figure 4-13. Servo Drive Assembly; fuse locations

153

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ELECTRICAL SERVICE

8.

9.

4.4 PCB REPLACEMENT

Please read this section in its entirety before attempting to replace any PCBs.

M

ICROPROCESSOR

, MOCON (MOTIF) & V

IDEO

/ K

EYBOARD

Note: The arrangement of these boards may differ from the order of replacement that follows. The steps for replacement will only differ in which board may need to be removed before getting to the necessary board.

WARNING! The electrical panel will have residual voltage, even after power has been shut off and/or disconnected . Never work inside this cabinet until the small red CHARGE light(s) on the servo amplifiers (servo drive assembly for brush machines) goes out. The servo drive assembly is on the left side of the main control cabinet and about halfway down. This light is at the top of the circuit card at the center of the assembly. Until this light goes out, there are dangerous voltages in the assembly EVEN WHEN POWER IS SHUT OFF.

MOCON (or MOTIF) BOARD —

Note: Refer to «Cable Locations» for a diagram of this board.

1. Turn machine power off.

2. Turn the main switch (upper right of electrical cabinet) to the off position.

3. Loosen the three screws on the cabinet door and then open the door enough to safely work on the electrical panel. Wait until at least the red CHARGE light on the servo amplifiers (servo drive assembly on brush machines) goes out before beginning any work inside the electrical cabinet.

4. Disconnect all leads to the Motor Controller (MOCON), or Motor Interface (MOTIF) board (for brush machines). Ensure all cables are properly labeled for reconnecting later.

5. After all cables have been disconnected, unscrew the standoffs, taking care to hold the board in place until all standoffs have been removed.

Note: If the VIDEO / KEYBOARD or PROCESSOR boards need replacing, please skip the next step.

6. Replace the MOCON (or MOTIF) board, attaching it to the VIDEO / KEYBOARD (beneath the MOCON /

MOTIF board) with the standoffs.

7. Reconnect all leads (previously removed) to their proper connections.

VIDEO / KEYBOARD —

Note: Refer to «Cable Locations» for a diagram of this board.

Remove the MOCON (or MOTIF) board as described in Steps 1-5.

Disconnect all leads to the Video / Keyboard. Ensure all cables are properly labeled for reconnecting later. The following illustration shows all cable numbers and the locations on the Video / Keyboard.

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ELECTRICAL SERVICE

10.

After all cables have been disconnected, unscrew the standoffs, taking care to hold the board in place until all standoffs have been removed.

Note: If the PROCESSOR board need replacing, please skip the next step.

11.

Replace the Video / Keyboard, attaching it to the PROCESSOR board (beneath the Video /

Keyboard) with the standoffs.

12.

Reconnect all leads (previously removed) to their proper connections.

PROCESSOR BOARD —

Note: Refer to «Cable Locations» for a diagram of this board.

13.

Remove the MOCON (or MOTIF) board as described in Steps 1-5, and the Video / Keyboard as described in Steps 8-9.

14.

Disconnect all leads to the Processor (68020) board. Ensure all cables are properly labeled for reconnecting later. The following illustration shows all cable numbers and the locations on the 68030 board.

15.

After all cables have been disconnected, unscrew the standoffs, taking care to hold the board in place until all standoffs have been removed.

16.

Replace the Processor (68030) board, attaching it to the electrical cabinet (beneath the 68030 board) with the standoffs.

17.

Reconnect all leads (previously removed) to their proper connections.

S

ERVO

D

RIVER

& SDIST

WARNING! The electrical panel will have residual voltage, even after power has been shut off and/or disconnected . Never work inside this cabinet until the small red CHARGE light on the servo drive assembly goes out. The servo drive assembly is on the left side of the main control cabinet and about halfway down. This light is at the top of the circuit card at the center of the assembly. Until this light goes out, there are dangerous voltages in the assembly EVEN

WHEN POWER IS SHUT OFF.

1.

2.

3.

Turn machine power off.

Turn the main switch (upper right of electrical cabinet) to the off position.

Using a large flat tip screwdriver, loosen the three screws on the cabinet door and then open the door enough to safely work on the electrical panel. Wait until at least the red CHARGE light on the servo drive assembly goes out before beginning any work inside the electrical cabinet.

SDIST BOARD —

4.

Note: Refer to «Cable Locations» for a diagram of this board.

Disconnect all leads to the Servo Distribution (SDIST) board. Ensure all cables are clearly marked for reconnecting later.

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ELECTRICAL SERVICE

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5.

6.

7.

Note: The connection labeled «860A» on the board should be used for the cable marked

«860B». Some boards, the connection for cable 920 has been incorrectly marked as

«1030». Please note its location for future reference.

Note: On some SDIST boards, there may be cables attached to the capacitors with a plastic strap. This will have to be cut off and the cables moved aside in order to remove the board. It will be necessary to replace this strap after the board is replaced.

After all cables have been disconnected, remove the eight screws attaching the board to the cabinet.

Take care to hold the board in place until all screws have been removed.

Replace the SDIST board, attaching it with the eight screws previously removed, using one of the screws as a grounding connection.

Reconnect all leads (previously removed) to their proper connection.

SERVO DRIVER BOARDS —

1.

2.

3.

4.

Note: Refer to «Cable Locations» for a diagram of this board.

Follow all precautions noted previously before working in the electrical cabinet.

Turn the main switch (upper right of electrical cabinet) to the off position.

Using a large flat tip screwdriver, loosen the three screws on the cabinet door and then open the door enough to safely work on the electrical panel.

Disconnect all leads to the Servo Driver (DRIVER) board that you wish to replace. Ensure all cables are properly labeled for reconnecting later.

1.

2.

3.

6.

7.

5.

Note: When replacing any DRIVER board, it will be necessary to disconnect all leads on all DRIVER boards in order to remove or replace the board.

Remove the board by first removing the two screws that fasten it to the cabinet. Take care to hold the board in place until both screws have been removed.

Replace the DRIVER board, attaching it to the cabinet with the two screws previously removed.

Reconnect all leads to all boards at this time. Ensure the red and black leads go to the appropriate connections.

I/O B

OARD

4.

Note: Refer to «Cable Locations» for a diagram of this board.

Follow all precautions noted previously before working in the electrical cabinet.

Turn the main switch (upper right of electrical cabinet) to the off position.

Using a large flat tip screwdriver, loosen the three screws on the cabinet door and then open the door enough to safely work on the electrical panel.

Disconnect all leads to the Input/Output board and move aside for removal. Ensure all cables are properly labeled for reconnecting later. The following illustration shows all cable numbers and the locations on the I/O board.

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ELECTRICAL SERVICE

5.

6.

7.

Remove the board by first removing the twelve screws that fasten it to the cabinet. Take care to hold the board in place until all screws have been removed.

Replace the I/O board, attaching it to the cabinet with the twelve screws previously removed.

Reconnect all leads to the I/O board at this time.

P

OWER

& L

OW

V

OLTAGE

S

UPPLY

POWER BOARD —

2.

3.

1.

4.

5.

Note: Refer to «Cable Locations» for a diagram of this board.

Follow all precautions noted previously before working in the electrical cabinet (See warning at beginning of «Servo Driver & SDIST» section).

Turn the main switch (upper right of electrical cabinet) to the off position.

Using a large flat tip screwdriver, loosen the three screws on the cabinet door and then open the door enough to safely work on the electrical panel.

Disconnect all leads to the Power Distribution (POWER) board and move aside for removal. Ensure all cables are properly labeled for reconnecting later. The illustration on the following page shows all cable numbers and the locations on the POWER board.

After all cables have been disconnected, remove the seven screws holding the POWER board to the cabinet and remove the board. Take care to hold the POWER board in place until all screws have been removed.

6.

7.

Note: If you need to replace the LOW VOLTAGE POWER SUPPLY board, please skip the next step.

Replace the POWER board, attaching it with the seven screws previously removed. Don’t forget to use the lower left screw for a ground connection.

Reconnect all cables to the POWER board at their proper location.

LOW VOLTAGE POWER SUPPLY —

8.

9.

Remove the Power Distribution (POWER) board as described in Steps 1-5.

Disconnect all leads to the Low Voltage Power Supply (LVPS) board. Ensure all cables are properly labeled for reconnecting later. The following illustration shows all cable numbers and the locations on the LVPS board.

10.

After all cables have been disconnected, unscrew the two standoffs at the bottom of the board.

Unscrew the remaining two screws at the top of the LVPS board, taking care to hold the board in place until all screws have been removed.

11.

Replace the LVPS board, attaching it to the cabinet with the two screws and two standoffs previously removed.

12.

Replace the POWER board as described in Steps 6-7.

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ELECTRICAL SERVICE

RS-232

Note: Refer to «Cable Locations» for a diagram of this board.

1. Follow all precautions noted previously before working in the electrical cabinet (See warning at beginning of «Servo Driver & SDIST» section).

2. Turn the main switch (upper right of electrical cabinet) to the off position.

3. Using a large flat tip screwdriver, loosen the three screws on the cabinet door and then open the door enough to safely work on the electrical panel.

Note: It is suggested to make use of a step ladder high enough to allow you to work from the top of the electrical cabinet. It will be necessary, when replacing the RS-232 board, to work from the inside and outside of the cabinet at the same time.

4. On the left side of the cabinet, at the top of the side panel are two serial port connections labeled «SERIAL

PORT #1″ and «SERIAL PORT #2», SERIAL PORT #1 being the upper connection.

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158

* Serial interface replaces cable 700 with cable 700B.

Figure 4-14. RS-232 wiring pictorial (with serial keyboard).

5. To remove the RS-232 board, unscrew the two hex screws (on the exterior of the cabinet) holding the connector to the cabinet. From the inside of the cabinet, pull the connector through the panel, and disconnect the cable.

6. Replace the RS-232 board by first connecting the appropriate cable to the board (850 to SERIAL

PORT #1, 850A to SERIAL PORT #2, then inserting the board (cable side up) through the left side panel. Attach with the two hex screws previously removed. Ensure the board for Serial Port #1 is the upper connector and the board for Serial Port #2 is the lower connector.

7. Replace the Serial Keyboard Interface (KBIF) board, using the four screws previously removed, starting at the top right. Attach the screw and standoff loosely, then all other screws and standoffs, until all are mounted. Tighten down completely.

8. Reconnect all cables to the Serial KBIF board at their proper locations.

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4.5. FRONT PANEL

Please read this section in its entirety before attempting to replace any component of the control panel.

CRT A

SSEMBLY

R

EPLACEMENT

1.

Turn the power off and disconnect power to the machine.

2.

3.

Remove the screws holding the cover panel on the back of the control panel. Take care to hold the cover panel in place until all screws have been removed.

At this time, remove the end cap on the support arm and unplug the white cable at the connection inside, then unplug the black cable at the connection in the control panel. It may be necessary to cut straps off the black cable’s connector to unplug.

4.

5.

Unscrew the four hex nuts on the bottom row of the CRT bracket and remove, along with the washers.

Set aside in a safe place.

While holding up the CRT assembly, remove the four hex nuts on the top row of the CRT bracket, along with the washers.

6.

7.

CAUTION! Take extreme care to not drop or damage the CRT assembly when removing from the control panel.

CAREFULLY pull the CRT assembly out toward the rear until it is clear of the control panel and all wiring. Set CRT assembly down in a safe place so as not to damage.

Replace by sliding the new assembly onto the eight bolts (four each on top and bottom). Starting with the bottom right, place the washers and hex nuts on the bolts to hold in place. Refer to Fig. 4-15 for the order of replacement.Once all washers have been attached and nuts have been hand-tightened, tighten down completely with the socket.

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Figure 4-15. Interior of control panel (rear).

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ELECTRICAL SERVICE

8.

9.

Plug the black cable and white cable into the matching cables. Feed the white cable through the opening in the top of the control panel.

Replace the back cover panel and attach with the four screws previously removed.

J

OG

H

ANDLE

R

EPLACEMENT

The JOG handle is actually a 100-line-per-revolution encoder. We use 100 steps per revolution to move one of the servo axes. If no axis is selected for jogging, turning of the crank has no effect. When the axis being moved reaches its travel limits, the handle inputs will be ignored in the direction that would exceed the travel limits.

Parameter 57 can be used to reverse the direction of operation of the handle.

1.

Turn the machine power off.

2.

3.

Remove the screws holding the cover panel on the back of the control panel. Take care to hold the cover panel in place until all screws have been removed.

Unplug the cable leading to the jog handle encoder. IMPORTANT! The blank pin side of the connector must face as shown in Fig. 4-16 when reconnecting; otherwise, damage may occur to the machine.

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4.

Figure 4-16. Jog handle encoder.

Using the 5/64″ allen wrench, loosen the two screws holding the knob to the control panel and remove.

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ELECTRICAL SERVICE

Figure 4-17. Jog Handle removal Figure 4-18. Jog Handle wiring diagram

5.

6.

Remove the three screws holding the jog handle encoder to the control panel and remove.

Replacement is reverse of removal. Keep in mind the important notice in Step 3.

S

WITCH

R

EPLACEMENT

1.

2.

3.

4.

5.

Note: This section is applicable for the POWER ON, POWER OFF, EMERGENCY STOP,

CYCLE START, and FEED HOLD switches.

Turn the machine power off.

Remove the four screws holding the cover panel on the back of the control panel. Take care to hold the cover panel in place until all screws have been removed.

Disconnect all leads to the switch’s connectors. Ensure all leads are properly marked for reconnecting later. Refer to Fig. 4-15 for proper locations.

Unscrew the two small set screws, one on top and one on the bottom, and turn the switch counterclockwise to loosen. Separate from the front portion and pull out.

For replacement, screw the front and rear portions together (reverse of removal) and tighten down the two small set screws when the switch is properly positioned.

6.

Note: The POWER ON, POWER OFF, and EMERGENCY STOP switches must all have the connectors on the bottom of the switch.

Reconnect all leads to the correct switch.

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S

PINDLE

L

OAD

M

ETER

R

EPLACEMENT

1.

Turn the power off and disconnect power to the machine.

2.

3.

Remove the four screws holding the cover panel on the back of the control panel. Take care to hold the cover panel in place until all screws have been removed.

Disconnect the two leads at the back of the spindle load meter assembly. Ensure the two leads are properly marked for reconnecting later.

4.

5.

Unscrew the four screws that hold the spindle load meter assembly to the control panel. Take care to hold the assembly in place until all screws have been removed. Remove the assembly.

Installation is reverse of removal. Ensure leads go the correct location.

3.

4.

5.

K

EYPAD

R

EPLACEMENT

1.

Turn the power off and disconnect power to the machine.

2.

Remove the four screws holding the rear cover panel to the back of the control panel. Take care to hold the cover panel in place until all screws have been removed.

Remove all switches, spindle load meter, and the jog handle as described in the previous sections.

Unplug the keypad’s 24-pin ribbon cable from the Keyboard Interface board.

Remove the screws from the front of the control panel. Take care to hold the front cover panel and bezel spacer in place until all screws have been removed. Remove the two pieces and set aside in a safe place.

6.

7.

Using a flat, blunt tool, such as putty knife, pry the keypad away from the control panel. Pull the ribbon cable through the opening in the control to remove.

To replace, first put the bezel spacer in place and fasten temporarily with screws in the top corners.

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Figure 4-19. Keypad installation.

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2.

3.

8.

9.

Insert the ribbon cable through the opening in the control panel and place the keypad in the upper right corner of the lower opening and press to the control panel to mount. Plug the ribbon cable into the Keyboard Interface board, taking care to not bend the pins on the board.

While holding the bezel spacer in place, remove the two screws holding the spacer, put the front cover panel in place, and fasten with all screws previously removed.

10.

Reinstall all switches, spindle load meter, and the jog handle as described in the previous sections.

11.

Replace the rear cover panel and fasten with the screws that were previously removed.

S

ERIAL

K

EYBOARD

I

NTERFACE

(KBIF)

1.

4.

5.

6.

7.

Note: Refer to «Cable Locations» for a diagram of this board.

Follow all precautions noted previously before working in the control cabinet (See warning at beginning of Section 5).

Turn the main switch (upper right of electrical cabinet) to the off position.

Remove the four screws on the back of the control box, then remove the cover panel. Take care to hold the panel in place until all screws have been removed.

Disconnect all leads to the Serial Keyboard Interface (KBIF) board. Ensure all cables are properly labeled for reconnecting later.

After all cables have been disconnected, unscrew the four screws holding the Serial KBIF board to the control box. Take care to hold the board in place until all screws have been removed. Place the screws and standoffs aside for later use.

Replace the Serial KBIF board, using the four screws previously removed, starting at the top right.

Attach the screw and standoff loosely, then all other screws and standoffs, until all are mounted.

Tighten down completely.

Reconnect all cables to the Serial KBIF board at their proper locations.

4.6 SPINDLE ENCODER REPLACEMENT

Please read this section in its entirety before attempting to remove or replace encoder.

2.

3.

4.

REMOVAL —

1.

Turn machine power on. Raise or lower spindle head to a position that will allow you to easily work on the encoder (must be above the enclosures). Turn machine off.

Remove head covers (Mechanical Service).

Disconnect the encoder cable at the top of the encoder.

Unscrew and remove the four 10-32 screws holding the encoder to the four standoffs (VF-1, VF-2, VF-

3,VF-4) or mounting bracket (VF-0). Remove the encoder, leaving the belt on the pulley at the orient ring.

INSTALLATION —

If you wish to install an encoder on a machine start at step 5; if this is just a replacement, skip to step 13.

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ELECTRICAL SERVICE

6.

7.

Please note the differences in installation between the VF-0, VF-1, VF-2, and the VF-3,VF-4.

5.

For the VF-1, VF-2, and VF-3, VF-4, put some blue Loctite on the threads of the four set screws and screw approximately halfway into the standoffs. Screw the hex end of the set screws into the standoffs.

Screw the standoffs into the four holes located at the rear of the transmission’s top plate.

For the VF-0, place the mounting bracket in place. Fasten to the top plate with the four screws and four lock washers.

8.

9.

Place the 18-tooth pulley onto the pulley bushing and tighten down. Place the SHCS through the center axis of the pulley.

Screw this assembly into the spindle orientation ring.

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Figure 4-20. Spindle encoder installation (VF-1/VF-2).

10.

Place the 36-tooth pulley onto the encoder, making the top of the pulley flush with the end of the shaft.

Tighten down with the 5/64″ hex wrench.

11.

Unscrew the four screws and remove the cover panel on the box at the base of the flexible tube.

12.

Feed the encoder cable through the flexible tube and connect at the plug in the box on top of the electrical cabinet.

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ELECTRICAL SERVICE

Figure 4-21. VF-0 encoder installation.

13.

Place the belt on the 36-tooth pulley, then loop over the 18-tooth pulley. Place the encoder assembly on the four standoffs (mounting bracket on the VF-0) and attach with the four 10-32 SHCS, placing the #10 lock washers between the socket head and the encoder base.

14.

Connect the encoder cable to the encoder assembly.

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5. TECHNICAL REFERENCE

5.1 TOOL CHANGER

The tool changer is an all electric fixed shuttle type. Tools are always loaded through the spindle and should never be installed directly in the carousel in order to avoid crashes. The pocket open to the spindle must always be empty in the retracted position. All wiring to the tool changer goes through connector P6 on the side of the control cabinet.

CAUTION! If machine is equipped with the optional 50 taper spindle, follow these guidelines:

Ø

Ø

25 lb. maximum per tool, and 300 lb. maximum total tool weight.

Extremely heavy tool weights should be distributed evenly.

CAUTION! If machine is equipped with the 20 or 32 pocket tool changer, follow these guidelines:

Ø

Ø

Ø

12 lb. maximum per tool (200 lb. maximum total tool weight for 32 pocket tool changer).

Extremely heavy tool weights should be distributed evenly.

Ensure there is adequate clearance between tools in the tool changer before running an automatic operation. This distance is 3.6″ for 20 pocket, and is 3.4″ for 32 pocket.

Low air pressure or insufficient volume will reduce the pressure applied to the tool unclamp piston and will slow down tool change time or will not release the tool.

If the shuttle should become jammed, the control will automatically come to an alarm state. To correct this, push the EMERGENCY STOP button and remove the cause of the jam. Push the RESET key to clear any alarms.

Press «Tool Changer Restore» button, to automatically reset the tool changer after a crash. Never put your hands near the tool changer when powered unless the EMERGENCY STOP button is pressed.

FU1 on the I/O PCB or the Power PCB is a fuse for the tool changer motors. It might be blown by an overload or jam of the tool changer. Operation of the tool changer can also be interrupted by problems with the tool clamp/unclamp and the spindle orientation mechanism. Problems with them can be caused by low air pressure or a blown solenoid circuit breaker CB4.

When a tool change operation is performed, the following sequence of events occurs:

1) Z axis moves up to machine zero,

2) If the spindle is turning, it is commanded to stop; coolant stopped,

3) Spindle oriented to Tool Changer,

4) Turn TSC pump off, (optional)

5) Turn purge on and off (optional)

6) Pre-charge is on (40 taper spindle only),

7) Shuttle moves in to release tool,

Tool unclamps,

9) Z axis moves up,

10) Tool Changer rotates,

11) Z axis moves down,

12) Tool clamps,

13) Pre-charge off (40 taper spindle only),

14) Shuttle moves out.

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P

ULL

S

TUDS

The tool holders used are CT #40 taper, V flange, commonly called “CT 40”. For the 50 taper spindle option, the tool holders used are CT #50 taper, V flange, commonly called “CT 50”. Use A “45 Degree, P40T Type 1

(P50T Type 1 for 50 taper) inch threads” pull stud built to JMTBA standard “MAS 403-1982”. This pull stud is characterized by a long shaft and a 45 with a sharp right angle (90 o o

shoulder under the head. Do not use the short shaft or pull studs

) head as they will not work and will cause serious damage. If the machine is equipped with the optional BT tool changer, use BT tooling only. Pull studs are available through HAAS.

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Tool holders and pull studs must be in good condition and tightened together with wrenches or they may stick in the spindle taper. Clean the tool tapers with a lightly-oiled rag to leave a film to prevent rusting. Tools that make a loud bang when being released indicate a problem and should be checked before serious damage to the shuttle occurs. When the TOOL RELEASE button is pressed, the tool should be pushed out of the spindle by a small amount (approximately .07″). This is an indication that the pull stud is correctly touching the release mechanism.

T

OOL

C

HANGER

L

UBRICATION

Place lubricating grease on the outside edge of the guide rails of the tool changer and run through all tools.

S

HUTTLE

I

N

/O

UT

M

OTOR

A DC brush motor is used to move the tool changer assembly towards and away from the spindle. This is called the shuttle. The motor is geared down to a low RPM and then connected to an arm that rotates through 180 and pushes the shuttle in and out.

o

Note: This motor should never be disassembled.

T

URRET

R

OTATION

M

OTOR

A DC brush motor is used to rotate the tool turret between tool changes. This motor is geared down to a low

RPM and connected to a Geneva mechanism. Each 1/2 revolution of the Geneva mechanism moves the tool turret one tool position forward or backward.

Note: This motor should never be disassembled.

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5.2 TOOL CLAMP/UNCLAMP

The tool holder drawbar is held clamped by spring pressure. Air pressure is used to release the tool clamp.

When the tool is unclamped, air is directed down the center of the spindle to clear the taper of water, oil, or chips. Tool unclamp can be commanded from a program (but this is quite dangerous), from the keyboard, and from the button on the front of the spindle head. The two manual buttons only operate in MDI or JOG modes.

T

OOL

C

LAMP

/U

NCLAMP

A

IR

S

OLENOIDS

A single solenoid controls the air pressure to release the tool clamp. This corresponds to relay K15. When the relay is activated, 115V AC is applied to the solenoid. This applies air pressure to release the tool. Relay

K15 is on the I/O PCB. Circuit breaker CB4 will interrupt power to this solenoid.

T

OOL

C

LAMP

/U

NCLAMP

S

ENSE

S

WITCHES

There are two switches used to sense the position of the tool clamping mechanism. They are both normally closed and one will activate at the end of travel during unclamping and the other during clamping. When both switches are closed, it indicates that the draw bar is between positions.

A tool change operation will wait until the unclamped switch is sensed before the Z-axis pulls up from the tool. This prevents any possibility of breaking the tool changer or its support mounts.

The diagnostic display can be used to display the status of the relay outputs and the switch inputs.

The Precharge and Through the Spindle Coolant system applies low air pressure and releases the clamped switch (with 40 taper spindle only).

R

EMOTE

T

OOL

U

NCLAMP

S

WITCH

The Remote Tool Unclamp switch is mounted on the front of the cover to the spindle head. It operates the same as the button on the keyboard. It must be held for ½ second before the tool will be released and the tool will remain released for ½ second after the button is released.

While the tool is unclamped, air is forced down the spindle to clear chips, oil, or coolant away from the tool holder.

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5.3 SPINDLE OPERATION

Spindle speed functions are controlled primarily by the S address code. The S address specifies RPM in integer values from 1 to maximum spindle speed (Parameter 131). NOT TO BE CHANGED BY USER! When using the

Through the Spindle Coolant option, the maximum spindle speed is 7500 RPM (5000 RPM for 50 taper spindles).

Speeds from S1 to the Parameter 142 value (usually 1200) will automatically select low gear and speeds above

Parameter 142 will select high gear. Two M codes, M41 and M42 can be used to override the gear selection.

M41 for low gear and M42 for high gear. Low gear operation above S1250 is not recommended. High gear operation below S100 may lack torque or speed accuracy. Spindle speed accuracy is best at the higher speeds and in low gear.

If there is no gear box in your machine (VF-0/E/OE) the gear box is disabled by parameters, it is always in high gear, and M41 and M42 commands are ignored.

The spindle is hardened and ground to the precise tool holder dimensions providing an excellent fit to the holder.

S

PINDLE

O

RIENTATION

Orientation of the spindle is automatically performed for tool changes and can be programmed with M19.

Orientation is performed by turning the spindle slowly until an air pressure driven pin drops into a detent and locks the spindle in place. This pin is located behind the spindle motor and above the gear box. If the spindle is oriented and locked, commanding spindle forward or reverse will release the lock.

On machines equipped with a Haas vector drive, orientation is performed electrically and no shot pin or solenoid is required for locking the motor in place. Orientation of the spindle is automatically performed for tool changes and can be programmed with M19 commands. Orientation is performed by turning the spindle until the encoder reference is reached , the spindle motor holds the spindle locked in position. If the spindle is orientated and locked, commanding spindle forward or reverse will release the lock.

S

PINDLE

O

RIENTATION

L

UBRICATION

The spindle orientation mechanism does not require regular lubrication.

S

PINDLE

O

RIENTATION

A

IR

S

OLENOID

(

WITH

S

HOT

P

IN

)

A solenoid controls the air valve supplying pressure to the orientation lock pin. The diagnostic display can be used to display the status of the relay output and the switch inputs. Circuit breaker CB4 will interrupt power to this solenoid.

S

PINDLE

O

RIENTATION

S

EQUENCE

When spindle orientation is commanded, the following sequence of operations occurs:

1) If the spindle is turning, it is commanded to stop,

2) Pause until spindle is stopped,

3) Spindle orientation speed is commanded forward,

4) Pause until spindle is at orientation speed,

5) (Vector drive only) Spindle encoder rotates past a reference mark,

6) (Vector drive only) The spindle drive stops and holds the spindle position at a parameter

distance from the reference mark,

7) Command spindle lock air solenoid active,

Pause until spindle locked status is active and stable,

9) If not locked after time-out time, alarm and stop.

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TECHNICAL REFERENCE

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Figure 5-1. Control cabinet general overview.

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Figure 5-2. Connectors on side of control cabinet.

5.5 SERVOS BRUSH / BRUSHLESS

S

ERVO

E

NCODERS

Haas machines are equipped with brushless motors, which provides for better performance, and no maintenance. In addition to the performance differences, these machines differ from brush type machines, which have already been discussed, in the following areas:

The brushless motors have 8192 line encoders built in, which result in differences in acceleration parameters

7, 21,35,49 and 157. The exponential accel/decel time is set by parameters 115, 116 and 168. «In Position» parameters 101, 102, 103, 104 and 165 also affect brushless motors.

The motor controller board has a dedicated processor which does all the servo control algorithm.

There is no servo distribution board anymore, therefore there is no CHARGE light present. Care should still be taken however, since there are high voltages present on the amplifiers, even when power is shut off. The high voltage comes from the spindle drive, which does have a CHARGE light.

The servo drive cards are replaced by Brushless Servo Amplifiers, and are controlled differently.

A low voltage power supply card is added to the servo drive assembly to supply the low voltage requirement to the amplifiers.

The CNC software is version 9.xx.

The user interface and motion profiling have not changed however, and the user should not see any functional differences between a brush type machine and a brushless machine.

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S

ERVO

C

HARACTERISTICS

Servo characterstics are explained in detail in the previous chapter. The following is an example of how to achieve 130 inches/minute.

The exponential accel/decel time constant is set by Parameters 113, 114, 115, 116 and 168. It has units of

0.0001 seconds. The speed limit at which exponential accel/decel is not available is defined by the relationship between Parameters 7 and 113 (for the X-axis). Thus if Parameter 7 is 8000000 steps/sec/sec and Parameter 113 is 375 (0.0375 seconds); the maximum velocity for accurate interpolation should be:

8000000 x 0.0375 = 300000 steps/second

For an 8192 line encoder and 6 mm screw, this would be:

60 x 300000 / 138718 = 130 inches/minute

S

ERVO

A

MPLIFIERS

The brushless servo amplifier is a PWM based current source. The PWM outputs control the current to a three phase brushless motor. The PWM frequency is 16 KHz. The amplifiers are current limited to 30 amps peak.

However there are fuse limits both in hardware and software to protect the amplifiers and motors from over current. The nominal voltage for these amplifiers is 320 volts. Therefore the peak power is about 9600 watts or 13 H.P. The amplifiers also have short circuit and over temperature and over heat protection.

There is a 10 amp supply fuse for failure protection. This fuse is relatively slow, therefore it can handle the

30 amp peak. Actual continues current limit to the motor is controlled by software.

Commands to the amplifier are +/-5 volts current in two legs of the motor and a digital enable signal. A signal from the amplifier indicates drive fault or sustained high current in stalled motor.

The connectors on the amplifiers are:

+H.V. +320 volts DC

-H.V.

A

B

C

J1

J2

320 volts return motor lead phase A motor lead phase B motor lead phase C

Three pin Molex connector used for +/-12 and GND.

Eight pin Molex connector used for input signals.

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5.6 INPUT/OUTPUT ASSEMBLY

The IOPCB contains a circuit for electronically turning the tool changer power on and off. This prevents any arcing of the tool changer relays and increases their life tremendously. This includes an adjustable current limit to the tool changer. Potentiometer R45 adjusts the current limit to the tool changer motors. R45 should be set to limit current to between four and six amps.

The IOPCB also contains a circuit for sensing a ground fault condition of the servo power supply. If more than 0.5 amps is detected flowing through the grounding connection of the 160V DC buss, a ground fault alarm is generated and the control will turn off servos and stop.

Relay K6 is for the coolant pump 230V AC It is a plug-in type and is double-pole. Relays K9 through K12 are also plug in types for controlling the tool changer.

The Input/Output Assembly consists of a single printer circuit board called the IOPCB.

The connectors on the IOPCB are:

P1 16-pin relay drivers from MOCON 1 to 8 (510)

P2 16-pin relay drivers from MOCON 9 to 16 (520)

P3 16-pin relay drivers from MOCON 17 to 24 (M21-M24) (540)

P4 34-pin inputs to MOCON (550)

P5 Servo power on relay 1-1 (110)

P6 230V AC from CB3 (930)

P7 230V AC to coolant pump (940)

P8 Auto-off relay 1-7 (170)

P9 Spindle drive commands (710)

P10 Spindle fan and oil pump 115V AC (300)

P12 115V AC to spindle head solenoids (880A)

P13 Tool changer status inputs (820)

P14 Low TSC(900)

P15 Spindle head status inputs (890)

P16 Emergency stop input (770)

P17 Low Lube input (960)

P18 Over Voltage Input (970)

P19 Low Air Input (950)

P20 Overheat input (830)

P21 Spindle drive status inputs (780)

P22 M-FIN input (100)

P23 Remote Unclamp input (tool release) (190)

P24 Spare 2 (790)

P25 Spare 3 (200)

P26 Spare terminals for M21 to M24

P27 Door lock (1040)

P28 115V AC from CB4 (910)

P29 A-axis brake solenoid output (390)

P30 Tool changer shuttle motor output (810A)

P31 230 VAC for Chip Conveyor (160)

P33 115V AC three-phase input from power supply assembly (90)

P34 115V AC to CRT (90A)

P35 115V AC to heat exchanger (90B)

P36 115V AC to CB4 (90C)

P37 115V AC spare (870)

P38 Door open (1050)

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TECHNICAL REFERENCE

P39 Tool changer turret motor output (810)

P40 (770A) A/B

P43 Ground fault sense signal input (1060) Axis Brake

P44 5TH axis brake (319)

P45 HTC Shuttle

P46 Chip Conveyor (140)

P47 Skip input signal (1070)

P48 spare 1

P49 spare 2

P50 Spigot Motor (200)

P51 16 PIN Relay drivers 17-24 (530)

P52 spare 1

P53 Spigot Sense (180)

P54 Servo Brake (350)

P55 Red/green lights (280)

P56 Thru spindle coolant pump (940A)

P57 115V spare

P58 115V spare

5.7 TWO-SPEED GEAR TRANSMISSION

The spindle head contains a two-speed gear transmission. The spindle motor is directly coupled to the transmission and the transmission is cog belt-coupled to the spindle.

G

EAR

B

OX

L

UBRICATION

Gear Box: Mobil DTE 25 oil.

The gear box uses an oil sump and is cooled by gear oil. The VF-0/E/OE does not have a gearbox and is aircooled.

G

EAR

B

OX

A

IR

S

OLENOIDS

There is a double solenoid valve controlling air to the gear box shifter. This solenoid sends air to select either the high gear or the low gear. When power is removed from the solenoids, the valve remains in its last state.

Air is always required to ensure the gears are held in either high of low gear. Circuit breaker CB4 will interrupt power to these solenoids. Power is left on the solenoid which is commanded last.

On machines equipped with a 50 taper spindle, an electric motor drives the gearbox shifter into high or low gear.

G

EAR

B

OX

S

ENSE

S

WITCHES

There are two switches in the gear box used to sense the position of the gears. One switch indicates HIGH by opening and the other indicates LOW by opening. Between gears, both switches are closed indicating a between-gear condition. The diagnostic display shows the status of these switches and the CURNT COMDS display shows which gear is selected. If the switches indicate that the gear box is between gears, the display will indicate “No Gear”.

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G

EAR

C

HANGE

S

EQUENCE

When a gear change is performed, the following sequence of events occurs:

1) If the spindle is turning, it is commanded to stop,

2) Pause until spindle is stopped,

3) Gear change spindle speed is commanded forward,

4) Pause until spindle is at speed,

5) Command high or low gear solenoid active,

6) Pause until in new gear or reversal time,

7) Alarm and stop if max gear change time elapsed,

If not in new gear, reverse spindle direction,

9) Turn off high and low gear solenoids

5.8 CONTROL PANEL

J

OG

H

ANDLE

The JOG handle is actually a 100-line-per-revolution encoder. We use 100 steps per revolution to move one of the servo axes. If no axis is selected for jogging, turning of the crank has no effect. When the axis being moved reaches its travel limits, the handle inputs will be ignored in the direction that would exceed the travel limits.

Parameter 57 can be used to reverse the direction of operation of the handle.

P

OWER

O

N

/O

FF

S

WITCHES

The POWER ON switch engages the main contactor. The on switch applies power to the contactor coil and the contactor thereafter maintains power to its coil. The POWER OFF switch interrupts power to the contactor coil and will always turn power off. POWER ON is a normally open switch and POWER OFF is normally closed.

The maximum voltage on the POWER ON and POWER OFF switches is 24V AC and this voltage is present any time the main circuit breaker is on.

S

PINDLE

L

OAD

M

ETER

The Load meter measures the load on the spindle motor as a percentage of the rated continuous power of the motor. There is a slight delay between a load and the actual reflection of the meter. The eighth A-to-D input also provides a measure of the spindle load for cutter wear detection. The second page of diagnostic data will display % of spindle load. The meter should agree with this display within 5%. The spindle drive display #7 should also agree with the load meter within 5%.

There are different types of spindle drive that are used in the control. They are all equivalent in performance but are adjusted differently.

E

MERGENCY

S

TOP

S

WITCH

The EMERGENCY STOP switch is normally closed. If the switch opens or is broken, power to the servos will be removed instantly. This will also shut off the tool changer, spindle drive, and coolant pump. The

EMERGENCY STOP switch will shut down motion even if the switch opens for as little 0.005 seconds.

Be careful of the fact that Parameter 57 contains a status switch that, if set, will cause the control to be powered down when EMERGENCY STOP is pressed.

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TECHNICAL REFERENCE

You should not normally stop a tool change with EMERGENCY STOP as this will leave the tool changer in an abnormal position that takes special action to correct.

Note that tool changer alarms can be easily corrected by first correcting any mechanical problem, pressing

RESET until the alarms are clear, selecting ZERO RETURN mode, and selecting “AUTO ALL AXES”.

If the shuttle should become jammed, the control will automatically come to an alarm state. To correct this, push the EMERGENCY STOP button and remove the cause of the jam. Push the RESET key to clear any alarms.

Push the ZERO RETURN and the AUTO ALL AXES keys to reset the Z-axis and tool changer. Never put your hands near the tool changer when powered unless the EMERGENCY STOP button is pressed.

K

EYBOARD

B

EEPER

There is a speaker inside the control panel that is used as an audible response to pressing keyboard buttons and as a warning beeper. The beeper is a one kHz signal that sounds for about 0.1 seconds when any keypad key, CYCLE START, or FEED HOLD is pressed. The beeper also sounds for longer periods when an auto-shut down is about to occur and when the “BEEP AT M30” setting is selected.

If the beeper is not audible when buttons are pressed, the problem could be in the keypad, keyboard interface

PCB or in the speaker. Check that the problem occurs with more than one button and check that the speaker volume is not turned down.

5.9 MICROPROCESSOR ASSEMBLY

The microprocessor assembly is in the rear cabinet at the top left position. It contains three large boards.

They are: microprocessor, the keyboard and the MOCON. All three boards of the processor assembly receive power from the low voltage power supply. The three PCB’s are interconnected by a local buss on dual 50pin connectors. At power-on of the control, some diagnostic tests are performed on the processor assembly and any problems found will generate alarms 157 or 158. In addition, while the control is operating, it continually tests itself and a self test failure will generate Alarm 152.

M

ICROPROCESSOR

PCB (68ECO30)

The Microprocessor PCB contains the 68ECO30 processor running at 40 MHz, one 128K EPROM; between

256K and 8MB of CMOS RAM and between 512K and 1MB of FAST STATIC RAM. It also contains a dual serial port, a five year battery to backup RAM, buffering to the system buss, and eight system status LED’s.

Two ports on this board are used to set the point at which an NMI* is generated during power down and the point at which RESET* is generated during power down.

The eight LED’s are used to diagnose internal processor problems. As the system completes power up testing, the lights are turned on sequentially to indicate the completion of a step. The lights and meanings are:

+5V +5V logic power supply is present. (Normally On)

If this light does not come on, check the low voltage power supply and check that all three phases of 230V input power are present.

HALT Processor halted in catastrophic fault. (Normally Off)

If this light comes on, there is a serious problem with the processor PCB. Check that the EPROM is plugged in. Test the card with the buss connectors off.

POR Power-on-reset complete. (Normally On)

If this light does not come on, there is a serious problem with the processor PCB. Check that the EPROM is plugged in. Test the card with the buss connectors off.

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TECHNICAL REFERENCE

SIO Serial I/O initialization complete. (Normally On)

If this light does not come on, there is a problem with the serial ports. Disconnect anything on the external RS-232 and test again.

MSG Power-on serial I/O message output complete. (Normally On)

If this light does not come on, there is a problem with serial I/O or interrupts. Disconnect anything on the external RS-232 and test again.

CRT CRT/VIDEO initialization complete. (Normally On)

If this light does not come on, there is a problem communicating with the VIDEO PCB.

Check the buss connectors and ensure the VIDEO PCB is getting power.

PGM Program signature found in memory.(Normally On)

If this light does not come on, it means that the main CNC program package was not found in memory or that the auto-start switch was not set. Check that switch S1-1 is on and the EPROM is plugged in.

RUN Program Running Without Fault Exception. (Normally On)

If this light does not come on or goes out after coming on, there is a problem with the microprocessor or the software running in it. Check all of the buss connectors to the other two PCB’s and ensure all three cards are getting power.

There 1 two-position DIP switch on the processor PCB labeled S1. Switch S1-1 must be

ON to auto-start the CNC operational program. If S1-1 is OFF, the PGM light will remain off.

Switch S2-1 is used to enable FLASH. If it is disabled it will not be possible to write to FLASH.

The processor connectors are:

J1 Address buss

J2 Data buss

J4 Serial port #1 (for upload/download/DNC) (850)

J5 Serial port #2 (for auxiliary 5th axis) (850A)

J3 Power connector

J6 Battery

M

EMORY

R

ETENTION

B

ATTERY

The memory retention battery is initially soldered into the processor PCB. This is a 3.3V Lithium battery that maintains the contents of CMOS RAM during power off periods. Prior to this battery being unusable, an alarm will be generated indicating low battery. If the battery is replaced within 30 days, no data will be lost. The battery is not needed when the machine is powered on. Connector J6 on the processor PCB can be used to connect an external battery.

V

IDEO

K

EYBOARD WITH

F

LOPPY

The VIDEO and KB PCB generates the video data signals for the monitor and the scanning signals for the keyboard. In addition, the keyboard beeper is generated on this board. There is a single jumper on this board used to select inverse video. The video PCB connectors are:

P1

P3*

P4

P5

P10

LOW VOLTAGE POWER SUPPLY PCB (860)

KEYBOARD INFO. (700)

ADDRESS BUSS

DATA BUSS

FLOPPY DR. POWER

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TECHNICAL REFERENCE

P11

P12

P13

J9

J13

SPARE

FLOPPY DR. SIGNAL

VIDEO SIGNAL (760)

RS422 B

SERIAL DATA (850)

M

OTOR

I

NTERFACE

PCB (MOTIF)

The Motor Interface PCB provides all of the interfaces to motors and discrete inputs and outputs. It contains a single pot R54 to adjust the output of the D-A converter. The MOTIF PCB connectors are:

P1 Data buss

P2 X drive control and overcurrent sense (610)

P3 Y drive control and overcurrent sense (620)

P4 Z drive control and overcurrent sense (630)

P5 A drive control and overcurrent sense (640)

P6 X-axis encoder, Z, home, and overheat (660)

P7 Y-axis encoder, Z, home, and overheat (670)

P8 Z-axis encoder, Z, home, and overheat (680)

P9 A-axis encoder, Z, home, and overheat (690)

P10 32 discrete inputs (550)

P11 Relay drives 1 to 8 (510)

P12 Relay drives 9 to 16 (520)

P13 Relay drives 17 to 24 (530)

P14 Relay drives 25 to 32 (540)

P15 Power connector (+5,+12+)

P16 D-to-A output and -12V DC (720)

P17 A-to-D inputs for DC buss voltage (980)

P18 Jog Crank input and aux 1,2 (750)

P19 Address buss

P20 Spindle encoder inputs (1000)

P21 A-to-D input for spindle temperature (1020)

P22 A-to-D input for spindle load monitor (730B)

P24 Home switch inputs X, Y, Z (990)

M

OTOR

C

ONTROLLER

(MOCON) — B

RUSHLESS

The brushless machining centers are equipped with a microprocessor based brushless motor controller board

(MOCON) that replaces the motor interface in the brush type controls. It runs in parallel with the main processor, receiving servo commands and closing the servo loop around the servo motors.

In addition to controlling the servos and detecting servo faults, the motor controller board, (MOCON), is also in charge of processing discrete inputs, driving the I/O board relays, commanding the spindle and processing the jog handle input. Another significant feature is that it controls 6 axes, so there is no need for an additional board for a 5 axis machine.

P1

P2

P3

P4

Data Buss

X amplifier control and fault sensing (610)

Y amplifier control and fault sensing (620)

Z amplifier control and fault sensing (630)

P5 A amplifier control and fault sensing (640)

P32 B amplifier control and fault sensing (640B)

P33 C amplifier control and fault sensing (640C)

P6 X encoder input (660)

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TECHNICAL REFERENCE

P7

P8

Y encoder input (670)

Z encoder input (680)

P9 A encoder input (690)

P30 B encoder input (690B)

P31 C encoder input (690C)

P18 Jog encoder input (750)

P20 Spindle encoder input (1000)

P10 Inputs from I/O board (550)

P11 I/O relays K1-8 (510)

P12 I/O relays K9-16 (520)

P13 I/O relays K17-24 (530)

P14 I/O relays K25-32 (540)

P15 Low Voltage Power (860)

P16 Spindle command output (720)

P19 Address bus

P24 Axis home switches (990)

5.10 SPINDLE DRIVE ASSEMBLY

The spindle drive is located in the main cabinet on the right side and halfway down. It operates from threephase 200 to 240V AC. It has a 10 (or 20) H.P. continuous rating, and a 15 (or 30) H.P. one-minute rating.

The spindle drive is protected by CB1. Never work on the spindle drive until the small red CHARGE light goes out. Until this light goes out, there are dangerous voltages inside the drive, even when power is shut off.

For all other data on the spindle drive, refer to the supplied documentation for your drive.

H

AAS

V

ECTOR

D

RIVE

The Haas vector drive is a current amplifier controlled by the Mocon software, using the C axis output. The vector drive parameters are a part of the machine parameters and are accessible through the Haas front panel.

The spindle encoder is used for the closed loop control and spindle orientation, as well as rigid tapping if the option is available. Spindle speed is very accurate, since this is a closed loop control and the torque output at low speeds is superior to non vector drive spindles.

5.11 RESISTOR ASSEMBLY

The Resistor Assembly is located on top of the control cabinet. It contains the servo and spindle drive regen load resistors.

S

PINDLE

D

RIVE

R

EGEN

R

ESISTOR

A resistor bank is used by the spindle drive to dissipate excess power caused by the regenerative effects of decelerating the spindle motor. If the spindle motor is accelerated and decelerated again in rapid succession repeatedly, this resistor will get hot. In addition, if the line voltage into the control is above 255V, this resistor will begin to heat. This resistor is overtemp protected at 100

0

C. At that temperature, an alarm is generated and the control will begin an automatic shutdown. If the resistor is removed from the circuit, an alarm may subsequently occur because of an overvoltage condition inside the spindle drive.

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TECHNICAL REFERENCE

S

ERVO

D

RIVE

R

EGEN

R

ESISTOR

A 25-ohm, 300-watt resistor is used by the brush-type servo drives to dissipate excess power caused by the effects of decelerating the servo motors. If the servo motors are accelerated and decelerated again in rapid succession repeatedly, this resistor will get hot. In addition, if the line voltage into the control is above 255V, this resistor will begin to heat. This resistor is overtemp protected at 100

0 because of an overvoltage condition for the servo buss.

C. At that temperature, an automatic control shutdown is begun. If that resistor is removed from the circuit, an alarm may subsequently occur

O

VERHEAT

S

ENSE

S

WITCH

There is an over-temperature sense switch mounted near the above-mentioned regen resistors. This sensor is a normally-closed switch that opens at about 100

0

C. It will generate an alarm and all motion will stop. After thirty seconds of an overheat condition, an automatic shutdown will occur in the control.

5.12 POWER SUPPLY ASSEMBLY

All power to the control passes through the power supply assembly. It is located on the upper right corner of the control cabinet.

M

AIN

C

IRCUIT

B

REAKER

CB1

Circuit breaker CB1 (see chart for ratings) is primarily used to protect the spindle drive and to shut off all power to the control. The locking On/Off handle on the outside of the control cabinet will shut this breaker off when it is unlocked. A trip of this breaker indicates a SERIOUS overload problem and should not be reset without investigating the cause of the trip. The full circuit breaker ratings are listed in the following chart.

96-8100

M

AIN

C

ONTACTOR

K1

Main contactor K1 is used to turn the control on and off. The POWER ON switch applies power to the coil of

K1 and after it is energized, auxiliary contacts on K1 continues to apply power to the coil. The POWER OFF switch on the front panel will always remove power from this contactor.

When the main contactor is off, the only power used by the control is supplied through two ½ amp fuses to the circuit that activates the contactor. An overvoltage or lightning strike will blow these fuses and shut off the main contactor.

The power to operate the main contactor is supplied from a 24V AC control transformer that is primary fused at ½ amp. This ensures that the only circuit powered when the machine is turned off is this transformer and only low voltage is present at the front panel on/off switches.

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182

TECHNICAL REFERENCE

L

OW

V

OLTAGE

P

OWER

S

UPPLY

The low voltage power supply provides +5V DC, +12V DC, and -12V DC to all of the logic sections of the control.

It operates from 115V AC nominal input power. It will continue to operate correctly over a 90V AC to 133V

AC range.

P

OWER

PCB (POWER)

The low voltage power distribution and high voltage fuses and circuit breakers are mounted on a circuit board called the POWER PCB. The following connectors are on it:

P1 Brings incoming 230 VAC ( 460 VAC) 3-phase from main breaker.

P2 On/Off connections to front panel (740)

P3 Coil and aux connections to contactor K1

P4 Auto-off connection to IOPCB (170)

P5 Primary and secondary connections to transformer T5.

P6 230V AC from CB3 to coolant pump (930)

P7 115V AC from CB4 to IOPCB for solenoids (910)

P8 115V AC from IOPCB to CB4 for solenoids (90)

P9 +5/+12/-12 GND from low volt supply to logic boards (to MOCON) (860).

P10 +5/+12/Gnd from low volt supply to logic boards (860)

P11 +5/+12/Gnd form low volt supply to logic boards (860)

P12 +5/+12/Gnd form low volt supply to logic boards (860)

P13 +5/+12/Gnd form low volt supply to logic boards (860)

P14 12V AC to operator’s lamp switch (800A) (not used)

P15 230V AC from main transformer to CB3 (70)

P16 Low voltage power from power supply (not used)

P17 +12V DC option connector (to MCD relay board) (860A)

P18 Not used

P19 Primary and Secondary connections to worklight transformer T4 (290) (not used)

P20 115V AC to low voltage power supply

P21 -12V DC option connector

P22 -12V DC option connector (to MOTIF)

P23 230 VAC from main transformer to CB5 (70A)

P24 230 VAC from CB3 to TSC coolant pump (930A)

P26 +5/+12/-12/ GND from low volt supply to logic boards (to processor) (860)

P27 +5/+12/-12/ GND from low volt supply to logic boards (860)

P28 +5/+12/-12 GND low volt power from power supply

P29 +5/-5 GND low volt power from power supply

P30 12V AC to operator’s light (800) (not used)

P31 +12V option connector (to stack fan)(860A)

TB1 115VAC 3-phase from main transformer (94,95,96)

TB2 115 VAC 3-phase to IOPCB (91,92,93)

S

ECONDARY

C

IRCUIT

B

REAKERS

Three more circuit breakers are on the Power supply assembly.

CB2 controls the 3-phase 115volt distribution. It can be tripped only if there is a short in the control cables or on the IOPCB.

CB3 controls the power to coolant pump only. It can be blown by an overload of the coolant pump motor or a short in the wiring to the motor.

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CB4 controls the 115V AC to the air solenoids, 4th axis brake, and the oiler. It is never expected to trip. If it does trip, it is likely caused by a short circuit in the wiring on the I/O assembly or the wiring to the solenoids on the spindle head.

CB5 Controls power to the TSC coolant pump only. It can be tripped by an overload of the TSC coolant pump motor or a short in the wiring to the motor.

P

OWER

-U

P

L

OW

V

OLTAGE

C

ONTROL

T

RANSFORMER

(T5)

The low voltage control transformer, T5, supplies power to the coil of the main contactor K1. It guarantees that the maximum voltage leaving the Power Supply assembly when power is off is 12V AC to earth ground.

It is connected via P5 to the POWER PCB.

5.13 POWER TRANSFORMER ASSEMBLY (T1)

The power transformer assembly is used to convert three-phase 354/488V to three-phase 230V and 115V and is primarily used by the servo drives. The video monitor, solenoids, fans, and oiler also use 115V AC.

This transformer’s maximum input voltage is 440V @ 60 Hertz, and 240V @ 50 Hertz. It is located in the main cabinet in the lower right corner. It is rated at 12KVA and its primary is protected to the figures listed in the preceding table.

This transformer has five high voltage connections that allow for a range of inputs from 354V to 488V. The transformer has a 230 volt secondary to supply three- phase to the spindle drives.

96-8100

Fig. 5-3a Transformer with 354-488V range Fig. 5-3b Transformer with 195-260V range

P

RIMARY

C

ONNECTION

T

O

T1

Input power to T1 is supplied through CB1, the 40 amp three-phase main circuit breaker. Three-phase 195-

260 VAC (354-488 VAC) to T1 is connected to the appropriate tap on T1.

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184

TECHNICAL REFERENCE

V

OLTAGE

S

ELECTION

T

APS

There are five labeled plastic terminal blocks for high voltage. Each block has three connections for wires labeled 74, 75, and 76. Follow the instructions printed on the transformer.

S

ECONDARY

C

ONNECTION

T

O

T1

The secondary output from T1 is 115V AC three-phase CB2 protects the secondary of transformer T1 and is rated at 25 amps.

5.14 FUSES

B

RUSH

M

OTORS

The servo drive (DRIVER) cards have three fuses on each of the X, Y, Z, and A PCB’s (F1, F2, F3). If these fuses are ever blown, the associated motor will stop. This will only happen if there is a failure of the drive card and the user should never attempt to replace these fuses.

The POWER PCB contains three ½-amp fuses located at the top right (FU1, FU2, FU3). If the machine is subject to a severe overvoltage or a lightning strike, these fuses will blow and turn off all of the power. Replace these fuses only with the same type and ratings. The two fuses FU4 and FU6 are not used.

On the servo drive assembly, there is a printed circuit board (SDIST) containing three one-amp fuses (FU1,

FU2, FU3). Two of these fuses protect the contactor and small transformers. They are never expected to blow.

The third fuse protects the regen load circuit load from shorts.

FUSE NAME TYPE RATING VOLTAGE

(amps)

LOCATION

FU1

FU2

FU3

(not used) Lamp

FU1

FU2

FU3

F1

F2

F3

FU1

FU2

FU3

FU4

ABC

ABC

ABC

ABC

ABC

ABC

AGC

AGC

AGC

AGC

AGC

AGC

AGC

ABC

5

5

5

5

20

10

½

½

5

20

½

½

½

½

250V

250V

250V

250V

250V

250V

250V

250V

250V

250V

250V

250V

250V

250V

«

«

«

POWER pcb,

«

» upper right

«

SDIST pcb,

» lower left right center

«

«

» top center

SDRIVER pcb’s (X, Y, Z, A)

I/O PCB

I/O PCB

I/O PCB

I/O PCB

B

RUSHLESS

M

OTORS

Each brushless amplifier contains a fuse, which will only blow if there is a failure of the amplifier. The user should never attempt to replace these fuses.

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The POWER PCB contains three ½-amp fuses located at the top right (FU1, FU2, FU3). If the machine is subject to a severe overvoltage or a lightning strike, these fuses will blow and turn off all of the power. Replace these fuses only with the same type and ratings. The two fuses FU4 and FU6 are not used.

FUSE NAME

FU1

FU2

FU3

(not used) Lamp

FU1

FU2

FU3

FU4

F1

TYPE

AGC

AGC

AGC

AGC

ABC

ABC

ABC

ABC

ABC

RATING

5

5

5

5

15

½

½

½

½

VOLTAGE

(amps)

250V

250V

250V

250V

250V

250V

250V

250V

250V

LOCATION

«

POWER pcb,

«

«

I/O PCB

I/O PCB

«

» upper right lower left

I/O PCB

I/O PCB

Amplifier (X,Y,Z,A,B)

5.15 SPARE USER M CODE INTERFACE

The M code interface uses outputs M21-23 and one discrete input circuit. M codes M21 through M23 will activate relays labelled M21-23. These relay contacts are isolated from all other circuits and may switch up to 120V AC at one amp. The relays are SPDT. WARNING! Power circuits and inductive loads must have snubber protection.

Note: If the optional M code relay board is installed, relays M21-28 become available on the secondary board. These relays will be controlled by outputs M21-28.

The M-FIN circuit is a normally open circuit that is made active by bringing it to ground. The one M-FIN applies to all eight of the user M codes.

The timing of a user M function must begin with all circuits inactive, that is, all circuits open. The timing is as follows:

96-8100

The Diagnostic Data display page may be used to observe the state of these signals.

M F

UNCTION

R

ELAYS

The IOPCB contains three relays (M21-M23) and the optional M code relay board contains eight (M21-M28), either one of these groups of relays may be available to the user. M21 is already wired out to P12 at the side of the control cabinet. This is a four-pin DIN connector and includes the M-FIN signal.

Note: If the optional M code relay board is installed, the relays on the IOPCB are to be left unused.

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TECHNICAL REFERENCE

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186

M-FIN D

ISCRETE

I

NPUT

The M-FIN discrete input is a low voltage circuit. When the circuit is open, there is +12V DC at this signal.

When this line is brought to ground, there will be about 10 milliamps of current. M-FIN is discrete input #10 and is wired from input #10 on the Inputs PCB on the Input/Output Assembly. The return line for grounding the circuit should also be picked up from that PCB. For reliability, these two wires should be routed in a shielded cable where the shield is grounded at one end only. The diagnostic display will show this signal a “1” when the circuit is open and a “0” when this circuit is grounded.

T

URNING

M F

UNCTIONS

O

N

A

ND

O

FF

The M code relays can also be separately turned on and off using M codes M51- M53 and M61- M63. M51 to M53 will turn on one of the relays and M61 to M63 will turn the relays off. M51 and M61 correspond to

M21, etc.

Note: If the M code relay board is installed M51-M58 will turn on the relays and M61- M68 will turn off the relays. M51 and M61 correspond to M21, etc. on the M code relay board.

W

IRING THE RELAYS

The relays are marked on both the IOPCB and the M code relay board, with their respective terminals forward of them. If the optional M code relay board is installed then the connections on the IOPCB are to be left unused as they are replaced by the relays on the optional board. Refer to the figures below, and the Probe Option figure in the Electrical Diagrams section for the terminal labeling. Maximum voltage for the relays is 125 VAC with a maximum amperage of 3 amps.

WARNING! Power circuits and inductive loads must have snubber protection.

IOPCB Relays M Code Relay Board

CAUTION! If a screw terminal is already in use DO NOT connect anything else to it. Call you dealer.

Relay M24 on the IOPCB is reserved for Through the Spindle Coolant (AUXCLT).

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TECHNICAL REFERENCE

5.16 LUBRICATION SYSTEM

The lubrication system is a resistance type system which forces oil through metering units at each of the 16 lubricating points within the machine. The system uses one metering unit at each of the lubricating points: one for each linear guide pad, one for each lead screw and one for spindle lubrication. A single oil pump is used to lubricate the system. The pump is powered only when the spindle and/or an axis moves. Once powered the pump cycles approximately 3.0 cc of oil every 30 minutes throughout the oil lines to the lube points. Every lube point receives approximately 1/16 of oil.

The control monitors this system through an internal level switch in the reservoir and external pressure switch on the lube panel.

L

OW

L

UBRICATION AND

L

OW

P

RESSURE

S

ENSE

S

WITCHES

There is a low lube sense switch in the oil tank. When the oil is low, an alarm will be generated. This alarm will not occur until the end of a program is reached. There is also an lube pressure switch that senses the lube pressure. Parameter 117 controls the lube pressure check. If Parameter 117 is not zero, the lube pressure is checked for cycling high within that period. Parameter 117 has units of , 1/50 seconds; so 30 minutes gives a value of 90000. Parameter 57, bit «Oiler on/off», indicates the lube pump is only powered when the spindle fan is powered. The lube pressure is only checked when the pump is on.

5.17 SWITCHES

L

AMP

O

N

/O

FF

S

WITCH

An on/off switch is supplied for the operator’s lamp. It is located on the side of the control cabinet below all of the motor connectors.

D

OOR

O

PEN

S

ENSE

S

WITCH

The DOOR OPEN sense switch is a magnetic reed switch type and consists of two switches; one on each half of the enclosure front doors. These switches are normally closed and wired in series. When the doors open, one or both of these switches will open and the machine will stop with a “Door Hold” function. When the door is closed again, operation will continue normally.

The wiring for the door switches is routed through the front panel support arm and down through the top of the enclosure.

If the doors are open, you will not be able to start a program. Door Hold will not stop a tool change operation or a tapping operation, and will not turn off the coolant pump. Also, if the doors are open, the spindle speed will be limited to 750 RPM.

The Door Hold function can be temporarily disabled with by turning Setting 51 on, if Parameter 57 bits DOOR

STOP SP and SAFETY CIRC are set to zero, but this setting will return to OFF when the control is turned off.

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TECHNICAL REFERENCE

L

IMIT

S

WITCHES

Note: There are a number of limit switches located on the VMC, and some are difficult to reach. Ensure the problem is the switch before beginning removal procedures. The following is a list of all switches, their general location, and a functional description:

CLAMP/UNCLAMP SWITCHES

[Tool Release Piston Assembly (2)]

There are two switches used to sense the position of the tool clamping mechanism. They are both normally closed and one will activate at the end of travel during unclamping and the other during clamping. When both switches are closed, it indicates that the draw bar is between positions.

A tool change operation will wait until the unclamped switch is sensed before the Z-axis pulls up from the tool. This prevents any possibility of breaking the tool changer or its support mounts.

The diagnostic display can be used to display the status of the relay outputs and the switch inputs.

SPINDLE ORIENT SWITCH

[Top rear of transmission]

Note: This switch does not exist on machines that have a Vector Drive.

A normally-open switch that is held closed is used to sense when the pin drops in to lock the spindle. When the pin drops the switch opens, indicating orientation is complete.

The normally-closed side of the same switch that is held open, is wired to the spindle drive and commands it into a «Coast Stop» condition. This is done to ensure the spindle motor is not powered when the pin is locking the spindle.

X, Y, AND Z LIMIT SWITCHES

Prior to performing an POWER UP/RESTART or an AUTO ALL AXES operation, there are no travel limits. Thus, you can jog into the hard stops in either direction for X, Y, or Z. After a ZERO RETURN has been performed, the travel limits will operate unless an axis hits the limit switch. When the limit switch is hit, the zero returned condition is reset and an AUTO ALL AXES must be done again. This is to ensure that if you hit the limit switch, you can still move the servo back away from it.

The limit switches are normally closed. When a search for zero operation is being performed, the X, Y, and

Z axes will move towards the limit switch unless it is already active (open); then they will move away from the switch until it closes again; then they will continue to move until the encoder Z channel is found. This position is machine zero.

Auto search for zero in the Z-axis is followed by a rapid move from the limit switch position down to the tool change position. This makes the Z-axis a little different from the other axes. The position found with the limit switch is not machine zero but is the position used to pull tools out of the spindle. Machine zero for Z is below this by Parameter 64. Be careful during the Z zero search and stay clear of that rapid move.

What Can Go Wrong With Limit Switches?

If the machine is operated without connector P5, a LOW LUBE and DOOR OPEN alarm will be generated. In addition, the Home search will not stop at the limit switch and will instead run into the physical stops on each axis.

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If the switch is damaged and permanently open, the zero search for that axis will move in the negative direction at about 0.5 in/min until it reaches the physical travel stops at the opposite end of travel.

If the switch is damaged and permanently closed, the zero search for that axis will move at about 10 in/min in the positive direction until it reaches the physical stops.

If the switch opens or a wire breaks after the zero search completes, an alarm is generated, the servos are turned off, and all motion stops. The control will operate as though the zero search was never performed. The

RESET can be used to turn servos on but you can jog that axis only slowly.

TOOL CHANGER POSITION SWITCHES

[Inside of Tool Carriage (2)]

GENEVA WHEEL POSITION MARK

The turret rotation mechanism has a switch mounted so that it is activated for about 30 o

of travel of the Geneva mechanism. When activated, this switch indicates that the turret is centered on a tool position. This switch is normally closed. The diagnostic display will show this status of this input switch as “TC MRK”. A “1” indicates the Geneva wheel is in position.

TOOL #1 SENSE SWITCH

The tool rotation turret has a switch that is activated when tool one is in position or facing towards the spindle.

At POWER ON this switch can indicate that tool #1 is in the spindle. If this switch is not active at power-on, the first tool change will rotate the turret until the switch engages and then move to the selected tool. The diagnostic display will show this status of this input switch as “TOOL #1”. A “1” indicates that tool #1 is in position.

SHUTTLE IN/OUT SWITCHES

[Tool Changer Holding Plate (2)]

Two switches are used to sense the position of the tool changer shuttle and the arm that moves it. One switch is activated when the shuttle is moved full travel inward and one is activated when it is full travel outward.

These switches are normally closed so that both will be closed between in and out. The diagnostic display will show this status of this input switch. A “1” indicates the associated switch is activated or open.

TRANSMISSION HIGH/LOW GEAR POSITION SWITCHES

[Bottom of Gearbox Assembly (2)]

On machines with a two-speed transmission, there are two switches in the gear box used to sense the position of the gears. One switch indicates HIGH by opening and the other indicates LOW by opening. Between gears, both switches are closed indicating a between-gear condition. The diagnostic display shows the status of these switches and the CURNT COMDS display shows which gear is selected. If the switches indicate that the gear box is between gears, the display will indicate “No Gear”.

Note: The Transmission High/Low Gear Position Switches are located at the bottom of the Gearbox Assembly and are extremely difficult to reach. Removal of this assembly is necessary to replace these switches. See Mechanical Service, for Spindle Motor and

Transmission removal.

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TECHNICAL REFERENCE

5.18 HYDRAULIC COUNTERBALANCE

The spindle head weight is balanced by the upward pull of a hydraulic cylinder. The hydraulic oil forces the piston to retract into the cylinder body. The oil is then pressurized by a nitrogen reservoir. The system is self contained and passive (no pump is required to maintain the lift). Normal Z-Axis of the gas/oil counter balance has the initial pressure to balance the weight at full system volume, plus an additional 50-75 psi overcharge for longevity.

5.19 DIAGNOSTIC DATA

The ALARM / MSGS display is the most important source of diagnostic data. At any time after the machine completes its power-up sequence, it will either perform a requested function or stop with an alarm. Refer to

Section 2.5 for a complete list of alarms, their possible causes, and some corrective action.

If there is an electronics problem, the controller may not complete the power-up sequence and the CRT will remain blank. In this case, there are two sources of diagnostic data; these are the audible beeper and the LED’s on the processor PCB. If the audible beeper is alternating a ½ second beep, there is a problem with the main control program stored in EPROM’s on the processor PCB. If any of the processor electronics cannot be accessed correctly, the LED’s on the processor PCB will or will not be lit.

If the machine powers up but has a fault in one of its power supplies, it may not be possible to flag an alarm condition. If this happens, all motors will be kept off and the top left corner of the CRT will have the message:

POWER FAILURE ALARM

and all other functions of the control will be locked out.

When the machine is operating normally, a second push of the PARAM/DGNOS key will select the diagnostics display page. The PAGE UP and PAGE DOWN keys are then used to select one of two different displays. These are for diagnostic purposes only and the user will not normally need them. The diagnostic data consists of discrete input signals, discrete output relays and several internal control signals. Each can have the value of 0 or 1. In addition, there are up to three analog data displays and an optional spindle RPM display. Their number and functions are described in the following section.

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#

1008

1009

1010

1011

1012

1013

1014

1015

1000

1001

1002

1003

1004

1005

1006

1007

#

1108

1109

1110

1111

1112

1113

1114

1115

1100

1101

1102

1103

1104

1105

1106

1107

5.20 DISCRETE INPUTS / OUTPUTS

Name

SRV PO spare spare spare

4TH BK

COOLNT

AUT OF

SP FAN

TC IN

TC OUT

TC CW

TC CCW

SP HIG

SP LOW

T UNCL spare

The inputs/outputs that are followed by an asterisk (*) are active when equal to zero (0).

DISCRETE INPUTS

Name

TC IN

TC OUT

T ONE

LO CNT

TC MRK

SP HIG

SP LOW

EM STP

DOOR S

M-FIN*

OVERVT

LO AIR

LO LUB

OVRHT

DB OPN

DB CLS

Description

Tool Changer In

Tool Changer Out

At Tool One

Low Coolant

T.C. Geneva Mark

Spindle In High

Spindle In Low

Emergency Stop

Door Open Switch

Not M Func Finish

Not Over Voltage

Low Air Pressure

Low Lube Oil

Not Over Heat

Tool Unclamped

Tool Clamped

#

1024

1025

1026

1027

1028

1029

1030

1031

1016

1017

1018

1019

1020

1021

1022

1023

DISCRETE OUTPUTS

Name

spare spare spare spare

LO OIL spare1 spare2 spare3

UNCLA*

LOPHSE spare4 spare5

GR FLT

SKIP

SPIGOT

CNVEYR

Description

Spindle/GB coolant low

Remote tool unclamp

Low voltage in phase 1

Ground fault

Skip Signal

Conveyor overload

Description

Servo Power On

4th Axis Brk Rel

Coolant Pump

Auto Turn Off

Spind Motor Fan

Tool Changer In

Tool Changer Out

Tool Changer CW

Tool Changer CCW

Spindle High Gear

Spindle Low Gear

Tool Unclamped

#

1124

1125

1126

1127

1128

1129

1130

1131

1116

1117

1118

1119

1120

1121

1122

1123

Name

SPGCW

SPGCCW spare

PURGE

PRE-CH

HTC SH

5TH BK

DOOR L

M21

M22

M23

AUXCLT

GRNBCN

REDBCN

CNVENA

CNVREV

Description

Spigot clockwise

Spigot counter/clockwise

TSC Purge

Pre-charge

Horizontal T.C. shuttle

5th Axis Brake

Door Lock

Auxiliary Coolant

Red beacon worklight

Red beacon worklight

Conveyor enabled

Conveyor reverse

96-8100

191

192

TECHNICAL REFERENCE

June 1998

The inputs are numbered the same as the connections on the inputs printed circuit board.

Note: If the machine is equipped with an APC the following inputs and outputs will change:

1009 Pallet Clamped SW

1021 Door SW

1022 Pin #1 CLR

1023 Pin #2 CLR

1026 PAL #2 Home

1027 PAL #1 Home

1121 PAL Clamp

1122 Door

1125 APC Motor

1126 Beeper

The second page of diagnostic data is displayed using the PAGE UP and PAGE DOWN keys.

It contains:

INPUTS 2

Name Description

X Z CH

X-axis Z Channel

Y Z CH

Y-axis Z Channel

Z Z CH

Z-axis Z Channel

A Z CH

A-axis Z Channel

B Z CH

B-axis Z Channel

Name

X HOME X-axis Home/Lim Switch

X DRVF

Y HOME Y-axis Home

Z HOME Z-axis Home

A HOME A-axis Home

B HOME B-axis Home

Y DRVF

Z DRVF

A DRVF

B DRVF

Description

X OVRH

X Motor Overheat

Y OVRH

Y Motor Overheat

Z OVRH

Z Motor Overheat

A OVRH

A Motor Overheat

B OVRH

B Motor Overheat

X-axis drive fault

Y-axis drive fault

Z-axis drive fault

A-axis drive fault

B-axis drive fault

Name Description

X CABL

Broken cable to X encoder

Y CABL

Broken cable to Y encoder

Z CABL

Broken cable to Z encoder

A CABL

Broken cable to A encoder

B CABL

Broken cable to B encoder

SZ CH

Spindle Z Channel

The following inputs and outputs pertain to the Haas Vector Drive. If it is not enabled, these will display a value of *. Otherwise, it will display a 1 or 0.

HAAS VECT

SP FWD

SP REV

SP LOK

AT SPD*

SP STP*

SP FLT

SP LKD

SP OHT

S CABL

Haas Vector Drive Enabled

Spindle Forward

Spindle Reverse

Spindle Lock Commanded

Spindle at Speed

Spindle Stopped

Spindle Fault

Spindle is Locked

Spindle Overheat

Spindle Cable

96-8100

June 1998

TECHNICAL REFERENCE

ANALOG DATA

Name

DC BUSS uP TEMP

SP LOAD

SP SPEED

RUN TIME

TOOL CHANGES

VER X.XXX

YY/MM/DD

MDL VF__

Description

Voltage from Haas Vector Drive (if equipped)

Microprocessor enclosure temperature (displayed only when Parameter 278 bit «uP ENCL TEMP» is set to 1).

Spindle load in %

Spindle RPM CW or CCW

Total machine run time

Number of tool changes

Software version number

Today’s date

Machine model

96-8100

193

TECHNICAL REFERENCE

June 1998

194

96-8100

June 1998

PARAMETERS

96-8100

6. PARAMETERS

Parameters are seldom-modified values that change the operation of the machine. These include servo motor types, gear ratios, speeds, stored stroke limits, lead screw compensations, motor control delays and macro call selections. These are all rarely changed by the user and should be protected from being changed by the parameter lock setting. If you need to change parameters, contact HAAS or your dealer. Parameters are protected from being changed by Setting 7.

The Settings page lists some parameters that the user may need to change during normal operation and these are simply called «Settings». Under normal conditions, the parameter displays should not be modified. A complete list of the parameters is provided here.

The PAGE UP, PAGE DOWN, up and down cursor keys , and the jog handle can be used to scroll through the parameter display screens in the control. The left and right cursor keys are used to scroll through the bits in a single parameter.

P

ARAMETER

L

IST

Parameter 1 X SWITCHES

Parameter 1 is a collection of single-bit flags used to turn servo related functions on and off. The left and right cursor arrows are used to select the function being changed. All values are 0 or 1 only. The function names are:

REV ENCODER

REV POWER

REV PHASING

DISABLED

Z CH ONLY

AIR BRAKE

DISABLE Z T

SERVO HIST

INV HOME SW

INV Z CH

CIRC. WRAP.

NO I IN BRAK

LOW PASS +1X

LOW PASS +2X

OVER TEMP NC

CABLE TEST

Z TEST HIST

SCALE FACT/X

INVIS AXIS

ROT ALM LMSW

ROT TRVL LIM

UNDEFINED

UNDEFINED

UNDEFINED

TORQUE ONLY

3 EREV/MREV

2 EREV/MREV

NON MUX PHAS

Used to reverse the direction of encoder data.

Used to reverse direction of power to motor.

Used to reverse motor phasing.

Used to disable any axis.

With A only, indicates that no home switch.

With A only, indicates that air brake is used.

Disables encoder Z test (for testing only).

Graph of servo error (for diagnostics only).

Inverted home switch (N.C. switch).

Inverted Z channel (normally high).

(Future Option — Not Yet Implemented) With A only, causes 360 wrap to return to 0.

With A only, removes I feedback when brake is active.

Adds 1 term to low pass filter.

Adds two terms to low pass filter.

Selects a normally closed overheat sensor in motor.

Enables test of encoder signals and cabling.

History plot of Z channel test data.

If set to 1, the scale ratio is interpreted as divided by

X; where X depends on bits SCALE/X LO and SCALE/X HI.

Used to create an invisible axis.

Rotary alarms at the limit switch.

Rotary travel limits are used.

For HAAS only.

For HAAS only.

For HAAS only.

Not currently used.

195

196

PARAMETERS

June 1998

Parameter

BRUSH MOTOR

LINEAR DISPL

SCALE/X LO

SCALE/X HI

2 X

Enables the brushless motor option.

This bit changes the display from degrees to inches (or millimeters) on the A and B axes.

With SCALE/X HI bit, determines the scale factor used in bit

SCALE FACT/X,

With SCALE/X LO bit, determines the scale factor used in bit

SCALE FACT/X. See below:

HI LO

0

0

1

1

0

1

0

1

P GAIN

Proportional gain in servo loop.

7

9

3

5

Parameter 3 X

Parameter

Parameter

Parameter

Parameter

Parameter

4

5

6

7

8

X

X

X

X

X

D GAIN

Derivative gain in servo loop.

I GAIN

Integral gain in servo loop.

RATIO (STEPS/UNIT)

The number of steps of the encoder per unit of travel. Encoder steps supply four (4) times their line count per revolution. Thus, an 8192 line encoder and a 6mm pitch screw give:

8192 x 4 x 25.4 / 6 = 138718

MAX TRAVEL (STEPS)

Max negative direction of travel from machine zero in encoder steps. Does not apply to A-axis. Thus a 20 inch travel, 8192 line encoder and 6 mm pitch screw give:

20.0 x 138718 = 2774360

ACCELERATION

Maximum acceleration of axis in steps per second per second.

MAX SPEED

Max speed for this axis in steps per second.

Parameter 9

Parameter

Parameter

Parameter

10

11

12

X

X

X

X

MAX ERROR

Max error allowed in servo loop before alarm is generated. Units are encoder steps.

FUSE LEVEL

Fuse level in % of max power to motor. Applies only when motor in motion.

BACK EMF

Back EMF of motor in volts per 1000 RPM times 10. Thus a 63 volt/KRPM motor gives 630.

STEPS/REVOLUTION

Encoder steps per revolution of motor. Thus, an 8192 line encoder gives:

8192 x 4 = 32768

96-8100

June 1998

Y

Y

Y

Y

Z

Z

Y

Y

Y

Y

Y

Y

Y

Y

Y

Y

X

X

Parameter 21

Parameter 22

Parameter 23

Parameter 24

Parameter 25

Parameter 26

Parameter 27

Parameter 28

Parameter 29

Parameter 30

Parameter 13

Parameter 14

Parameter 15

Parameter 16

Parameter 17

Parameter 18

Parameter 19

Parameter 20

PARAMETERS

BACKLASH

Backlash correction in encoder steps.

DEAD ZONE

Dead zone correction for driver electronics. Units are 0.0000001 seconds.

SWITCHES

See Parameter 1 for description.

P GAIN

See Parameter 2 for description.

D GAIN

See Parameter 3 for description.

I GAIN

See Parameter 4 for description.

RATIO (STEPS/UNIT)

See Parameter 5 for description.

MAX TRAVEL (STEPS)

See Parameter 6 for description.

ACCELERATION

See Parameter 7 for description.

MAX SPEED

See Parameter 8 for description.

MAX ERROR

See Parameter 9 for description.

FUSE LEVEL

See Parameter 10 for description.

BACK EMF

See Parameter 11 for description.

STEPS/REVOLUTION

See Parameter 12 for description.

BACKLASH

See Parameter 13 for description.

DEAD ZONE

See Parameter 14 for description.

SWITCHES

See Parameter 1 for description.

P GAIN

See Parameter 2 for description.

96-8100

197

198

PARAMETERS

Parameter 31

Parameter 32

Parameter 33

Parameter 34

Parameter 35

Parameter 36

Parameter 37

Parameter 38

Parameter 39

Parameter 40

Parameter 41

Parameter 42

Parameter 43

Z

Z

Z

Z

Z

Z

Z

Z

Z

Z

Z

Z

A

Parameter 44

Parameter 45

Parameter 46

Parameter 47

Parameter 48

A

A

A

A

A

D GAIN

See Parameter 3 for description.

I GAIN

See Parameter 4 for description.

RATIO (STEPS/UNIT)

See Parameter 5 for description.

MAX TRAVEL (STEPS)

See Parameter 6 for description.

ACCELERATION

See Parameter 7 for description.

MAX SPEED

See Parameter 8 for description.

MAX ERROR

See Parameter 9 for description.

FUSE LEVEL

See Parameter 10 for description.

BACK EMF

See Parameter 11 for description.

STEPS/REVOLUTION

See Parameter 12 for description.

BACKLASH

See Parameter 13 for description.

DEAD ZONE

See Parameter 14 for description.

SWITCHES

See Parameter 1 for description AND make sure that this parameter is set to enable the fourth axis before you try to enable the fourth axis from settings.

P GAIN

See Parameter 2 for description.

D GAIN

See Parameter 3 for description.

I GAIN

See Parameter 4 for description.

RATIO (STEPS/UNIT)

See Parameter 5 for description.

MAX TRAVEL (STEPS)

See Parameter 6 for description.

June 1998

96-8100

June 1998

PARAMETERS

Parameter

Parameter

Parameter

Parameter

Parameter

Parameter

Parameter

Parameter

49

50

51

52

53

54

55

56

A

A

A

A

A

A

A

A

ACCELERATION

See Parameter 7 for description.

MAX SPEED

See Parameter 8 for description.

MAX ERROR

See Parameter 9 for description.

FUSE LEVEL

See Parameter 10 for description.

BACK EMF

See Parameter 11 for description.

STEPS/REVOLUTION

See Parameter 12 for description

BACKLASH

See Parameter 13 for description.

DEAD ZONE

See Parameter 14 for description.

Parameters 57 through 128 are used to control other machine dependent functions. They are:

Parameter 57 COMMON SWITCH 1

Parameter 57 is a collection of general purpose single bit flags used to turn some functions on and off. The left and right cursor arrows are used to select the function being changed. All values are 0 or 1 only. The function names are:

REV CRANK

DISABLE T.C.

DISABLE G.B.

POF AT E-STP

RIGID TAP

REV SPIN ENC

REPT RIG TAP

EX ST MD CHG

SAFETY CIRC.

SP DR LIN AC

PH LOSS DET

COOLANT SPGT

OVER T IS NC

SKIP OVERSHT

NONINV SP ST

SP LOAD MONI

SP TEMP MONI

ENA ROT & SC

ENABLE DNC

ENABLE BGEDT

ENA GRND FLT

KEYBD SHIFT

ENABLE MACRO

Reverses direction of jog handle.

Disables tool changer operations.

Disables gear box functions.

Stops spindle then turns the power off at EMERGENCY STOP

Indicates hardware option for rigid tap.

Reverses sense direction of spindle encoder.

Selects repeatable rigid tapping.

Selects exact stop in moves when mode changes.

This enables safety hardware, if machine is so equipped.

Selects linear deceleration for rigid tapping. 0 is quadratic.

When enabled, will detect a phase loss.

Enables coolant spigot control and display.

Selects control over temp sensor as N.C.

Causes Skip (G31) to act like Fanuc and overshoot sense point.

Non-inverted spindle stopped status.

Spindle load monitor option is enabled.

Spindle temperature monitor option is enabled.

Enables rotation and scaling.

Enables DNC selection from MDI.

Enables BACKGROUND EDIT mode.

Enables ground fault detector.

Enables use of keyboard with shift functions.

Enables macro functions.

96-8100

199

200

PARAMETERS

INVERT SKIP

HANDLE CURSR

NEG WORK OFS

SPIN COOLANT

ENA QUIKCODE

OILER ON/OFF

NC OVER VOLT

UNUSED

DOOR STOP SP

Parameter

Parameter

Parameter

58

59

60

Parameter 61

Parameter 62

Parameter 63

Parameter 64

Parameter 65

Parameter 66

Parameter 67

Invert sense of skip to active low=closed.

Enable use of jog handle to move cursor.

Selects use of work offsets in negative direction.

Enables spindle low oil pressure detection.

Enables conversational programming.

Enables oiler power when servos or spindle is in motion.

Inverts sense of over voltage signal.

Enables functions to stop spindle and manual operations at door switch.

LEAD COMPENS SHIFT

Shift factor when applying lead screw compensation. Lead screw compensation is based on a table of 256 offsets; each +-127 encoder steps. A single entry in the table applies over a distance equal to two raised to this parameter power encoder steps.

MAX FEED RATE (INCH)

Maximum feed rate in inches per minute.

TURRET START DELAY

Maximum delay allowed in start of tool turret. Units are milliseconds. After this time, an alarm is generated.

TURRET STOP DELAY

Maximum delay allowed in motion of tool turret. Units are milliseconds. After this time, an alarm is generated.

SHUTTLE START DELAY

Maximum delay allowed in start of tool shuttle. Units are milliseconds. After this time, an alarm is generated.

SHUTTLE STOP DELAY

Maximum delay allowed in motion of tool shuttle. Units are milliseconds. After this time, an alarm is generated.

Z TOOL CHANGE OFFSET

On Vertical mills: For Z-axis; displacement from home switch to tool change position and machine zero. About 4.6 inches, so for an 8192 line encoder this gives:

4.6 x 138718 = 638103

On Horizontal mills, this parameter is not used. It should be set to zero.

NUMBER OF TOOLS

Number of tool positions in tool changer. This number must be set to the machine’s configuration. The maximum number of tool positions is 32.

SPINDLE ORI DELAY

Maximum delay allowed when orienting spindle. Units are milliseconds. After this time, an alarm is generated.

GEAR CHANGE DELAY

Maximum delay allowed when changing gears. Units are milliseconds. After this time, an alarm is generated.

June 1998

96-8100

June 1998

Parameter 68

Parameter 69

Parameter 70

Parameter 71

Parameter 72

Parameter 73

Parameter 74

Parameter 75

Parameter 76

Parameter 77

Parameter

Parameter

78

79

Parameter 80

PARAMETERS

DRAW BAR MAX DELAY

Maximum delay allowed when clamping and unclamping tool. Units are milliseconds.

After this, time an alarm is generated.

A AIR BRAKE DELAY

Delay provided for air to release from brake on A-axis prior to moving. Units are milliseconds.

MIN SPIN DELAY TIME

Minimum delay time in program after commanding new spindle speed and before proceeding. Units are milliseconds.

DRAW BAR OFFSET

Offset provided in motion of Z-axis to accommodate the tool pushing out of the spindle when unclamping tool. Units are encoder steps.

DRAW BAR Z VEL UNCL

Speed of motion in Z-axis to accommodate tool pushing out of the spindle when unclamping tool. Units are encoder steps per second.

SP HIGH G/MIN SPEED

Command speed used to rotate spindle motor when orienting spindle in high gear. Units are maximum spindle RPM divided by 4096. This parameter is not used in machines equipped with a Haas vector drive.

SP LOW G/MIN SPEED

Command speed used to rotate spindle motor when orienting spindle in low gear. Units are maximum spindle RPM divided by 4096. This parameter is not used in machines equipped with a Haas vector drive.

GEAR CHANGE SPEED

Command speed used to rotate spindle motor when changing gears. Units are maximum spindle RPM divided by 4096.

LOW AIR DELAY

Delay allowed after sensing low air pressure before alarm is generated. Alarm skipped if air pressure returns before delay. Units are 1/50 seconds.

SP LOCK SETTLE TIME

Required time in milliseconds that the spindle lock must be in place and stable before spindle orientation is considered complete.

GEAR CH REV TIME

Time in milliseconds before motor direction is reversed while in a gear change.

SPINDLE STEPS/REV

Sets the number of encoder steps per revolution of the spindle. Applies only to rigid tapping option.

MAX SPIN DELAY TIME

The maximum delay time control will wait for spindle to get to commanded speed or to get to zero speed. Units are milliseconds.

96-8100

201

202

PARAMETERS

Parameter

Parameter

Parameter

Parameter

Parameter

Parameter

Parameter

Parameter

Parameter

Parameter

Parameter

81

82

83

84

85

86

87

88

89

90

91

Parameter 92

Parameter 93

Parameter 94

Parameter 95

Parameter 96

Parameter 97

Parameter 98

Parameter 99

Parameter 100

Parameter 101

Parameter 102

Parameter 103

Parameter 104

Parameter 105

Parameter 106

Parameter 107

Parameter 108

Parameter 109

M MACRO CALL O9000

M code that will call O9000. Zero causes no call.

M MACRO CALL O9001 same as 81

M MACRO CALL O9002 same as 81

M MACRO CALL O9003 same as 81

M MACRO CALL O9004 same as 81

M MACRO CALL O9005 same as 81

M MACRO CALL O9006 same as 81

M MACRO CALL O9007 same as 81

M MACRO CALL O9008 same as 81

M MACRO CALL O9009 same as 81

G MACRO CALL O9010

G code that will call O9010. Zero causes no call.

G MACRO CALL O9011 same as 91

G MACRO CALL O9012 same as 91

G MACRO CALL O9013 same as 91

G MACRO CALL O9014 same as 91

G MACRO CALL O9015 same as 91

G MACRO CALL O9016 same as 91

G MACRO CALL O9017 same as 91

G MACRO CALL O9018 same as 91

G MACRO CALL O9019 same as 91

IN POSITION LIMIT X

How close motor must be to endpoint before any move is considered complete when not in exact stop (G09 or G61). Units are encoder steps.

IN POSITION LIMIT Y

Same definition as Parameter 101.

IN POSITION LIMIT Z

Same definition as Parameter 101.

IN POSITION LIMIT A

Same definition as Parameter 101.

X MAX CURRENT

Fuse level in % of max power to motor. Applies only when motor is stopped.

Y MAX CURRENT

Same definition as Parameter 105.

Z MAX CURRENT

Same definition as Parameter 105.

A MAX CURRENT

Same definition as Parameter 105.

D*D GAIN FOR X

Second derivative gain in servo loop.

June 1998

96-8100

June 1998

PARAMETERS

Parameter

Parameter

Parameter

Parameter

Parameter

Parameter

Parameter

Parameter

Parameter

Parameter

Parameter

Parameter

110

111

112

113

114

115

116

117

118

119

120

121

D*D GAIN FOR Y

Second derivative gain in servo loop.

D*D GAIN FOR Z

Second derivative gain in servo loop.

D*D GAIN FOR A

Second derivative gain in servo loop.

X ACC/DEC T CONST

Exponential acceleration time constant. Units are 1/10000 seconds. This parameter provides for a constant ratio between profiling lag and servo velocity. It is also the ratio between velocity and acceleration.

Y ACC/DEC T CONST

Same definition as Parameter 113

Z ACC/DEC T CONST

Same definition as Parameter 113

A ACC/DEC T CONST

Same definition as Parameter 113

LUB CYCLE TIME

If this is set nonzero, it is the cycle time for the lube pump and the Lube pressure switch option is checked for cycling in this time. It is in units of 1/50 seconds.

SPINDLE REV TIME

Time in milliseconds to reverse spindle motor.

SPINDLE DECEL DELAY

Time in milliseconds to decelerate spindle motor.

SPINDLE ACC/DECEL

Accel/decel time constant in steps/ms/ms for spindle motor.

X PHASE OFFSET

The motor phase offset for X motor. This is arbitrary units.

Parameter

Parameter

122

123

Y PHASE OFFSET

See Parameter 121 for description.

Z PHASE OFFSET

See Parameter 121 for description.

Parameter 124 A PHASE OFFSET

See Parameter 121 for description.

Parameter 125 X GRID OFFSET

This parameter shifts the effective position of the encoder Z pulse. It can correct for a positioning error of the motor or home switch.

Parameter 126 Y GRID OFFSET

See Parameter 125 for description.

96-8100

203

204

PARAMETERS

Parameter 127 Z GRID OFFSET

See Parameter 125 for description.

Parameter 128 A GRID OFFSET

See Parameter 125 for description.

Parameter 129 GEAR CH SETTLE TIME

Gear change settle time. This is the number of one millisecond samples that the gear status must be stable before considered in gear.

Parameter 130 GEAR STROKE DELAY

This parameter controls the delay time to the gear change solenoids when performing a gear change.

Parameter 131 MAX SPINDLE RPM

This is the maximum RPM available to the spindle. When this speed is programmed, the D-to-A output will be +10V and the spindle drive must be calibrated to provide this.

Parameter 132 Y THERMAL COMP. COEF.

This is the coefficient of heating of the lead screw and is used to decrease or shorten the screw length.

Parameter 133 Z THERMAL COMP. COEF.

This is the coefficient of heating of the lead screw and is used to decrease or shorten the screw length.

Parameter 134 X EXACT STOP DIST.

Parameter 135 Y EXACT STOP DIST.

Parameter 136 Z EXACT STOP DIST.

Parameter 137 A EXACT STOP DIST.

These parameters control how close each axis must be to its end point when exact stop is programmed. They apply only in G09 and G64. They are in units of encoder steps. A value of 34 would give 34/138718 = 0.00025 inch.

Note: To change the values of parameters 134-137 permanently the machine must be rebooted.

Parameter 138 X FRICTION FACTOR

Parameter 139 Y FRICTION FACTOR

Parameter 140 Z FRICTION FACTOR

Parameter 141 A FRICTION FACTOR

These parameters compensate for friction on each of the four axes. The units are in 0.004V.

Parameter 142 HIGH/LOW GEAR CHANG

This parameter sets the spindle speed at which an automatic gear change is performed. Below this parameter, low gear is the default; above this, high gear is the default.

Parameter 143 DRAW BAR Z VEL CLMP

This parameter sets the speed of the Z-axis motion that compensates for tool motion during tool clamping. Units are in encoder steps per second.

June 1998

96-8100

June 1998

PARAMETERS

Parameter 144 RIG TAP FINISH DIST

This parameter sets the finish tolerance for determining the end point of a rigid tapping operation. Units are encoder counts.

Parameter 145 X ACCEL FEED FORWARD

Parameter 146 Y ACCEL FEED FORWARD

Parameter 147 Z ACCEL FEED FORWARD

Parameter 148 A ACCEL FEED FORWARD

These parameters set the feed forward gain for the axis servo. They have no units.

Parameter 149 PRE-CHARGE DELAY

This parameter sets the delay time from pre-charge to tool release. Units are milliseconds.

Parameter 150 MAX SP RPM LOW GEAR

Max spindle RPM in low gear.

Parameter 151 B SWITCHES

See Parameter 1 for description.

Parameter 152 B P GAIN

See Parameter 2 for description.

Parameter 153 B D GAIN

See Parameter 3 for description.

Parameter 154 B I GAIN

See Parameter 4 for description.

Parameter 155 B RATIO (STEPS/UNIT)

See Parameter 5 for description.

Parameter 156 B MAX TRAVEL (STEPS)

See Parameter 6 for description.

Parameter 157 B ACCELERATION

See Parameter 7 for description.

Parameter 158 B MAX SPEED

See Parameter 8 for description.

Parameter 159 B MAX ERROR

See Parameter 9 for description.

Parameter 160 B FUSE LEVEL

See Parameter 10 for description.

Parameter 161 B BACK EMF

See Parameter 11 for description.

Parameter 162 B STEPS/REVOLUTION

See Parameter 12 for description.

96-8100

205

206

PARAMETERS

Parameter 163 B BACKLASH

See Parameter 13 for description.

Parameter 164 B DEAD ZONE

See Parameter 14 for description.

Parameter 165 IN POSITION LIMIT B

Same definition as Parameter 101.

Parameter 166 B MAX CURRENT

Same definition as Parameter 105.

Parameter 167 D*D GAIN FOR B

Second derivative gain in servo loop.

Parameter 168 B ACC/DEC T CONST

Same definition as Parameter 113.

Parameter 169 B PHASE OFFSET

See Parameter 121 for description.

Parameter 170 B GRID OFFSET

See Parameter 125 for description.

Parameter 171 B EXACT STOP DIST.

See Parameters 134 for description.

Parameter 172 B FRICTION FACTOR

See Parameter 138 for description.

Parameter 173 B ACCEL FEED FORWARD

Same description as Parameter 145.

Parameter 174 SPINDLE B TEMP. COEF.

This parameter controls the amount of correction to the B-axis in response to heating of the spindle head. It is 10 times the number of encoder steps per degree F.

Parameter 175 B AIR BRAKE DELAY

Delay provided for air to release from brake on B-axis prior to moving. Units are milliseconds.

Note: The C-axis parameters (176-200) are used to control the Haas Vector Drive.

Parameter 278 bit HAAS VECT DR must be set to 1 for these parameters to be available.

Parameter 176 C SWITCHES

See Parameter 1 for description.

Parameter 177 C P GAIN

See Parameter 2 for description.

Parameter 178 C D GAIN

See Parameter 3 for description.

June 1998

96-8100

June 1998

PARAMETERS

Parameter 179 C I GAIN

See Parameter 4 for description.

Parameter 180 C SLIP GAIN

The value that the slip rate would assume at maximum speed and maximum current.

Parameter 181 C MIN SLIP

The minimum value allowed for the slip rate.

Parameter 182 C ACCELERATION

See Parameter 7 for description.

Parameter 183 C MAX FREQ

The frequency at which the motor will be run when maximum spindle RPM is commanded.

Parameter 184 C MAX ERROR

The maximum allowable error (in Hz) between commanded spindle speed and actual speed. If set to zero, it will default to 1/4 of Parameter 183.

Parameter 185 C FUSE LEVEL

See Parameter 10 for description.

Parameter 186 C DECELERATION

Maximum deceleration of axis in encoder steps per second per second.

Parameter 187 C HIGH GEAR STEPS/REV

The number of encoder steps per revolution of the motor when the transmission is in high gear. If the machine does not have a transmission, this is simply the number of encoder steps per revolution of the motor.

Parameter 188 C ORIENT GAIN

The proportional gain used in the position control loop when performing a spindle orientation.

Parameter 189 C BASE FREQ

This is the rated frequency of the motor.

Parameter 190 C HI SP CURR LIM

At speeds higher than the base frequency, the maximum current that is applied to the motor must be reduced.

Parameter 191 C MAX CURRENT

Same definition as Parameter 105.

Parameter 192 C MAG CURRENT

This is the magnetization component of the current in the motor, also called the flux or field current.

Parameter 193 C SPIN ORIENT MARGIN

When a spindle orientation is done, if the actual position of the spindle is within this value (plus or minus), the spindle will be considered locked. Otherwise, the spindle will not be locked.

96-8100

207

208

PARAMETERS

Parameter 194 SPINDLE STOP FREQ

The spindle is considered to be stopped (discrete input SP ST*=0) when the speed drops below this value. Units are encoder steps/millisecond.

Parameter 195 C START/STOP DELAY

This delay is used at the start of motion to magnetize the rotor before accelera tion starts.

Parameter 196 C ACCEL LIMIT LOAD

This is the % load limit during acceleration.

Parameter 197 SWITCH FREQUENCY.Unit:Hz.

This is the frequency at which the spindle motor windings are switched. Note that there is a hysteresis band around this point, defined by parameter 198.

Parameter 198 SWITCH HYSTERESIS. UNIT:Hz.

This defines the + hysteresis band around parameter 197. For example if par. 197 is 85 Hz, and par. 198 is 5Hz, the switching will take place at 90Hz when the spindle is speeding up, and at 80 Hz when the spindle is slowing down.

Parameter 199 PRE-SWITCH DELAY. UNIT: ms.

This is the amount of time allowed for the current in the motor to drop before the winding change contactors are switched.

Parameter 200 POST- SWITCH DELAY. UNIT: ms

This is the amount of time allowed for the contactors to stabilize after a switch is commanded, before current is applied to the motor.

Parameter 201 X THERMAL COMP. COEF.

This is the coefficient of heating of the lead screw and is used to shorten the screw length.

Parameter 202 X AIR BRAKE DELAY

This parameter is not used.

Parameter 203 Y AIR BRAKE DELAY

This parameter is not used.

Parameter 204 Z AIR BRAKE DELAY

This parameter is not used.

Parameter 205 A SPINDLE TEMP. COEF.

This parameter controls the amount of correction to the A-axis in response to heating of the spindle head. It is 10 times the number of encoder steps per degree F.

Parameter 206 SPIGOT POSITIONS

Maximum number of spigot positions.

Parameter 207 SPIGOT TIMEOUT (MS)

Maximum timeout allowed for spigot to traverse one spigot location.

Parameter 208 SPIN. FAN OFF DELAY

Delay for turning the spindle fan off after the spindle has been turned off.

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PARAMETERS

Parameter

HORIZONTAL

209 COMMON SWITCH 2

Parameter 209 is a collection of general purpose single bit flags used to turn some functions on and off. The left and right cursor arrows are used to select the function being changed. All values are 0 or 1 only. The function names are:

When set to (1), the control identifies the machine as a horizontal mill. The control will then make the necessary adjustments, such as enabling the horizontal tool changer.

Tool changer can be stopped with RESET button.

RST STOPS T.C.

UNUSED

ENA CONVEYOR

50% RPD KBD

FRONT DOOR

TC Z NO HOME

Enables chip conveyor, if machine is so equipped.

When (1) the control will support the new style keyboards with the 50% rapid traverse key. For controls without a 50% rapid keypad set this bit to (0).

When enabled the control will look for an additional door switch and will generate an operator message.

In Horizontal mills only. This bit prevents Z-axis motion to machine zero prior to a tool change.

M36 AUTO MOT

AUX AXIS TC

SPIGOT KEY INV

T SUBROUTINE

SPIN Y ENCDR

REV CONVEYOR

When (1) the commands to the conveyor motor are reversed so that forward becomes reverse. If the conveyor is wired incorrectly, this bit can be set so that the conveyor runs in the proper direction.

Reserved for future use.

For Lathe only. When enabled, spindle encoder input is to the Y-axis.

Reverses the direction of the chip conveyor.

M27-M28 CONVYR Usually the chip conveyor motor and direction relays are attached to the user relays M21 and M22. When this bit is set, the control expects to see the conveyor hooked up to M27 and M28.

RESERVED

GREEN BEACON

In Horizontal only. When set to (1), an M36 rotates the A-axis after the PART READY button is pressed.

In Horizontal mills only. When enabled, means the tool changer carousel is driven by an aux. axis.

RED BEACON

When (1) user relay M25 is used to flash a beacon. If the control is in a reset state, the beacon will be off. If the control is running normally, the beacon will be steadily on. If the control is in a M00, M01, M02, M30 feedhold, or single block state, then the beacon will flash.

When (1) user relay M26 is used to flash a beacon. The beacon flashes if the control is experiencing an alarm or emergency stop condition.

CONVY DR OVRD When (1) the conveyor will continue to run with the door open. When (0) the conveyor will stop when the door is open, but will resume when the door is closed. For safety it is recommended that the bit be set to (0).

96-8100

209

210

PARAMETERS

DSBL CLNT IN

DSC INP PR

RMT TOOLS RLS

FLOPPY ENABL

TCR KEYPAD

MCD RLY BRD

If set to 1 low coolant input will not be used.

Discrete pallet rotate/part ready; inputs enabled if set to 1.

If set to 1, allows use of remote tool release button on spindle head.

If set to 1, enables the optional floppy drive.

If set to 1, enables tool changer restore button on keypad.

If set to 1, adds 8 additional relays, for a total of 40. These additional relays (M21-M28) become available on a secondary board, and are shown on the discrete outputs page.

TSC ENABLE

AUX JOG NACC

ALISM PRGRST

DSBL JOG TST

AIR DR @ M24

UNDEFINED

P RDY @ Y160

SPNDL NOWAIT

When set to 1, «DSBL CLNT IN» bit is ignored, M24, M54 and M64 are disabled, and TSC will operate. When set to zero, the control functions normally.

Does not allow accumulation on auxiliary axis jog.

Alias M codes during program restart.

Disables the encoder test for the jog handle.

Used on horizontal mills only.

Used on horizontal mills only.

When (1), the machine will not wait for the spindle to come up to speed immediately after an M03 or M04 command. Instead, it will check and/or wait for the spindle to come up to speed immediately before the next interpolated motion is initiated. This bit does not affect rigid tapping or the TSC option.

Parameter 210 X TOOL CHANGE OFFSET

This parameter is not used.

Parameter 211 Y TOOL CHANGE OFFSET

On Horizontal mills: For Y-axis; displacement from the home position to tool change position.

Parameter 212

On Vertical mills, this parameter is not used.

A TOOL CHANGE OFFSET

This parameter is not used.

Parameter 213

Parameter

Parameter

214

215

B TOOL CHANGE OFFSET

This parameter is not used.

D:Y CURRENT RATIO %. UNIT: %.

This defines the ratio between the two winding configurations. This default winding is

Y, and the parameters are set for the Y winding. This number is used to adjust the parameters for the delta winding when the windings are switched.

CAROUSEL OFFSET

Parameter used to align tool 1 of tool changing carousel precisely. Units are encoder steps.

Parameter 216 CNVYR RELAY DELAY

Delay time in 1/50 seconds required on conveyor relays before another action can be commanded. Default is 5.

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PARAMETERS

Parameter 217 CNVYR IGNORE OC TIM

Amount of time in 1/50 seconds before overcurrent is checked after conveyor motor is turned on. Default is 50.

Parameter 218 CONVYR RETRY REV TIM

Amount of time that the conveyor is reversed in 1/50 seconds after overcurrent is sensed. Default is 200.

Parameter 219 CONVYR RETRY LIMIT

Number of times that the conveyor will cycle through the reverse/forward sequencing when an overcurrent is sensed before the conveyor will shut down.

An overcurrent is sensed when chips jam the conveyor. By reversing and then forwarding the conveyor, the chip jam may be broken. Default is 3.

Parameter 220 CONVYR RETRY TIMEOUT

Amount of time in 1/50 seconds between consecutive overcurrents in which the overcurrents is considered another retry. If this amount of time passes between overcurrents, then the retry count is set to (0). Default is 1500, 30 seconds.

Parameter 221 MAX TIME NO DISPLAY

The maximum time (in 1/50 sec.) between screen updates.

Parameter 222 ROTARY AXIS INCRMNT

For Horizontal mills only. This parameter sets the degrees of rotation of the Aaxis at an M36 or Pallet Rotate.

Parameter 223 AIR TC DOOR DELAY

For Horizontal mills only. This parameter sets the delay to open the tool changer door (in milliseconds). If the tool changer does not have a pneumatic door, this parameter is set to zero.

Parameter 224 ROT AXIS ZERO OFSET

This parameter shifts the zero point of A for a wheel fixture or tombstone.

Parameter 225 MAX ROT AXIS ALLOW

For Horizontal mills with a wheel fixture only. This parameter sets the maximum rotation (in degrees) allowed before stopping at front door.

Parameter 226 EDITOR CLIPBOARD

This parameter assigns a program number (nnnn) to the contents of the clipboard.

Parameter 227 FLOPPY DIR NAME

This parameter sets the program numbers to store in the floppy directory.

Parameter 228 QUICKCODE FILE

This parameter set the program numbers to store in the Quickcode definition.

Parameter 229 X LEAD COMP 10E9

This parameter sets the X-axis lead screw compensation signed parts per billion.

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PARAMETERS

Parameter 230 Y LEAD COMP 10E9

This parameter sets the Y-axis lead screw compensation signed parts per billion.

Parameter 231 Z LEAD COMP 10E9

This parameter sets the Z-axis lead screw compensation signed parts per billion.

Parameter 232 A LEAD COMP 10E9

This parameter sets the A-axis lead screw compensation signed parts per billion.

Parameter 233 B LEAD COMP 10E9

This parameter sets the B-axis lead screw compensation signed parts per billion.

Parameter 234 C RESERVED

Parameter 235 TSC PISTON SEAT

With the 50 TSC option, the amount of time given for the piston to seat during system start-up. The default is 500 milliseconds. If machine has a 50 Taper

spindle and the TSC option, this parameter must be set to 0.

Parameter 236 TSC LOW PR FLT

After the TSC system has stabilized following startup, Alarm 151 is generated if coolant pressure falls below 40 psi for the amount of time set in this parameter. The default is 1000 milliseconds.

Parameter 237 TSC CLNT LINE PURGE

The amount of time given for the coolant to purge when the TSC system is shut off. This parameter may be increased by the user to a higher value to help purge coolant from small orifice tooling. The minimum (default) value is 2500 millisec onds.

Parameter 238 MAX TSC SPINDLE RPM

When TSC is enabled and in use, this parameter limits the maximum spindle speed. Default value is 7500 RPM. On 50 taper machines, TSC can be run at the maximum speed of 5000 RPM

Parameter 239 SPNDL ENC STEPS/REV

This parameter sets the number of encoder steps per revolution of the spindle encoder.

Parameter 240 C AXIS MAX TRAVEL

This parameter sets the C-axis maximum travel in the positive direction.

Parameter 241 U AXIS MAX TRAVEL

This parameter sets the U-axis maximum travel in the positive direction.

Parameter 242 V AXIS MAX TRAVEL

This parameter sets the V-axis maximum travel in the positive direction.

Parameter 243 W AXIS MAX TRAVEL

This parameter sets the W-axis maximum travel in the positive direction.

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PARAMETERS

Parameter 244 C AXIS MIN TRAVEL

This parameter sets the C-axis minimum travel in the negative direction.

Parameter 245 U AXIS MIN TRAVEL

This parameter sets the U-axis minimum travel in the negative direction.

Parameter 246 V AXIS MIN TRAVEL

This parameter sets the V-axis minimum travel in the negative direction.

Parameter 247 W AXIS MIN TRAVEL

This parameter sets the W-axis minimum travel in the negative direction.

Parameter 255 CONVEYOR TIMEOUT

The amount of time (in minutes) the conveyor will operate without any machine motion or keyboard action. After this time, the conveyor will automatically shut off.

Parameter 256 PALLET LOCK INPUT

Used in horizontal mills only.

Parameter 257 SPINDL ORIENT OFSET

If the machine is equipped with a spindle vector drive (as set in bit 7 of

Parameter 278), this bit sets the spindle orientation offset. The offset is the number of encoder steps between the Z pulse and the correct spindle orientation position.

Parameter 258 LS PER INCH

The number of steps on the linear scale per inch of travel.

Parameter 259 LS PER REV

The number of steps between Z pulses on the linear scale.

Parameter 266 X SWITCHES

Parameter 266 is a collection of single-bit flags used to turn servo related functions on and off. The left and right cursor arrows are used to select the function being changed. All values are 0 or 1 only. The function names are:

X LIN SCALE EN

X INVRT LN SCL

X DSBL LS ZTST

X ZERO AXIS TC

X 2ND HOME BTN

X NEG COMP DIR

X DELAY AXIS 0

Used to enable linear scales for the X axis.

Used to invert the X-axis linear scale.

Used to disable the linear scale Z test.

Used to return axis to zero prior to tool change.

Used to move axis to coordinate specified in Work Ofset G129

Used to negate the direction of thermal compensation

Used with an APL to ensure X axis is zeroed before A axis of APL

Parameter 267 Y SWITCHES

Parameter 267 is a collection of single-bit flags used to turn servo related functions on and off. The left and right cursor arrows are used to select the function being changed. All values are 0 or 1 only. The function names are:

Y LIN SCALE EN

Y INVRT LN SCL

Y DSBL LS ZTST

Y ZERO AXIS TC

Used to enable linear scales for the Y axis.

Used to invert the Y-axis linear scale.

Used to disable the linear scale Z test.

Used to return axis to zero prior to tool change.

213

214

PARAMETERS

June 1998

Y 2ND HOME BTN

Y NEG COMP DIR

Y DELAY AXIS 0

Used to move axis to coordinate specified in Work Ofset G129

Used to negate the direction of thermal compensation

Used with an APL to ensure Y axis is zeroed before A axis of APL

Parameter 268 Z SWITCHES

Parameter 268 is a collection of single-bit flags used to turn servo related functions on and off. The left and right cursor arrows are used to select the function being changed. All values are 0 or 1 only. The function names are:

Z LIN SCALE EN

Z INVRT LN SCL

Z DSBL LS ZTST

Z ZERO AXIS TC

Z 2ND HOME BTN

Z NEG COMP DIR

Z DELAY AXIS 0

Used to enable linear scales for the Z axis.

Used to invert the Z-axis linear scale.

Used to disable the linear scale Z test.

Used to return axis to zero prior to tool change.

Used to move axis to coordinate specified in Work Offset G129

Used to negate the direction of thermal compensation

Used with an APL to ensure Z axis is zeroed before A axis of APL

Parameter 269 A SWITCHES

Parameter 269 is a collection of single-bit flags used to turn servo related functions on and off. The left and right cursor arrows are used to select the function being changed. All values are 0 or 1 only. The function names are:

A LIN SCALE EN

A INVRT LN SCL

A DSBL LS ZTST

A ZERO AXIS TC

A 2ND HOME BTN

A DELAY AXIS 0

Used to enable linear scales for the A axis.

Used to invert the A-axis linear scale.

Used to disable the linear scale Z test.

Used to return axis to zero prior to tool change.

Used to move axis to coordinate specified in Work OPffset G129

Used with an APL to ensure A axis is zeroed before A axis of APL

Parameter 270 B SWITCHES

Parameter 269 is a collection of single-bit flags used to turn servo related functions on and off. The left and right cursor arrows are used to select the function being changed. All values are 0 or 1 only. The function names are:

B LIN SCALE EN

B INVRT LN SCL

B DSBL LS ZTST

B ZERO AXIS TC

B 2ND HOME BTN

B DELAY AXIS 0

Used to enable linear scales for the B axis.

Used to invert the B-axis linear scale.

Used to disable the linear scale Z test.

Used to return axis to zero prior to tool change.

Used to move axis to coordinate specified in Work Offset G129

Used with an APL to ensure B axis is zeroed before A axis of APL

Parameter 271 C SWITCHES

Parameter 271 is a collection of single-bit flags used to turn servo related functions on and off. This parameter is not used when machine is equipped with a Haas vector drive. The left and right cursor arrows are used to select the function being changed. All values are 0 or 1 only. The function names are:

C LIN SCALE EN

C INVRT LN SCL

C DSBL LS ZTST

C ZERO AXIS TC

C 2ND HOME BTN

C DELAY AXIS 0

Used to enable linear scales for the C axis.

Used to invert the C-axis linear scale.

Used to disable the linear scale Z test.

Used to return axis to zero prior to tool change.

Used to move axis to coordinate specified in Work Offset G129

Used with an APL to ensure C axis is zeroed before A axis of APL

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PARAMETERS

Parameter 272 X THERM COMP T. CONST

This parameter is the thermal compensation time constant, and is the time constant governing the rate of cool down of the screw.

Parameter 273 Y THERM COMP T. CONST

This parameter is the thermal compensation time constant, and is the time constant governing the rate of cool down of the screw.

Parameter 274 Z THERM COMP T. CONST

This parameter is the thermal compensation time constant, and is the time constant governing the rate of cool down of the screw.

Parameter 278 COMMON SWITCH 3

Parameter 278 is a collection of general purpose single bit flags used to turn some functions on and off. This bit will cause the machine to use discrete outputs 21 and 26 to command the shuttle to move in and out. On mills with the Air Driven Shuttle it must be set to 1. On all other mills it must be set to 0.The

left and right cursor arrows are used to select the function being changed. All values are 0 or 1 only. The function names are:

INVERT G.B.

This bit allows an alternate gearbox configuration. It inverts the sense of the gearbox inputs. Used for 50 taper option.

DPR SERIAL

CK PALLET IN

CK HIDN VAR

DISPLAY ACT

TSC PRG ENBL

RESERVED

SPND DRV LCK

Causes the main serial inputs/outputs to go through the floppy video board.

This bit is used on horizontal mills only.

This bit is used on horizontal mills only.

When set to 1, displays the actual spindle speed on the Current Commands display page.

Enables purge output on TSC option.

Reserved for later use.

RESERVED

CNCR SPINDLE

RESERVED

HAAS VECT DR

This bit must be set to 1 if machine is equipped with a non-Haas vector spindle drive. This bit will must be set to 1 if the machine has a 50 taper spindle or a non-Haas vector drive.

Reserved for later use.

(Concurrent Spindle) When set to 1, the spindle will be commanded to start concurrently with other commands in the same block. In the following example, with this bit set to 1, the spindle will start at the same time as the feed:

G1 X-1. F1. S7500 M3;

Reserved for later use.

(Haas Vector Drive) This bit must be set to 1 if machine is equipped with a HAAS vector spindle drive. When set to 1, voltage to the Haas vector drive is displayed in the diagnostics display as DC BUSS.

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215

216

PARAMETERS

UP ENCL TEMP

HAAS RJH

SPIN TEMP NC

AIR DRV SHTL

GIMBAL SPNDL

NO MFIN CKPU

D:Y SWITCH

ENABLE

D:Y SW ON FLY

5 AX TOFS -X

5 AX TOFS -Y

5 AX A MOV B

SAFETY INVERT

(Microprocessor Enclosure Temperature) When set to 1, the enclosure temperature will be displayed on INPUTS2 screen of the diagnostics display.

(Haas Remote Jog Handle) This bit must be set to 1 if the machine is equipped with a Haas 5-Axis Remote Jog Handle.

(Spindle Temperature Sensor Normally Closed) This bit specifies the type

(normally open or normally closed) of the spindle temperature sensor. This bit should be set to 1 for machines with a Haas vector drive, and 0 for machines that do not have a vector drive.

This bit will cause the machine to use discrete outputs 21 and 26 to command the shuttle to move in and out. On mills with the Air Driven Shuttle it must be set to 1. On all other mills it must be set to 0.

This bit will cause the machine to check that the Z,A and B axes are at zero before a tool change is started. If one is not , alarm 150 will be generated. On mills with the gimbaled Spindle it must be set to 1. On all other mills it must be set to 0.

When this bit is set, it will prevent checking of MFIN at power-up. It should be set for 1 for all machines that have the new Haas Automatic Pallet Changer attached, and 0 for all other machines.

This bit enables the switching of spindle motor windings, provided the hardware is installed, and the proper parameters are set. If this switch is set, but bit 19 is not, then the winding switching will only be done when the spindle is at rest, depending on the target speed of the spindle.

This bit enables switching on the fly, as the spindle motor is accelerating or decelerating through the switch point. If bit 18 is not set, this switch will be ignored.

This bit is used with the G143 (modal 5 axes tool length compensation) on machines with a Gimbaled Spindle. If it is set to 1, this means that when the corresponding rotary axes is moved, the sign of the X Position must be inverted.

Normally, this bit should be set to 0.

This bit is used with the G143 (modal 5 axes tool length compensation) on machines with a Gimbaled Spindle. If it is set to 1, this means that when the corresponding rotary axes is moved, the sign of the Y Position must be inverted.

Normally, this bit should be set to 0.

This bit is used with the G143 (modal 5 axes tool length compensation) on machines with a Gimbaled Spindle. The B axes normally moves the A axes, but if this is not true, this bit can be set to change which is the inner axes. Normally, this bit should be set to 0.

This bit supports the CE door interlock that locks when power is turned off. For machines that have the regular door lock that locks when power is applied, this bit must be set to 0. For machines that have the inverted door lock, this bit must be set to 1.

June 1998

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PARAMETERS

Parameter 279 X MAX 3rd DERIV

This parameter supports S-curve. It is initialized to 250000000 and can be altered as needed. In order to ensure the desired effect, the minimum value that the control will use is:

11700* ACCELERATION / ACC / DEC T CONST

If the parameter is set to a lower value, the control will instead use the value computed using the above formula.

Parameter 280 Y MAX 3rd DERIV

See parameter 279 for description

Parameter 281 Z MAX 3rd DERIV

See parameter 279 for description

Parameter 282 A MAX 3rd DERIV

See parameter 279 for description

Parameter 283 B MAX 3rd DERIV

See parameter 279 for description

Parameter 284 C MAX 3rd DERIV

See parameter 279 for description

Parameter 294 MIN BUSS VOLTAGE

This parameter specifies the minimum Haas Vector Drive buss voltage. When a Haas Vector Drive is installed, it should be set to 200 volts. Otherwise, it should be set to zero. Alarm 160 will be generated if the voltage falls below this value.

Parameter 295 SHTL SETTLE TIME

This is for the air driven shuttle (used on the VR series mills). This parameter allows settling time for the shuttle after it has moved toward the spindle and before a tool change is performed. It should be set to approximately half a second (500) on all mills with the Air Driven Shuttle. This may very. All other mills can be set to 0 as they are unaffected by it.

Parameter 296 MAX OVER VOLT TIME

Specifies the amount of time (in 50ths of a second) that an overvoltage condition (alarm 119 OVER VOLTAGE) will be tolerated before the automatic shut down process is started.

Parameter 298 MAX FEED (DEG/MIN)

This parameter specifies the maximum rotary feed rate in degrees per minute.

Any attempt at cutting faster than this will result in «LIM» being displayed next to the FEED message on the Program Command Check screen.

On mills with a Gimbaled Spindle, this parameter must be set to 200. For all other mills, this bit should be set to 99999.

Parameter 297 MAX OVERHEAT TIME

Specifies the amount of time (in 50ths of a second ) that an overheat condition

(alarm 122 REGEN OVERHEAT) will be tolerated before the automatic shut down process is started.

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PARAMETERS

Parameter 299 AUTOFEED-STEP-UP

This parameter works with the AUTOFEED feature. It specifies the feed rate stepup percentage per second and should initially be set to 10.

Parameter 300 AUTOFEED STEP-DOWN

This parameter works with the AUTOFEED feature. It specifies the feed rate stepdown percentage per second and should initially be set to 20.

Parameter 301 AUTOFEED-MIN-LIMIT

This parameter works with the AUTOFEED feature. It specifies the minimum allowable feed rate override percentage that the AUTOFEED feature can use and should initially be set to 1.

L

EAD

S

CREW

C

OMPENSATION

Separate lead screw compensation is provided for each of the X, Y, and Z axes. The operator-entered compensation values are spaced at 0.5 inch intervals within the machine coordinate system. The compensation values are entered in inches with a resolution of 0.0001 inch. The operator entered values are used to interpolate into a table of 256 entries. The spacing between two entries in the table of 256 is defined by

Parameter 58. The entered values are limited to +/-127 encoder steps; so the limit in inches is dependent on

Parameters 5, 19, and 33.

Note that the first entry corresponds to machine position zero and subsequent entries are for increasingly negative positions in the machine coordinate system. The user should not ever need to adjust the lead screw compensation tables.

E

LECTRONIC

T

HERMAL

C

OMPENSATION

When ballscrews rotate they generate heat. Heat causes the ballscrews to expand. In constant duty cycles as in mold making the resultant ball screw growth can lead to cutting errors on the next morning start up.

Haas’ new ETC algorithm can accurately model this heating and cooling effect and electronically expand and contract the screw to give near glass scale accuracy and consistency.

This compensation is based on a model of the lead screw which calculates heating based on the distance traveled and the torque applied to the motor. This compensation does not correct for thermal growth due to changes in ambient temperature or due to part expansion.

Electronic thermal compensation works by estimating the heating of the screw based on the total amount of travel over its length and including the amount of torque applied to the screw. This heat is then turned into a thermal coefficient of expansion and the position of the axis is multiplied by the coefficient to get a correction amount.

The compensation time constant is on the order of 20 to 50 minutes to lose half of the heat in the screw. If the machine is turned off when there is some compensation applied (due to motion and heating of screw), when the machine is turned back on, the compensation will be adjusted by the clock indicated elapsed time.

Thus a real time clock is required for this compensation to work if the machine is turned off for less than 2 hours.

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MAINTENANCE

7. MAINTENANCE SCHEDULE

The following is a list of required regular maintenance for the HAAS VF-Series Vertical Machining Centers.

Listed are the frequency of service, capacities, and type of fluids required. These required specifications must be followed in order to keep your machine in good working order and protect your warranty.

INTERVAL MAINTENANCE PERFORMED

DAILY

ü

Check coolant level every eight hour shift (especially during heavy TSC usage).

ü

Check way lube lubrication tank level.

ü

Clean chips from way covers and bottom pan.

ü

Clean chips from tool changer.

ü

Wipe spindle taper with a clean cloth rag and apply light oil.

WEEKLY

MONTHLY

SIX MONTHS

ANNUALLY

ü

Check Through the Spindle Coolant (TSC) filters. Clean or replace element if needed.

ü

Check automatic dump air line’s water trap for proper operation.

ü

On machines with the TSC option, clean the chip basket on the coolant tank.

Remove the tank cover and remove any sediment inside the tank. Be careful to disconnect the coolant pump from the controller and POWER OFF the control before working on the coolant tank. Do this MONTHLY for machines without

the TSC option.

ü

Check air gauge/regulator for 85 psi.

ü

For machines with the TSC option, place a dab of grease on the V-flange of tools.

Do this MONTHLY for machines without the TSC option.

ü

Check air filter at top of spindle motor.

ü

Clean exterior surfaces with mild cleaner. DO NOT use solvents.

ü

Check the hydraulic counterbalance pressure according to the machine’s specifications.

ü

Check oil level in gear box. For 40 taper spindles: Remove inspection cover beneath spindle head. Add oil slowly from top until oil begins dripping from overflow tube at bottom of sump tank. For 50 taper spindles: Check oil level in sightglass. Add from side of gearbox if necessary.

ü

Inspect way covers for proper operation and lubricate with light oil, if necessary.

ü

Dump the oil drain bucket.

ü

Place a dab of grease on the outside edge of the guide rails of the tool changer and run through all tools.

ü

Replace coolant and thoroughly clean the coolant tank.

ü

Check all hoses and lubrication lines for cracking.

ü

Replace the gearbox oil. Drain the oil from the bottom of the gearbox. Remove inspection cover beneath spindle head. Add oil slowly from top until oil begins dripping from overflow tube at bottom of sump tank. For 50 taper spindles, add oil from the side of the transmission.

ü

Check oil filter and clean out residue at bottom of filter.

ü

Replace air filter on control box every (2) years.

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MAINTENANCE

SYSTEM:

LOCATION

LUBRICATION CHART

WAY LUBE AND PNEUMATICS

Under the control panel at the rear of the machine

TRANSMISSION

Above the spindle head

COOLANT TANK

Rear of machine

June 1998

DESCRIPTION

Piston pump with 30-minute cycle time.

Pump is only on when spindle is turning or when axis is moving.

Linear guides and ball nuts

LUBRICATES

QUANTITY

LUBRICANT

1.5 QT. Tank

Mobil Vactra #2

Transmission only

40 taper 2-QT

50 taper 36 OZ.

Mobil DTE 25

40 Gallons

80 Gallons (VF 6 -10)

Water soluble, synthetic

220

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June 1998

MAINTENANCE

TSC M

AINTENANCE

3 Check dirt indicator on 100 micron filter with TSC system running and no tool in the spindle. Change element when the indicator reaches the red zone.

3 Clean pump intake filter when indicator is in red zone. Reset indicator with button. All intake filters can be cleaned with a wire brush.

3 On the High Pressure System and old 40 taper system, after changing or cleaning filter elements, run TSC system with no tool in spindle for at least one minute to prime system. On old 50 taper TSC system, close the P-cool and lock line shutoff valves and run the normal coolant pump to prime the TSC system.

Wing Nuts (4)

Disconnect

Hose for

Cleaning

100 Mesh

Intake

Filter

Gasket

Intake Filter

Housing

Figure 1. TSC coolant pump assembly. Figure 2. Cleaning the intake filter.

CHECKING DRAWBAR HEIGHT

New TSC systems have carbide tips and carbide tipped drawbars. The coolant tip should last the life of the machine. On old TSC systems that have a bronze coolant tip the drawbar height must be checked every 6 months or 1000 hours of TSC system use. This is done to check for wear on the Coolant Tip.

CAUTION! Failure to check coolant tip wear regularly will result in tool changer damage.

Tools Required

ü

ü

Machined aluminum block (2″ x 4″ x 4″)

Tool holder (without a tool)

1. Place a sheet of paper under the spindle for table protection, then place a machined block of aluminum

(approximately 2″ x 4″ x 4″) on the paper (Figure 3).

2. POWER ON the VMC. Insert a tool holder WITHOUT ANY TYPE OF CUTTER into the spindle taper.

3. Go to the HANDLE JOG mode. Choose Z-axis and set jog increments to .01.

4. Jog Z-axis in the negative (-) direction until the tool holder is approximately .03 from the block. At this point, stop jogging the spindle and push the TOOL RELEASE button. You will notice that the tool holder comes out of the taper.

96-8100

221

222

MAINTENANCE

June 1998

Figure 3. Placement of aluminum block under spindle. Figure 4. Coolant Tip (TSC machines only)

.

5. The clearance from the tool holder to the block should be zero (0). To accomplish this, set the jog increments to .001 and jog in the negative (-) Z direction a few increments of the hand wheel at a time.

Between these moves, push the tool release button and feel for movement by placing your finger between the tool holder and the spindle. Do this until no movement is felt. You are now at zero (0).

CAUTION! Do not jog too far in the negative (-) direction or it will cause an overcurrent in the

Z-axis.

6. Press MDI and turn hand wheel to zero (0). Press HANDLE JOG button. Jog the Z-axis in the positive (+) direction 0.100″.

7. Press and hold the TOOL RELEASE button, grasp the block and try to move it. The block should be tight at .100 and loose at .110.

Ø

If block moves at .100, jog the Z-axis in the negative (-) direction one increment at a time. Press the TOOL RELEASE button and check for movement between increments until block is tight.

Ø

If the block is tight at 0.070 or less, the Coolant Tip (Figure 4) must be replaced. Replace coolant tip and seal housing at the same time (TSC Service Kit 93-9000A).

96-8100

June 1998

CABLE LOCATIONS

8. PCB’S, CABLE LOCATIONS AND BOARD DIAGRAMS

96-8100

223

CABLE LOCATIONS

June 1998

224

KEYBOARD INTERFACE P/N 32-4030

96-8100

June 1998

CABLE LOCATIONS

MICRO PROCESSOR PCB — P/N 32-3091

CABLE CONNECTIONS

PROC.

PLUG #

ADDRESS

& DATA

P3

P6

PORT 1

PORT 2

CABLE #

860

N/A

850

850A

SIGNAL NAME

ADDRESS BUSS

DATA BUSS

LOW VOLTAGE

EXTERNAL BATTERY

SERIAL PORT #1

SERIAL PORT #2

ð

TO

ð

LOCATION

VIDEO

MOTIF PCB

POWER SUPPLY PCB

(EXT. BATTERY)

SERIAL PORT #1

SERIAL PORT #2

PLUG #

——-

——-

——-

——-

——-

——-

96-8100

225

CABLE LOCATIONS

June 1998

226

96-8100

June 1998

CABLE LOCATIONS

BRUSHLESS SERVO AMPLIFIER — P/N 32-5550B

CABLE CONNECTIONS

MOCON PLUG # CABLE #

SIGNAL NAME

ð

TO

ð

LOCATION PLUG #

P

TB A, B, C

P

TB -HV +HV

Y AXIS AMP

P

TB A, B, C

P

TB -HV +HV

Z AXIS AMP

P

TB A, B, C

P

TB -HV +HV

A AXIS AMP

P

TB A, B, C

P

TB -HV +HV

570

——-

610

——-

580

——-

620

——-

590

——-

630

——-

600

——-

640

——-

LOW VOLTAGE

MOTOR DRIVE

X DRIVE SIGNAL

320VDC

LOW VOLTAGE

MOTOR DRIVE

Y DRIVE SIGNAL

320VDC

LOW VOLTAGE

MOTOR DRIVE

Z DRIVE SIGNAL

320VDC

LOW VOLTAGE

MOTOR DRIVE

A DRIVE SIGNAL

320VDC

L. V. POWER SUPPLY

X SERVO MOTOR

MOCON PCB

SPINDLE DRIVE

L. V. POWER SUPPLY

Y SERVO MOTOR

MOCON PCB

SPINDLE DRIVE

L. V. POWER SUPPLY

Z SERVO MOTOR

MOCON PCB

SPINDLE DRIVE

L. V. POWER SUPPLY

A SERVO MOTOR

MOCON PCB

SPINDLE DRIVE

——-

——-

P2

——-

——-

——-

P3

——-

——-

——-

P4

——-

——-

——-

P5

——-

96-8100

227

CABLE LOCATIONS

June 1998

228

POWER PCB 32-5010

96-8100

June 1998

CABLE LOCATIONS

POWER PCB 32-5010

CABLE CONNECTIONS

PLUG # CABLE #

P10

P11

P12

P13

P14

P15

P17

P19

P6

P7

P8

P9

P1

P3

P4

P5

P21

P22

P24

P26

P27

P30

P31

TB1

TB2

POWER ON/OFF

860

860

860

860

800A

70

860A

290

——

——

170

PRI-SEC

930

910

90

860

PORT 1&2

——-

SPARE

860

860

800

860A

——-

——-

SIGNAL NAME

ð

TO

ð

190-260VAC INPUT

K1 COIL

AUTO OFF

PRI-SEC/T5

230VAC/COOLANT PUMP

115VAC CB/SOLENOID

115VAC/T1

LOW VOLTAGE

LOW VOLTAGE

LOW VOLTAGE

LOW VOLTAGE

LOW VOLTAGE

——-

230VAC/K1 CONTACTORS

I/O +12VDC

230VAC/T4

-12VDC PORT 1 & 2

-12VDC

SPARE

LOW VOLTAGE

LOW VOLTAGE

——-

+12VDC

115VAC IN

115VAC OUT

740 POWER ON/OFF

LOCATION PLUG #

CB1

K1 CONTACTOR

I/O PCB

T5

I/O PCB

I/O PCB

I/O PCB

POWER

POWER

POWER

POWER

POWER

——-

K1 CONTACTOR

POWER

T4

PROCESSOR PCB P3

——-

SPARE

POWER

POWER

——-

POWER

——-

N/A

——-

——-

——-

——-

T1 — SECONDARY ——-

——-

——-

——-

——-

——-

——-

——-

——-

——

——

P8

——

P6

P28

P36

—-

ON/OFF SWITCH ——-

96-8100

229

CABLE LOCATIONS

June 1998

230

I/O PCB 32-3080

96-8100

June 1998

96-8100

I/O PLUG #

P51

P52

P53

P54

P55

P56

P57

P58

P59

P60

P61

P43

P44

P45

P46

P47

P48

P49

P50

P34

P35

P36

P37

P38

P39

P40

P42

P25

P26

P27

P28

P29

P30

P31

P33

P17

P18

P19

P20

P21

P22

P23

P24

P9

P10

P11

P12

P13

P14

P15

P16

P5

P6

P7

P8

P1

P2

P3

P4

CABLE LOCATIONS

870

1050

810

770A

300

1060

319

——-

910

390

810A

160

90

90A

90B

90C

880A

820

900

890

770

960

970

950

830

780

100

190

790

240

M21-24

1040

140

1070

——-

——-

200

530

——-

180

350

280

940A

910D

SPARE

I/O PCB — P/N 32-3080 CABLE CONNECTIONS

CABLE #

510

520

540

550

110

930

940

170

710

300

930A

770B

ð

TO

ð

LOCATION PLUG #

SPARE 3

(EXTERNAL)

DOOR LOCK

POWER PCB

(EXTERNAL)

SHUTTLE MOTOR

CHIP CONVEYOR

T1

CRT

FANS (HEAT EXCHANGE)

POWER PCB

115 VAC SPARE

DOOR SWITCH

TURRET MOTOR

HYD PRESSURE TANK

LUBE OIL PUMP

NOT USED

5TH BRAKE

HTC

CHIP CONVEYOR

(EXTERNAL)

SPARE 1

SPARE 2

COOLANT TANK

MOCON PCB

SPARE 1

SPIGOT SENSE

SERVO BRAKE (TSC)

RED/GREEN LTS

TSC PUMP COOL

WORK LIGHT

115 VAC SPARE

GB /IF

TSC 230 IN

E-STOP C

MOCON PCB

MOCON PCB

MOCON PCB

MOCON PCB

SERVO POWER ON

POWER PCB

COOL PUMP

POWER PCB

SPINDLE DRIVE

SP.FAN/GEAR BOX

SPIN LOCK I/F

SPINDLE HEAD

TOOL CHANGER

TSC PUMP (LOW TSC)

SPINDLE HEAD

E-STOP SWITCH

AIR/OIL (LOW OIL)

NOT USED

——-

N/A

AIR/OIL (LOW) ——-

REGEN RESISTORS (OVERH) ——-

SPINDLE DRIVE

(EXTERNAL) M-FIN

SHOT PIN

SPARE 2

——-

——-

——-

N/A

N/A

——-

——-

P7

——-

——-

——-

——-

——-

——-

——-

——-

P11

P12

P14

P10

——-

P6

——-

P4

——-

——-

——-

——-

P13

——-

——-

——-

——-

——-

——-

——

——-

——-

——-

——-

N/A

——-

——-

——-

——-

——-

——-

——-

——-

——-

P8

——-

——-

——-

231

CABLE LOCATIONS

June 1998

232

96-8100

June 1998

CABLE LOCATIONS

PLUG#

P1

P2

P3

P4

P5

P6

J1

J2

J3

J5

J7

J12

SERIAL KEYBOARD INTERFACE PCB WITH HANDLE JOG

P/N 32-4030

CABLE CONNECTIONS

ð

TO

ð

CABLE#

700B

—-

700A

730

—-

—-

—-

—-

750

—-

—-

860C

LOCATION

PROCESSOR

KEYPAD

CYCLE START/

HOLD SWITCHES

SP LOAD METER

SPEAKER

AUX FPANEL

JOG HANDLE

REMOTE JOG HANDLE

MOCON

(MIKRON ONLY)

EXTERNAL KEYBOARD

FT. PANEL FAN

PLUG#

850

—-

—-

—-

—-

—-

—-

—-

P18

—-

—-

—-

* See «Keyboard Diagnostic» section of this manual for Troubleshooting information.

96-8100

233

CABLE LOCATIONS

June 1998

234

VIDEO & KEYBOARD PCB 32-3201

96-8100

June 1998

CABLE LOCATIONS

VIDEO & KEYBOARD PCB W/ FLOPPY DRIVE

P/N 32-3201A

CABLE CONNECTIONS

VIDEO PLUG # CABLE #

SIGNAL NAME

ð

TO

ð

LOCATION PLUG #

P1

J3*

J4

J5

J10

J11

J12

P13

J9

J13

860

700

——-

——-

——-

——-

——-

760

——-

850

LOW VOLTAGE

KEYBOARD INFO.

ADDRESS BUSS

DATA BUSS

FLOPPY DR. POWER

SPARE

FLOPPY DR. SIGNAL

VIDEO SIGNAL

RS422 B

SERIAL DATA

POWER SUPPLY PCB

KEYBOARD INT.

MICRO PROC. PCB

MOTIF PCB

FLOPPY DRIVE

N/A

FLOPPY DRIVE

CRT

N/A

N/A

——-

——-

——-

——-

——-

N/A

——-

——-

N/A

J1

* Not used with Serial Keyboard Interface

96-8100

235

CABLE LOCATIONS

June 1998

236

VIDEO & KEYBOARD PCB W/O FLOPPY

96-8100

June 1998

CABLE LOCATIONS

VIDEO & KEYBOARD PCB — P/N 32-3200

CABLE CONNECTIONS

VIDEO PLUG #

ADDRESS &

DATA

P1

P13

P4

CABLE #

——-

——-

860

760

700

SIGNAL NAME

ADDRESS BUSS

DATA BUSS

LOW VOLTAGE

VIDEO SIGNAL

KEYBOARD INFO.

ð

TO

ð

LOCATION

MICRO PROC. PCB

MOTIF PCB

POWER SUPPLY PCB

CRT

KEYBOARD INT.

PLUG #

——-

——-

——-

——-

——-

96-8100

237

CABLE LOCATIONS

June 1998

238

MOCON PCB 32-4023

96-8100

June 1998

CABLE LOCATIONS

MOCON PCB — P/N 32-4023

CABLE CONNECTIONS

P1

P2

P3

P4

P5

P32

P6

P7

P8

P9

P30

P10

P11

P12

P13

P14

P15

P16

P17

P18

P19

P20

P21

P22

P24

P33

MOCON PLUG # CABLE #

——-

610

620

630

640

640B

660

670

680

690

690B

550

510

520

530

540

860

720

640C

750

1000

980

730B

990

640C

SIGNAL NAME

DATA BUSS

X DRIVE SIGNAL

Y DRIVE SIGNAL

Z DRIVE SIGNAL

A DRIVE SIGNAL

B DRIVE SIGNAL

X ENCODER INPUT

Y ENCODER INPUT

Z ENCODER INPUT

A ENCODER INPUT

B ENCODER INPUT

MOTIF INPUTS/

I/O OUTPUTS

I/O RELAYS 1-8

I/O RELAYS 9-16

I/O RELAYS 17-24

I/O RELAYS 25-32

LOW VOLTAGE

SP. LOAD METER

VCTR CR CUR. CMDS.

JOG INFO

ADDRESS BUSS

SP. ENCODER OUTPUT

VOLTAGE MONITOR

SP. DRIVE LOAD

HOME SENSORS

VCTR DR CUR. CMD.

ð

TO

ð

LOCATION

VIDEO PCB

MICRO PROC. PCB

X SERVO DRIVE AMP.

Y SERVO DRIVE AMP.

Z SERVO DRIVE AMP.

A SERVO DRIVE AMP.

B SERVO DRIVE AMP.

X ENCODER

Y ENCODER

Z ENCODER

A ENCODER

B ENCODER

I/O PCB

I/O PCB

I/O PCB

I/O PCB

I/O PCB

POWER SUPPLY PCB

LOAD METER

SPINDLE DRIVE

JOG HANDLE

VIDEO PCB

MICRO PROC. PCB

SPINDLE ENCODER

N/A

SPINDLE DRIVE

X, Y & Z LIMIT

SPINDLE DRIVE

PLUG #

P4

P1

P2

P51

P3

——-

——-

J3

——-

——-

——-

——-

N/A

——-

P

P

——-

——-

P

P

P

——-

——-

——-

——-

——-

——-

J3

96-8100

239

CABLE LOCATIONS

June 1998

240

96-8100

June 1998

CABLE LOCATIONS

MOTIF

PLUG #

P16

P17

P18

P20

P21

P22

P24

P8

P9

P10

P11

P12

P13

P14

P15

P4

P5

P6

P7

ADDRESS

& DATA

P2

P3

CABLE #

680

690

550

510

520

530

540

860

——-

——-

610

620

630

640

660

670

720

980

750

1000

1020

730B

990

MOTIF PCB — P/N 32-4020

CABLE CONNECTIONS

SIGNAL NAME

ð

TO

ð

LOCATION

ADDRESS BUSS

DATA BUSS

X DRIVE SIGNAL

Y DRIVE SIGNAL

Z DRIVE SIGNAL

A DRIVE SIGNAL

X ENCODER OUTPUT

Y ENCODER OUTPUT

Z ENCODER OUTPUT

A ENCODER OUTPUT

MOTIF INPUTS / I/O OUTPUTS

I/O RELAYS 1-8

I/O RELAYS 9-16

I/O RELAYS 17-24

I/O RELAYS 25-32

LOW VOLTAGE

SP. SPEED COMMAND

VOLTAGE MONITOR

JOG INFO.

SP. ENCODER OUTPUT

SP. TEMP

SP. DRIVE LOAD

HOME SENSORS

VIDEO PCB

MICRO PROC. PCB

X SERVO DRIVE

Y SERVO DRIVE

Z SERVO DRIVE

A SERVO DRIVE

X ENCODER

Y ENCODER

Z ENCODER

A ENCODER

I/O PCB

I/O PCB

I/O PCB

I/O PCB

I/O PCB

POWER SUPPLY PCB

SPINDLE DRIVE

SDIST PCB

JOG HANDLE

SPINDLE ENCODER

SPINDLE

SPINDLE DRIVE

X, Y & Z LIMIT SW.

PLUG #

——-

——-

P4

P1

P2

P51

P3

——-

——-

——-

P3

P3

P3

P3

——-

——-

——-

P9

——-

——-

——-

——-

——-

96-8100

241

CABLE LOCATIONS

June 1998

242

96-8100

June 1998

CABLE LOCATIONS

I/O

PLUG #

P10

P11

P12

P13

TB1

TB2

P5

P7

P8

P9

P1

P2

P3

P4

SERVO DISTRIBUTION (SDIST) PCB — P/N 32-5020

CABLE CONNECTIONS

CABLE #

570

580

590

600

860A

FAN

80

980

920

110

970

1060

N/A

N/A

SIGNAL NAME

ð

TO

ð

LOCATION

X DRIVER LOW VOLTAGE

Y DRIVER LOW VOLTAGE

Z DRIVER LOW VOLTAGE

A DRIVER LOW VOLTAGE

12VDC

FAN VOLTAGE

160VDC

VOLTAGE MONITOR

REGEN RESISTORS

SERVO POWER

OV V

GND FAULT

115VAC FROM T1

160VDC TO AMPS.

X SERVO DRIVER

Y SERVO DRIVER

Z SERVO DRIVER

A SERVO DRIVER

POWER SUPPLY PCB

FAN (SERVO)

I/O PCB

MOTIF PCB

REGEN RESISTORS

I/O PCB

I/O PCB

I/O PCB

T1

SERVO DRIVERS

PLUG #

——-

P5

P18

P43

——-

P8

P1

P1

P1

P1

——-

——-

P32

P17

96-8100

243

CABLE LOCATIONS

June 1998

244

96-8100

June 1998

CABLE LOCATIONS

P1

P2

P3

P8

A AXIS

P1

P2

P3

P8

I/0

PLUG #

X AXIS

P1

P2

P3

P8

Y AXIS

P1

P2

P3

P8

Z AXIS

580

——-

620

——-

590

——-

630

——-

600

——-

640

——-

SERVO DRIVER PCBs — P/N 32-4070

CABLE CONNECTIONS

CABLE #

570

——-

610

——-

SIGNAL NAME

LOW VOLTAGE

MOTOR DRIVE

X DRIVE SIGNAL

+160VDC

ð

TO

ð

LOCATION

SDIST PCB

X SERVO MOTOR

MOTIF PCB

SDIST PCB

PLUG #

P1

——-

P2

TB2

LOW VOLTAGE

MOTOR DRIVE

X DRIVE SIGNAL

+160VDC

LOW VOLTAGE

MOTOR DRIVE

X DRIVE SIGNAL

+160VDC

LOW VOLTAGE

MOTOR DRIVE

X DRIVE SIGNAL

+160VDC

SDIST PCB

Y SERVO MOTOR

MOTIF PCB

SDIST PCB

SDIST PCB

Z SERVO MOTOR

MOTIF PCB

SDIST PCB

SDIST PCB

A SERVO MOTOR

MOTIF PCB

SDIST PCB

P2

——-

P3

TB2

P3

——-

P4

TB2

P4

——-

P5

TB2

96-8100

245

246

CABLE LOCATIONS

EXTERNAL

PLUG

P1

J1

INTERNAL

PLUG

PLUG #

P1

INTERNAL

J1

EXTERNAL

RS-232 PORT #1 PCB — P/N 32-4090

CABLE CONNECTIONS

ð

TO

ð

CABLE #

850

——-

LOCATION

VIDEO &

KEYBOARD

——-

PLUG #

J13

——-

June 1998

96-8100

June 1998

CABLE LOCATIONS

P2

P3

J1

J2

P1

PLUG #

P1

P2

P3

SPINDLE LOCK PCB — P/N 32-3095

CABLE CONNECTIONS

ð

TO

ð

CABLE #

890

520

——-

LOCATION

I/O PCB

I/O PCB

VECT DRV

PLUG #

P15

P2

——-

96-8100

247

CABLE LOCATIONS

June 1998

248

96-8100

June 1998

CABLE LOCATIONS

PLUG #

P1

P2

P3

P4

TB2

TB3

TRANSMISSION P.S. / HYDRAULIC C.B. PCB

P/N 32-4095 REV.B

CABLE CONNECTIONS

ð

TO

ð

CABLE #

880B

90

410

350

340

70

LOCATION PLUG #

IO PCB

POWER PCB

GEAR BOX

IO PCB

HYDRAULIC MTR

MAIN TRANSFORMER

(VECTOR DRIVE UNIT)

P12

P8

P54

96-8100

249

CABLE LOCATIONS

Y-DELTA SWITCH ASSEMBLY

P/N 32-5850A

June 1998

250

96-8100

June 1998

CABLE LOCATION DIAGRAM

CABLE LOCATIONS

96-8100

251

CABLE LOCATIONS

June 1998

252

96-8100

June 1998

9. CABLE LIST

J

UNE

1998

71

72

73

L1

L2

L3

WIRE/

TERMINAL FUNCTION NAME:

NUMBER

INCOMING POWER 195-260 VAC (353-488 VAC OPTIONAL)

INCOMING 195-260VAC, PHASE 1, TO CB1-1

INCOMING 195-260VAC, PHASE 2, TO CB1-2

INCOMING 195-260VAC, PHASE 3, TO CB1-3

PROTECTED 195-260 VAC FROM MAIN CB1-4 TO K1-1

PROTECTED 195-260 VAC FROM MAIN CB1-5 TO K1-2

PROTECTED 195-260 VAC FROM MAIN CB1-6 TO K1-3

77

78

79

74

75

76

195-260 VAC FROM K1-4 TO XFORMER T1

195-260 VAC FROM K1-5 TO XFORMER T1

195-260 VAC FROM K1-6 TO XFORMER T1

230VAC PHASE 1 , FROM XFORMER T1 TO VECTOR / CHIP CONV

230VAC PHASE 2 , FROM XFORMER T1 TO VECTOR / CHIP CONV

230VAC PHASE 3 , FROM XFORMER T1 TO VECTOR / CHIP CONV

92

93

94

90 115 VAC FROM TB2 (CB2 OUTPUT) TO IOPCB P33 — (3 + SHIELD)

91 STEPPED-DOWN 115 VAC (FROM XFRMER T1) #18

STEPPED-DOWN 115 VAC (FROM XFRMER T1) #18

STEPPED-DOWN 115 VAC (FROM XFRMER T1) #18

SHIELD DRAIN

—- 115 VAC FROM XFORMER T1 TO TB1 (CB2 INPUT)

94

95

96

STEPPED-DOWN 115 VAC (FROM XFORMER T1)

STEPPED-DOWN 115 VAC (FROM XFORMER T1)

STEPPED-DOWN 115 VAC (FROM XFORMER T1)

90A 115 VAC TO CRT — (2 + SHIELD)

91A

92A

93A

LEG 1 #16

LEG 2 #16

SHIELD DRAIN

90B 115 VAC TO HEAT EXCHANGER — (2 + SHIELD)

91B

92B

93B

LEG 1 #16

LEG 2 #16

SHIELD DRAIN

90C 115 VAC TO CB4 — (2 + SHIELD)

91C

92C

93C

LEG 1 #16

LEG 2 #16

SHIELD DRAIN

96-8100

CABLE LIST

253

254

CABLE LIST

100 M-FIN (IOASM TO SIDE OF BOX) — (2 + SHIELD)

101

102

101

102

103

SIGNAL #20

COMMON #20

SIGNAL #20

COMMON #20

SHIELD DRAIN

140 230VAC 3PH POWER TO CHIP CONVEYOR MOTOR (5 + SHIELD)

141

142

143

144

145

146

PHASE A 230VAC

PHASE B 230VAC

PHASE C 230VAC

STARTING WINDING 230VAC

STARTING WINDING 230VAC

SHIELD DRAIN

160 3PH 230VAC TO CHIP CONVEYOR CONTROLLER (3 + SHIELD)

161

162

163

164

PHASE A 230VAC

PHASE B 230VAC

PHASE C 230VAC

SHIELD DRAIN

170 AUTO OFF FUNCTION — (2 + SHIELD)

171

172

173

UNSWITCHED LEG 1 #20

SWITCHED LEG 2 #20

SHIELD DRAIN

180 COOLANT SPIGOT DETENT SWITCH (2 + SHIELD)

181

182

183

SIGNAL

COMMON

SHIELD DRAIN

190 UNCLAMP FROM SPINDLE HEAD TO IOASM

191

192

INPUT 25

DIGITAL RETURN

200 COOLANT SPIGOT MOTOR (12VDC)

201

202

MOTOR +

MOTOR —

210 DATA CABLE TO 3″ FLOPPY DISK DRIVE (40 PINS)

220 SERVO BRAKE 115VAC — (2 + SHIELD)

221

222

223

115VAC COMMON

115VAC SWITCHED

SHIELD DRAIN

230 5’th AXIS BRAKE

240 SPARE INPUTS FROM IOPCB P25

250 SPARE OUTPUTS FROM IOPCB P45

260 K210 CABLING FOR EC

270 K111 CABLING FOR EC

June 1998

96-8100

June 1998

280 RED/GREEN STATUS LIGHT WIRING (3+ SHIELD)

281

282

283

284

RED LAMP 115VAC

GREEN LAMP 115VAC

COMMON 115VAC

SHIELD DRAIN

300 115VAC TO SPINDLE MOTOR FAN/OIL PUMP/OILER (2 + SHIELD)

301

302

303

LEG 1 115VAC PROTECTED #18

LEG 2 115VAC PROTECTED #18

SHIELD DRAIN

350 SERVO BRAKE RELEASE 115VAC — (2 + SHIELD)

351

352

353

LEG 1 COMMON

LEG 2 SWITCHED

SHIELD DRAIN

360-389 RESERVED

390 115VAC TO 4’TH AXIS BRAKE (LATHE PART DOOR) — (2 + SHIELD)

391

392

393

LEG 1 COMMON

LEG 2 SWITCHED

SHIELD DRAIN

410-483 RESERVED

490 ALL BRUSHLESS AXIS SERVO MOTOR DRIVE POWER CABLE

491

492

493

494

A PHASE

B PHASE

C PHASE

GROUND

490A

490B

490X

490Y

490Z

A AXIS MOTOR POWER

B AXIS MOTOR POWER

X AXIS MOTOR POWER

Y AXIS MOTOR POWER

Z AXIS MOTOR POWER

500 OVERTEMP SENSOR FROM SPINDLE MOTOR — (2 + SHIELD)

501

502

503

OVERTEMP WIRE 1 #20 (N.C.)

OVERTEMP WIRE 2 #20

SHIELD DRAIN

510 RELAY CARD 1 DRIVE CABLE — 16 WIRE RIBBON #24

520 RELAY CARD 2 DRIVE CABLE — 16 WIRE RIBBON #24

530 RELAY CARD 3 DRIVE CABLE — 16 WIRE RIBBON #24

540 RELAY CARD 4 DRIVE CABLE — 16 WIRE RIBBON #24

550 INPUTS CARD CABLE (MOTIF-P10) 34 WIRE RIBBON #24

610 X AXIS HAAS AMPLIFIER CABLE TO MOTOR CONTROLLER BOARD

(MOTOR CONTROLLER BOARD SIDE CONNECTION)

610-1

610-2

+A CHANNEL

ANALOG GROUND

96-8100

CABLE LIST

255

256

CABLE LIST

610-3

610-4

610-5

610-6

610-7

610-8

610-9

610-10

620 Y AXIS HAAS AMPLIFIER CABLE TO MOTOR CONTROLLER BOARD

(SAME AS 610-1 THRU 610-10)

630 Z AXIS HAAS AMPLIFIER CABLE TO MOTOR CONTROLLER BOARD

(SAME AS 610-1 THRU 610-10)

640A A AXIS HAAS AMPLIFIER CABLE TO MOTOR CONTROLLER BOARD

(SAME AS 610-1 THRU 610-10)

640B

+B CHANNEL

ANALOG GROUND

ENABLE

LOGIC GROUND

FAULT

LOGIC GROUND

NOT USED

SHIELD/ANALOG GROUND

640C

B AXIS HAAS AMPLIFIER CABLE TO MOTOR CONTROLLER BOARD

(SAME AS 610-1 THRU 610-10)

C AXIS HAAS VECTOR CURRENT COMMAND CABLE TO MOTOR CONTROLLER BD.

(SAME AS 610-1 THRU 610-10)

650 THREE PHASE POWER TO SPINDLE MOTOR — (3 + SHIELD)

651

652

653

654

LEG 1 OF 230VAC

LEG 2

LEG 3

SHIELD DRAIN

650A

651A

652A

653A

654A

650B

651B

652B

653B

654B

THREE PHASE POWER TO SPINDLE MOTOR — (3 + SHIELD)

LEG 1 OF 230VAC

LEG 2

LEG 3

SHIELD DRAIN

THREE PHASE POWER TO SPINDLE MOTOR — (3 + SHIELD)

LEG 1 OF 230VAC

LEG 2

LEG 3

SHIELD DRAIN

660 X-ENCODER CABLE (ALL #24)

660-1

660-2

660-3

660-4

660-5

660-6

660-7

660-8

660-9

660-10

660-11

660-12

660-13

LOGIC RETURN (D GROUND)

ENCODER A CHANNEL

ENCODER B CHANNEL

+5 VDC

ENCODER Z CHANNEL (OR C)

HOME/LIMIT SW

OVERHEAT SWITCH

ENCODER A*

ENCODER B*

ENCODER Z* (OR C*)

X HALL A (NOT USED)

X HALL B (NOT USED)

X HALL C (NOT USED)

June 1998

96-8100

June 1998

CABLE LIST

660-14

660-15

660-16

X HALL D (NOT USED)

SHIELD DRAIN

NOT USED

670 Y-AXIS ENCODER CABLE

(SAME AS 660-1 THRU 660-16)

680 Z-AXIS ENCODER CABLE

(SAME AS 660-1 THRU 660-16)

690 A-AXIS ENCODER CABLE

(SAME AS 660-1 THRU 660-16)

690B B-AXIS ENCODER CABLE

(SAME AS 660-1 THRU 660-16)

690C C-AXIS ENCODER CABLE

(SAME AS 660-1 THRU 660-16)

700 KEYBOARD CABLE — 34 WIRE RIBBON WITH IDC

(FROM VIDEO P4 TO KBIF P1)

710 FORWARD/REVERSE/RESET TO SPINDLE — (4 + SHIELD) (BRUSH SYSTEMS)

711

712

713

714

715

FORWARD COMMAND (CN1-19 TO IO P9-3)

REVERSE COMMAND (CN1-19 TO IO P9-3)

RESET COMMAND (CN1-21 TO IO P9-2)

COMMON (CN1-14 TO IO P9-1)

SHIELD DRAIN

720 ANALOG SPEED COMMAND TO SPINDLE — (2 + SHIELD) (BRUSH SYSTEMS)

721

722

723

0 TO +10 VOLTS SPEED COMMAND (SPINDLE DRIVE CN1-1) #24

SPEED COMMAND REFERENCE (A GROUND) (CN1-17) #24

SHIELD DRAIN

730 POWER METER FROM SPINDLE DRIVE TO KBIF — (2 + SHIELD) (BRUSH SYSTEMS)

731

732

723

METER + (SPINDLE DRIVE CN1-5 TO KBIF) #24

METER — (CN1-6 TO KBIF) #24

SHILD DRAIN

730A

733

734

734

730B

731

732

POWER METER FROM KBIF TO METER — (2 + SHIELD)

METER + AFTER TRIM POT (KBIF TO METER) #24

METER — AFTER TRIM POT (KBIF TO METER) #24

METER — AFTER TRIM POT (KBIF TO METER) #24

(BRUSH SYSTEMS)

ANALOG SIGNAL FROM SPINDLE DRIVE LOAD MONITOR(BRUSH SYSTEMS)

SIGNAL 0..5V

GROUND

740 POWER ON/OFF CABLE TO FRONT PANEL — (4 + SHIELD)

741

742

743

744

745

POWER ON SWITCH LEG 1 (24 VAC) #24

POWER ON SWITCH LEG 2 #24 N.O.

POWER OFF SWITCH LEG 1 (24 VAC) #24

POWER OFF SWITCH LEG 2 #24 N.C.

SHIELD DRAIN

96-8100

257

258

CABLE LIST

750 JOG-CRANK DATA CABLE (REM JOG SIDE CONNECTION) — (4 + SHIELD) (ALL #28)

(CABLE NUMBER 33-5750)

750-1

750-2

750-3

750-4

750-5

750-6

750-7

750-8

750-9

750-10

750-11

750-12

750-13

750-14

750-15

750-16

750-2

750-4

750-6

LOGIC RETURN (D GROUND) 0VDC

ENCODER A CHANNEL

ENCODER B CHANNEL

+5 VDC

N/C

X-AXIS

Y-AXIS

N/C

N/C

N/C

Z-AXIS

A-AXIS

X 10

X 1

SHIELD DRAIN

N/C

CYCLE START

D GROUND

FEED HOLD

760 MONITOR VIDEO DATA CABLE — (9 + SHIELD) (ALL #24)

(FROM VIDEO P3 TO CRT)

770 EMERGENCY STOP INPUT CABLE — SHIELD +2

771

772

772

SIGNAL (INPUT #20

RETURN (D GROUND) (65) #20

RETURN (D GROUND) (65) #20

770A

770B

SECOND E-STOP INPUT FOR HORIZONTAL

THIRD E-STOP INPUT FOR APC (REMOTE CONTROL PANEL)

780 STATUS CABLE FROM SPINDLE DRIVE — (4 + SHIELD) (BRUSH SYSTEMS)

781

782

783

784

785

+12 VDC (SPINDLE DRIVE CN1-25) #24

FAULT (INPUT 18 TO CN1-24) #24

AT SPEED (INPUT 20 TO CN1-23) #24

STOPPED (INPUT 19 TO CN1-22) #24

SHIELD DRAIN

790 SPARE INPUTS FROM IOPCB P24

791

792

793

SPARE 1

SPARE 2

COMMON

810 TOOL CHANGER MOTORS — (2 + SHIELD) #20

811

812

812

TURRET MOTOR + (IO P30-2 TO P6-J) #14

TURRET MOTOR — (IO P30-1 TO P6-I) #14

SHIELD DRAIN

810A

813

814

812

TOOL CHANGER MOTORS — (2 + SHIELD) #20

SHUTTLE MOTOR — (IO P30-4 TO P6-A) #14

SHUTTLE MOTOR + (IO P30-3 TO P6-B) #14

SHIELD DRAIN

June 1998

96-8100

June 1998

820 TOOL CHANGER STATUS — (7 + SHIELD)7

821

822

823

824

825

826

827

LOGIC RETURN (D GROUND) (P6-F/H/L/M) #24

GENEVA MARK (INPUT 5 TO P6-G) #24 (LATHE PART DOOR)

TOOL #1 (INPUT 3 TO P6-E) #24

SHUTTLE IN (INPUT 1 TO P6-C) #24 (LATHE TURRET CLAMPED)

SHUTTLE OUT (INPUT 2 TO P6-D) #24 (LATHE TURRET UNCLAMPED)

SHUTTLE IN (INPUT 1 TO P6-C) #24 (LATHE TURRET CLAMPED)

SHIELD DRAIN

830 OVERHEAT THERMOSTAT — (2 + SHIELD)

831

832

833

OVERHEAT SIGNAL (INPUT 14) #20

OVERHEAT RETURN (D GROUND) (65) #20

SHIELD DRAIN

840 CIRCUIT BREAKER FOR 160 VDC — SHIELD +2

841

842

843

LEG 1 (TO 81) #14

LEG 2 #14

SHIELD DRAIN

850 SERIAL PORT #1 TO SERIAL KEYBOARD INTERFACE CABLE (16 WIRE RIBBON #24)

850A SERIAL PORT #2 INTERFACE CABLE (16 WIRE RIBBON #24)

860 +12V/+5V/Gnd POWER CABLES — 6 WIRE (all #18)

861

862

863

864

865

866

+12 VOLTS

-12 VOLTS FROM LOW V SUPPLY TO 68020 PCB

+5 VOLTS

-5 VOLTS

LOGIC POWER RETURN (D GROUND)

POWER GOOD SIGNAL FROM SUPPLY

860A

861

862

12 VOLT POWER TO IOPCB — SHIELD +2

+12 VOLTS

LOGIC POWER RETURN (D GROUND)

860B

860C

+5 POWER TO 3″ FLOPPY DRIVE

+5,+12,-12 POWER TO 68030

870 115VAC TO OILER — (2 + SHIELD)

871

872

873

115VAC LEG 1 #18

115VAC LEG 2 #18

SHIELD DRAIN

880A

881

882

883

884

885

886

887

880B

881

882

HIGH/LOW GEAR UNCLAMP/LOCK SOLENOID POWER — SHIELD +6

115 VAC SOLENOID COMMON (IO P12-5) #18

HIGH GEAR SOLENOID (IO P12-4) #18

LOW GEAR SOLENOID (IO P12-3) #18

TOOL UNCLAMP SOLENOID (IO P12-2) #18

SPINDLE LOCK SOLENOID (IO P12-1) #18

PRE-CHARGE SOLENOID #18 (IO P12-7)

SHIELD DRAIN

TRANSMISSION HIGH/LOW GEAR SOLENOIDS FOR LATHE

115 VAC SOLENOID COMMON (IO P12-5) #18

HIGH GEAR SOLENOID (IO P12-4) #18

96-8100

CABLE LIST

259

260

CABLE LIST

883

884

LOW GEAR SOLENOID (IO P12-3) #18

SHIELD DRAIN

890 SPINDLE STATUS SWITCHES (6 + SHIELD)

891

892

893

894

895

896

897

SIGNAL RETURN (D GROUND) (65) #24

HIGH GEAR (INPUT 6) #24

LOW GEAR (INPUT 7) #24

TOOL UNCLAMPED (INPUT 15) #24

TOOL CLAMPED (INPUT 16) #24

SPINDLE LOCKED (INPUT 17) #24

SHIELD DRAIN

900 LOW COOLANT STATUS — (2 + SHIELD)

901

902

903

LOW COOLANT SIGNAL (INPUT 4 TO P7-C) #20

LOW COOLANT RETURN (D GROUND) (65 TO P7-D) #20

SHIELD DRAIN

910 115 VAC CIRCUIT BREAKER TO SOLENOIDS — (2 + SHIELD)

911

912

913

LEG 1 #18

LEG 2 #18

SHIELD DRAIN

910A

910B

910C

910D

115VAC FROM CB4 ON MAIN POWER DIST.

115VAC TO SERVO FAN

115VAC TO DELTA/WYE COIL

115VAC TO WORK LIGHT

920 REGENERATIVE LOAD RESISTOR FOR SERVO — (2 + SHIELD) (BRUSH SYSTEMS)

921

922

923

LEG 1 #18

LEG 2 #18

SHIELD DRAIN

930 FUSED 230 VAC FOR COOLANT PUMP — (2 + SHIELD)

931

932

933

LEG 1 #14

LEG 2 #14

SHIELD DRAIN

940 230 VAC TO COOLANT PUMP — (2 + SHIELD)

941

942

943

LEG 1 (P7-A) #14

LEG 2 (P7-F) #14

SHIELD DRAIN

950 LOW AIR PRESSURE SENSOR — (3 + SHIELD)

951

952

953

954

LOW AIR SIGNAL (INPUT 12) #20

LOW AIR/OIL RETURN (D GROUND) (65) #20

LOW OIL PRESSURE SWITCH FOR VERTICAL TRANSMISSION #20

SHIELD DRAIN

950A

952

953

954

LOW HYDRAULIC PRESSURE SWITCH FOR LATHE — (2 + SHIELD)

LOW HYDRAULIC RETURN (D GROUND) (65) #20

LOW HYD PRESSURE SWITCH FOR VERTICAL TRANSMISSION #20

SHIELD DRAIN

960 LOW LUB/DOOR OPEN SENSORS — (4 + SHIELD)

961

962

LOW LUB SIGNAL (INPUT 13) #24

LOW LUB RETURN (D GROUND) (65) #24

June 1998

96-8100

June 1998

96-8100

1040

1041

1042

1050

1051

1052

1053

1020

1021

1022

1023

1024

1030

1031

1032

1033

1060

1061

1062

1070

1071

1072

1073

963

964

965

DOOR OPEN SIGNAL (INPUT 9) #24 (OBSOLETE OPTION)

DOOR OPEN RETURN (D GROUND) (65) #24 (OBSOLETE OPTION)

SHIELD DRAIN

970 LOW VOLTAGE SENSOR — (2 + SHIELD)

971

972

973

LOW VOL SIGNAL (INPUT 11 FROM PMON P9-3) #24

LOW VOL RETURN (D GROUND) (PMON P9-4) #24

SHIELD DRAIN

980 VOLTAGE MONITOR — (2 + SHIELD)

981

982

983

VOLTAGE MONITOR 0 TO +5 (PMON P9-1 / MOTIF P17-1) #24

VOLTAGE MON RET (A GND) (PMON P9-2 / MOTIF P17-2) #24

VOLTAGE MON RET (A GND) (PMON P9-2 / MOTIF P17-2) #24

1000

1001

1002

1003

1004

1005

1006

990 HOME SENSORS — (4 + SHIELD)

991

992

993

994

995

X HOME SWITCH (MOTIF P24-2 TO P5-B) #24

Y HOME SWITCH (MOTIF P24-3 TO P5-D) #24 (LATHE TAIL STOCK)

Z HOME SWITCH (MOTIF P24-4 TO P5-L) #24

HOME SWITCH RETURN (MOTIF P24-1 TO P5-C) #24

SHIELD DRAIN

SPINDLE ENCODER CABLE — (5 + SHIELD) (LATHE TAIL STOCK)(BRUSH SYSTEMS)

LOGIC RETURN (D GROUND) (TO MOTIF P20-1) #24

ENCODER A CHANNEL (TO MOTIF P20-2) #24

ENCODER B CHANNEL (TO MOTIF P20-3) #24

+5 VDC (TO MOTIF P20-4) #24

ENCODER Z CHANNEL (TO MOTIF P20-5) #24

SHIELD DRAIN

SPINDLE TEMPERATURE SENSOR CABLE — (3 + SHIELD)

SIGNAL

ANALOG RETURN

+5 VOLTS TO SENSOR

SHIELD GROUND

SPINDLE LOAD RESISTOR — (2 + SHIELD)

REGEN LOAD RESISTOR FOR SPINDLE DRIVE (B1) #18

REGEN LOAD RESISTOR FOR SPINDLE DRIVE (B2) #18

SHIELD DRAIN

Y160 (MIKRON DOOR LOCK OR HORIZONTAL PART READY LAMP)

SWITCHED RELAY CONTACT

SWITCHED RELAY CONTACT

DOOR SWITCH WIRING THRU SUPPORT ARM — (2 + SHIELD)

DOOR OPEN SIGNAL (INPUT 9) #24

DOOR OPEN RETURN (D GROUND) (65) #24

SHIELD DRAIN

GROUND FAULT DETECTION SENSE INPUT

+ INPUT FROM SENSE RESISTOR

— INPUT FROM SENSE RESISTOR

SKIP INPUT FROM SENSOR — (2 + SHIELD)

LOGIC COMMON

SKIP SIGNAL

SHIELD DRAIN

CABLE LIST

261

CABLE LIST

June 1998

262

96-8100

June 1998

ELECTRICAL

WIRING DIAGRAMS

ELECTRICAL DIAGRAMS

96-8100

263

ELECTRICAL DIAGRAMS

June 1998

264

96-8100

June 1998

ELECTRICAL DIAGRAMS

96-8100

265

ELECTRICAL DIAGRAMS

June 1998

266

96-8100

June 1998

ELECTRICAL DIAGRAMS

96-8100

267

ELECTRICAL DIAGRAMS

June 1998

268

96-8100

June 1998

ELECTRICAL DIAGRAMS

96-8100

269

ELECTRICAL DIAGRAMS

June 1998

270

96-8100

June 1998

ELECTRICAL DIAGRAMS

96-8100

271

ELECTRICAL DIAGRAMS

June 1998

272

96-8100

June 1998

ELECTRICAL DIAGRAMS

96-8100

273

ELECTRICAL DIAGRAMS

June 1998

274

96-8100

June 1998

ELECTRICAL DIAGRAMS

96-8100

275

ELECTRICAL DIAGRAMS

June 1998

276

96-8100

June 1998

ELECTRICAL DIAGRAMS

96-8100

277

ELECTRICAL DIAGRAMS

June 1998

278

96-8100

June 1998

ELECTRICAL DIAGRAMS

96-8100

279

ELECTRICAL DIAGRAMS

June 1998

280

96-8100

June 1998

ELECTRICAL DIAGRAMS

96-8100

281

ELECTRICAL DIAGRAMS

June 1998

282

96-8100

June 1998

ELECTRICAL DIAGRAMS

96-8100

283

ELECTRICAL DIAGRAMS

June 1998

284

96-8100

June 1998

ELECTRICAL DIAGRAMS

96-8100

285

ELECTRICAL DIAGRAMS

June 1998

286

96-8100

June 1998

ELECTRICAL DIAGRAMS

96-8100

287

ELECTRICAL DIAGRAMS

June 1998

288

96-8100

June 1998

ASSEMBLY DRAWINGS

ASSEMBLY DRAWINGS

96-8100

289

ASSEMBLY DRAWINGS

June 1998

290

50 Taper Tool Release Piston

96-8100

June 1998

ASSEMBLY DRAWINGS

IT

13

14

15

16

9

10

11

12

7

8

5

6

3

4

1

2

QTY PART_NO

64

64

64

32

32

1

8

64

64

32

32

32

1

1

32

64

20-9193

20-9324

22-7067F

22-9256

22-9574A

24-2010A

24-9257

25-7249

25-9328

25-9333

40-1500

40-16095

40-1697

40-1704

45-0045

48-0004

TITLE

CAROUSEL SUPPORT PLATE

CAROUSEL, 32 TOOL

KEY, EXTRACTOR

BUSHING, EXTRACTOR

CT-EXTRACTOR

COMPRESSION SPRING

SPRING, EXTRACTOR

SLIDING PANEL

32 TOOL SLIDING PANEL COVER

NUMBER RING, 32 T/C

SHCS, 5/16-18 X 1″

SHCS, 10-32 x 1/4″

SHCS, 1/4-20 x 3/4″

FHCS, 10-32 x 1/4″

WASHER, BLK HARD 1/4″ x 1/8″ THK.

SPRING PIN, 3/8″ x 1″

32 Tool Carousel Assembly (CT)

96-8100

291

ASSEMBLY DRAWINGS

June 1998

IT

13

14

15

16

9

10

11

12

7

8

5

6

3

4

1

2

QTY PART_NO

64

64

64

32

32

1

8

64

64

32

32

32

1

1

32

64

20-9193

20-9324

22-7067F

22-7166A

22-9256

24-2010A

24-9257

25-7249

25-9328

25-9333

40-1500

40-16095

40-1697

40-1704

45-0045

48-0004

TITLE

CAROUSEL SUPPORT PLATE

CAROUSEL, 32 TOOL

KEY, EXTRACTOR

EXTRACTOR, BT-40 TOOL CHN

BUSHING, EXTRACTOR

COMPRESSION SPRING

SPRING, EXTRACTOR

SLIDING PANEL

32 TOOL SLIDING PANEL COVER

NUMBER RING, 32 T/C

SHCS, 5/16-18 X 1″

SHCS, 10-32 x 1/4″

SHCS, 1/4-20 x 3/4″

FHCS, 10-32 x 1/4″

WASHER, BLK HARD 1/4″ x 1/8″ THK.

SPRING PIN, 3/8″ x 1″

32 Tool Carousel Assembly (BT)

292

96-8100

June 1998

ASSEMBLY DRAWINGS

96-8100

Tool Changer Assembly VF-3/4

293

IT

29

30

31

32

25

26

27

28

21

22

23

24

17

18

19

20

13

14

15

16

9

10

11

12

7

8

5

6

3

4

1

2

45

46

47

41

42

43

44

37

38

39

40

33

34

35

36

ASSEMBLY DRAWINGS

QTY PART NO

6

1

1

1

1

2

1

1

2

1

1

1

1

1

1

1

1

1

1

2

2

3

1

1

1

1

1

1

1

1

1

1

1

17

1

5

1

4

4

4

8

4

12

3

6

6

10

25-7162

25-7168

25-9085

25-9329

25-9331

25-9334

26-7239

29-7612

30-0005

30-0006

32-1800

32-2010

32-7011

32-7611

40-1500

40-16091

20-7035G

20-7038A

20-7475

20-7476

20-9008

20-9325

20-9326

20-9330

22-2065

22-7034

22-7106

22-7163

22-7255A

22-7263

22-7477

25-7036

40-1632

40-1669

40-1676

40-1697

40-1803

40-1850

40-1970

40-1980

40-2000

43-1602

43-7000

44-1710

45-0050

45-1600

45-1725

30-0008 TOOL CHANGER ASSEMBLY, 32 TOOL, VF-3,4

TITLE

VERTICAL AXLE

BEARING HOUSING

ARM, SLIP CLUTCH

HUB, SLIP CLUTCH

TOOL HOLDING ARM

32 TOOL GENEVA STAR, 2 PIN

TOOL CARRIAGE, MACHINING

32 T/C HOLDING PLATE

LOCATING PIN

SPACER, CAM FOLLOWER

‘V’ TRACK, T/C

RIDER, TRAP DOOR

TOOL #1 STAND OFF

SWITCH MOUNTING BLOCK

PRESSURE PLATE

CAP, TOOL CHANGER

CONNECTOR BRACKET

DOOR OPENER BRACKET

CONDUIT MTG PLATE

DOOR T/C COVER

TOOL CHANGER COVER

SHUTTLE COVER PLATE

SPACER RING

CT TOOLING DECAL

GENEVA DRIVER ASSY

CAROUSEL ASSY, 32 TOOL

SHUTTLE MOTOR ASSY

24″ LIMIT SWITCH

CONDUIT ASSY, T/C

CONDUIT ASSY, TOOL CARRIAGE

SHCS, 5/16-18 x 1″

BHCS, 10-32 x 1″

SHCS, 1/4-20 x 1/2″

BHCS, 8-32 x 3/8″

SHCS, 5/16-18 x 2″

SHCS, 1/4-20 x 3/4″

SHCS, 8-32 x 1 1/4″

SHCS, 10-32 x 3/8″

FHCS, 1/4-28 x 1″

BHCS, 1/4-20 x 1/2″

SHCS, 1/4-20 x 5/8″

HHB, 1/2-13 x 3″

HHB, 5/16-18 x 1 3/4″

SSS, CUP PT 1/4-20 x 3/8″

WASHER, 5702-313-120

WASHER, SPLIT LOCK, 5/16 MED.

WASHER, FLAT CUT 3/4″

294

June 1998

96-8100

June 1998

IT

60

61

62

63

56

57

58

59

52

53

54

55

48

49

50

51

68

69

70

71

64

65

66

67

QTY PART NO

2

2

2

4

1

1

2

1

1

2

1

1

2

1

4

10

6

1

1

1

57-9139

57-9335

63-1031

70-0050

1

1

75-15721

78-1996

1.75′ 79-1000

1.70′ 79-1001

45-1740

45-1800

45-2020

46-1705

48-0005

48-0019

48-0020

48-1750

51-0010

51-0012

51-6000

54-0010

54-0020

54-0030

54-0040

55-0010

TITLE

WASHER, BLACH HARD 1/2″

WASHER, SPLIT LOCK 1/4″ MED.

WASHER, NYLON

LOCK-NUT, ELASTIC, 3/4-10

PIN, DOWEL 3/16 x 3/8″

PIN, DOWEL 1/4 x 5/8″

PIN, DOWEL 1/4 x 1″

PIN, DOWEL 1/2 x 1 1/2″

BEARING DEEP GROOVE

BEARING LOCK NUT, BH-06

BEARING LOCK NUT, NT-05

CAM FOLLOWER, TOOL CHANGER

BUSHING, GUIDE WHEEL

GUIDE WHEEL

STANDARD BUSHING, GD. WHEEL

SPRING WASHER, B2500-080

GASKET, TOOL HOLD ARM

SHUTTLE COVER GASKET

CABLE CLAMP, 1/4″

PLT4S-M CABLE TIES

MOLEX BSNG. 2 PIN MALE

SPLIT FLEX TUBING 1/2″ I.D.

WIRE CHANNEL, 1″ x 2″

COVER, 1″ WIRE CHANNEL

ASSEMBLY DRAWINGS

96-8100

295

ASSEMBLY DRAWINGS

June 1998

296

Tool Changer Assembly VF-6..10

96-8100

June 1998

IT

29

30

31

32

25

26

27

28

21

22

23

24

17

18

19

20

13

14

15

16

9

10

11

12

7

8

5

6

3

4

1

2

45

46

47

41

42

43

44

37

38

39

40

33

34

35

36

QTY PART NO

1

1

1

2

1

1

2

1

1

1

1

1

1

1

1

1

1

1

4

1

1

2

1

1

1

1

1

1

1

1

2

1

5

1

9

12

4

8

13

8

4

6

10

8

6

6

1

25-0014

25-7036

25-7162

25-7168

25-9329

25-9331

25-9334

25-9912

26-7239

29-7612

30-0005

30-0006

32-1800

32-2013

32-7012B

32-7611

20-0031

20-7035G

20-7038A

20-7475

20-7476

20-9325

20-9326

20-9330

20-9834

22-2065

22-7034

22-7106

22-7163

22-7255A

22-7477

22-9805

40-1500

40-16091

40-1632

40-1669

40-1676

40-1697

40-1800

40-1830

40-1850

40-1970

40-1980

40-2000

43-7000

44-1710

45-0045

30-0009 TOOL CHANGER ASSEMBLY, 32 TOOL, VF-6…10

TITLE

ADJ. SWITCH BLOCK

VERTICAL AXLE

BEARING HOUSING

ARM, SLIP CLUTCH

HUB, SLIP CLUTCH

32 TOOL GENEVA STAR, 2 PIN

TOOL CARRIAGE, MACHINING

32 T/C HOLDING PLATE

TOOL CHANGER CLUTCH ARM

LOCATING PIN

SPACER, CAM FOLLOWER

‘V’ TRACK, T/C

RIDER, TRAP DOOR

TOOL #1 STAND OFF

PRESSURE PLATE

HOLDING ARM

BRACE

CAP, TOOL CHANGER

CONNECTOR BRACKET

DOOR OPENER BRACKET

DOOR T/C COVER

TOOL CHANGER COVER

SHUTTLE COVER PLATE

CONDUIT MOUNTING PLATE, VF-6C

SPACER RING

CT TOOLING DECAL

GENEVA DRIVER ASSY

CAROUSEL ASSY, 32 TOOL

SHUTTLE MOTOR ASSY

TELMECH 44″ CABLE ASS’Y

MOLDED ATC CABLE ASSY

CONDUIT ASSY, TOOL CARRIAGE

SHCS, 5/16-18 X 1″

BHCS, 10-32 x 1″

SHCS, 1/4-20 x 1/2″

BHCS, 8-32 x 3/8″

SHCS, 5/16-18 x 2″

SHCS, 1/4-20 x 3/4″

SHCS, 8-32 X 3/4″ LG.

HHB, 1/2-13 x 1 3/4″

SHCS, 10-32 x 3/8″

FHCS, 1/4-28 x 1″

BHCS, 1/4-20 x 1/2″

SHCS, 1/4-20 x 5/8″

HHB, 5/16-18 x 1 3/4″

SSS, CUP PT 1/4-20 x 3/8″

WASHER, BLK HRD, 1/4 X 1/8 THK

ASSEMBLY DRAWINGS

96-8100

297

ITEM PART

104

105

106

107

108

109

110

111

96

97

98

99

100

101

102

103

112

113

114

115

58-3657

58-7357

58-7358A

58-7377

58-7635

58-7636

58-9114B

59-0027

59-0046

59-1482

59-2040

59-4006

59-7130

60-1810

62-3010

63-0001

63-1031

70-0020

76-2420

77-8001

ASSEMBLY DRAWINGS

30-0009 TOOL CHANGER ASSEMBLY, 32 TOOL, VF-6…10

DESCRIPTION

1/4 FEMALE 1/8 MALE ADPT

TOP PLATE TUBE — A

OP PLATE TUBE — B

AIR REG / SOLENOID TUBE

LOW GEAR TUBE VF-3

HIGH GEAR TUBE VF-3

TRANS FILL TUBE

HOSE CLAMP 1/2 HOSE

SOUNDCOAT SHROUD RT/LT

NYLON FINISH PLUG, 13/16

CABLE CLAMP, 7/16

HOSE CRIMP, 35/64

PROTECTIVE STRIP

SHAFT ENCODER 2000 LINE

SPINDLE MTR, 10 HP

NYLON CABLE CLAMP 1/2

CABLE CLAMP 1/4

PLT1.5M CABLE TIES

CRIMP RING, 12-10 10 STUD

WIRE NUT, IDEAL #30-076

QTY

3

1

1

25

2

1

2

2

1

2

0.5FT

1

1

1

1

1

1

1

1

1

June 1998

298

96-8100

June 1998

ASSEMBLY DRAWINGS

96-8100

Spindle Assembly VF 50 Taper

299

ASSEMBLY DRAWINGS

June 1998

300

50 Taper Tool Changer Assembly

96-8100

June 1998

96-8100

QTY

6

1

1

1

1

2

1

1

2

1

1

1

1

1

1

1

1

1

1

2

2

3

1

1

1

1

1

1

1

1

1

1

1

4

1

17

5

1

4

4

4

8

4

12

3

6

6

10

ITEM

29

30

31

32

25

26

27

28

21

22

23

24

17

18

19

20

13

14

15

16

9

10

11

12

7

8

5

6

3

4

1

2

45

46

47

48

41

42

43

44

37

38

39

40

33

34

35

36

30-0015 TOOL CHANGER ASSEMBLY, 50 TAPER

PART NO

25-7162

25-7168

25-9085

25-9329

25-9331

25-9334

26-7239

29-7612

30-0005

30-0006

32-1800

32-2010

32-7011

32-7611

40-1500

40-16091

20-7035G

20-7038A

20-7475

20-7476

20-9008

20-9325

20-9326

20-9330

22-2065

22-7034

22-7106

22-7163

22-7255A

22-7263

22-7477

25-7036

40-1632

40-1669

40-1676

40-1697

40-1803

40-1850

40-1970

40-1980

40-2000

43-1602

43-7000

44-1710

45-0050

45-1600

45-1725

45-1740

TITLE

VERTICAL AXLE

BEARING HOUSING

ARM, SLIP CLUTCH

HUB, SLIP CLUTCH

TOOL HOLDING ARM

32 TOOL GENEVA STAR, 2 PIN

TOOL CARRIAGE, MACHINING

32 T/C HOLDING PLATE

LOCATING PIN

SPACER, CAM FOLLOWER

‘V’ TRACK, T/C

RIDER, TRAP DOOR

TOOL #1 STAND OFF

SWITCH MOUNTING BLOCK

PRESSURE PLATE

CAP, TOOL CHANGER

CONNECTOR BRACKET

DOOR OPENER BRACKET

CONDUIT MTG PLATE

DOOR T/C COVER

TOOL CHANGER COVER

SHUTTLE COVER PLATE

SPACER RING

CT TOOLING DECAL

GENEVA DRIVER ASSY

CAROUSEL ASSY, 32 TOOL

SHUTTLE MOTOR ASSY

24″ LIMIT SWITCH

CONDUIT ASSY, T/C

CONDUIT ASSY, TOOL CARRIAGE

SHCS, 5/16-18 x 1″

BHCS, 10-32 x 1″

SHCS, 1/4-20 x 1/2″

BHCS, 8-32 x 3/8″

SHCS, 5/16-18 x 2″

SHCS, 1/4-20 x 3/4″

SHCS, 8-32 x 1 1/4″

SHCS, 10-32 x 3/8″

FHCS, 1/4-28 x 1″

BHCS, 1/4-20 x 1/2″

SHCS, 1/4-20 x 5/8″

HHB, 1/2-13 x 3″

HHB, 5/16-18 x 1 3/4″

SSS, CUP PT 1/4-20 x 3/8″

WASHER, 5702-313-120

WASHER, SPLIT LOCK, 5/16 MED.

WASHER, FLAT CUT 3/4″

WASHER, BLACH HARD 1/2″

ASSEMBLY DRAWINGS

301

302

ASSEMBLY DRAWINGS

2

2

2

4

1

1

2

1

1

2

1

1

QTY

10

2

1

6

1

1

1

1

1

1.75′

1.70′

60

61

62

63

56

57

58

59

ITEM

49

50

51

52

53

54

55

68

69

70

71

64

65

66

67

PART NO

45-1800

45-2020

46-1705

48-0005

48-0019

48-0020

48-1750

51-0010

51-0012

51-6000

54-0010

54-0020

54-0030

54-0040

55-0010

57-9139

57-9335

63-1031

70-0050

75-15721

78-1996

79-1000

79-1001

TITLE

WASHER, SPLIT LOCK 1/4″ MED.

WASHER, NYLON

LOCK-NUT, ELASTIC, 3/4-10

PIN, DOWEL 3/16 x 3/8″

PIN, DOWEL 1/4 x 5/8″

PIN, DOWEL 1/4 x 1″

PIN, DOWEL 1/2 x 1 1/2″

BEARING DEEP GROOVE

BEARING LOCK NUT, BH-06

BEARING LOCK NUT, NT-05

CAM FOLLOWER, TOOL CHANGER

BUSHING, GUIDE WHEEL

GUIDE WHEEL

STANDARD BUSHING, GD. WHEEL

SPRING WASHER, B2500-080

GASKET, TOOL HOLD ARM

SHUTTLE COVER GASKET

CABLE CLAMP, 1/4″

PLT4S-M CABLE TIES

MOLEX BSNG. 2 PIN MALE

SPLIT FLEX TUBING 1/2″ I.D.

WIRE CHANNEL, 1″ x 2″

COVER, 1″ WIRE CHANNEL

June 1998

96-8100

June 1998

ASSEMBLY DRAWINGS

ITEM QTY DWG. NO.

7

8

5

6

3

4

1

2

9

10

1

40

20

40

20

1

5

40

40

40

20-9296

20-9297

20-9298

22-9256

24-9257

25-9349

40-16095

40-1631

40-1860

45-0045

50T CAROUSEL ASSEMBLY — CT

DESCRIPTION

50 TAPER CAROUSEL — 20 TOOL

EXTRACTION FINGER 50 TAPER

ALIGNMENT KEY 50 TAPER

BUSHING, EXTRACTOR,

SPRING, EXTRACTOR, VF-ALL

20 TOOL NUMBER RING 50 T

SHCS, 10-32 X 1/4

SHCS,1/4-20 X 3/8

SHCS, 1/4-20 X 7/8

WSHR, BLK HRD 1/4 X 1/8 THK

50 Taper Carousel Assembly (CT)

96-8100

303

ASSEMBLY DRAWINGS

June 1998

304

VF-6/8 (X-Axis) Lead Screw Assembly

96-8100

June 1998

ASSEMBLY DRAWINGS

96-8100

VF-10 Leadscrew

305

ASSEMBLY DRAWINGS

June 1998

ITEM QTY PART NO.

13

14

15

16

9

10

11

12

7

8

5

6

3

4

1

2

21

22

23

24

17

18

19

20

25

26

34

6

14

6

5

2

1

1

1

1

34

1

1

1

1

1

1

4

1

34

4

1

2

20

1

.05

20-0150

20-9215

20-9218

20-9800

22-7458

25-7267

25-9203

30-1212A

30-7420A

32-5056

40-0011

40-16413

40-1660

40-1712

40-1715

40-1750

40-1950

45-1600

50-9010

57-0075

57-0080

58-1560

58-3031

59-2033

62-0013

99-4521

TITLE

NUT HOUSING 40/50mm BS MACH

Y-AXIS BUMPER BRG END

Y-AXIS BUMPER MTR END

BASE, MACHINING

CAM, LINEAR GUIDE

Y-AXIS MOUNTING BRACKET

COVER PLATE MOTOR MOUNT

LEAD SCREW Y-AXIS

BASE OIL LINE ASSEMBLY

LIMIT SWITCH ASSEMBLY

MSHCS M10 X 25mm

MSHCS, M3 X 5

SHCS, 1/2-13 X 1 1/2

SHCS, 5/16-18 X 1 1/4

SHCS, 5/16-18 X 1 1/2

BHCS, 10-32 X 3/8

SHCS, 10-32 X 3/4

WASHER, LOCK

LINEAR GUIDE, X-AXIS VF-3

O-RING 2-021 BUNA

O-RING 2-023 BUNA

ADPT 1/8 M BSPT TO 5/16 F

BANJO ELBOW 5/16 F X M6 M

1/2″ CONDUIT STRAP

SERVO MOTOR YASKAWA

ELECTRICAL GREASE

VF-10 Base

306

96-8100

June 1998

ASSEMBLY DRAWINGS

96-8100

VF-10 Column

307

ASSEMBLY DRAWINGS

ITEM QTY DWG. NO.

29.

30.

31.

32.

25.

26.

27.

28.

21.

22.

23.

24.

17.

18.

19.

20.

13.

14.

15.

16.

9.

10.

11.

12.

5.

6.

7.

8.

1.

2.

3.

4.

37.

38.

39.

40.

33.

34.

35.

36.

41.

42.

43.

44.

45.

2

4

2

6

34 40-1660

6

2

40-1712

40-1750

24 40-2021

11 45-0045

6 45-1600

12 45-1665

14 45-1681

15 45-1800

4

1

1

1

2

6

2

1

46-1810

48-0045

48-1699

50-0001

57-0075

57-0080

58-1560

58-3031

34 59-2033

59-4002

59-4016

59-9829

62-0013

.05

99-4521

1

1

1

1

2

1

1

1

1

2

1

2

2

2

20-0150

20-9216

20-9217

20-9801

1 20-9802

34 22-7458

22-9826A

22-9927

25-7267

25-7560B

25-9813

25-9929

30-1211A

30-3250A

30-3980A

30-7400

1 32-2050

15 40-1628

14 40-16372

12 40-16391

2 40-16413

16 40-1655

TITLE

NUT HOUSING 40/50 mm BS

Z-AXIS BUMPER MTR END 40MM

Z-AXIS BUMPER SPRT END 40MM

COLUMN, MACHINED

SPINDLE HEAD, MACHINED

CAM, LINEAR GUIDE

COUNTER WEIGHT HEAD BRACKET

CYL. BRKT. COUNTER BALANCE

Y-AXIS MOUNTING BRACKET

HYD. FLUID TANK MOUNT

WAY COVER

STABILIZER BRKT. HYD. CYL.

BL LEADSCREW ASSEMBLY Z AXIS

FLUID TANK ASSEMBLY

HYD. CYLINDER ASSEMBLY

COLMUMN OIL LINE ASSEMBLY

TELEMECHANIQUE ASSEMBLY

SHCS, 1/4-20 X 1/4

SHCS, 3/8-16 X 1 1/2

SHCS, 3/8-16 X 1/2

MSHCS, M3 X 5

MSHCS, M12 X 65

SHCS, 1/2-13 X 1 1/2

SHCS, 5/16-18 X 1 1/4

BHCS, 10-32 X .38

FHCS, 1/4-20 X 3”

WASHER, BLACK HARD 1/4 X 1/8 THK

WASHER, LOCK 5/16

WASHER, FLAT 3/8 I.D.

WASHER, SPLIT LOCK 3/8 MED.

WASHER, SPLIT LOCK 1/4 MED.

JAM NUT, HEX 3/8-24

PIN, PULL 3/8 X 1 1/2

PIN, DOWEL 5/8 X 2 1/4

LINEAR GUIDE

O-RING 2-021 BUNA

O-RING 2-023 BUNA

ADPT 1/8 M BSPT TO 5/16 F

BANJO ELBOW 5/16 F X M6 M

1/2″ CONDUIT STRAP

HOSE CLAMP

HYD. HOSE CLAMP

CLEVIS COUNTER WEIGHT

SERVO MOTOR YASKAWA

ELECTRICAL GREASE

308

June 1998

96-8100

June 1998

ASSEMBLY DRAWINGS

ITEM QTY DWG. NO.

21.

22.

23.

24.

17.

18.

19.

20.

25.

26.

27.

28.

13.

14.

15.

16.

9.

10.

11.

12.

5.

6.

7.

8.

1.

2.

3.

4.

1

4

4

1

6

6

14

4

1

86

1

.05

2

4

86

6

1

1

1

14

1

1

86

1

1

2

1

1

40-1750

45-1600

45-1681

48-0045

50-0001

57-0075

57-0080

58-1560

58-3031

59-2033

62-0013

99-4521

20-0150

20-0153

20-0154

20-0156

22-7458

25-7459

25-9219

25-9220

30-0036

30-0037

32-2051

40-16372

40-16413

40-16455

40-1660

40-1712

TITLE

NUT HOUSING 40/50 mm BS

SADDLE, VF-10 MACHINED

TABLE, VF-10 MACHINED

BUMPER, 1″ 40 & 50 mm LD SCREW

CAM, LINEAR GUIDE

TRIP BRACKET, TABLE

LIMIT SWITCH BRACKET X- AXIS

TRIP BRACKET X-AXIS

X-AXIS OIL LINE ASSEMBLY

BL LEADSCREW ASSEMBLY X AXIS

LIMIT SWITCH X HOME

SHCS, 3/8-16 X 1 1/2

MSHCS, M3 X 5

SHCS, 10-32 X .88

SHCS, 1/2-13 X 1 1/2

SHCS, 5/16-18 X 1 1/4

BHCS, 10-32 X .38

WASHER, LOCK

WASHER, SPLIT LOCK

PULL PIN 3/8 X 1 1/2

LINEAR GUIDE

O-RING 2-021 BUNA

O-RING 2-023 BUNA

ADPT 1/8 M BSPT TO 5/16 F

BANJO ELBOW 5/16 F X M6 M

1/2″ CONDUIT STRAP

SERVO MOTOR YASKAWA

ELECTRICAL GREASE

VF-10 Saddle

96-8100

309

ASSEMBLY DRAWINGS

June 1998

310

APC Assembly

96-8100

June 1998

ITEM QTY.

PART NO.

29.

30.

31.

32.

25.

26.

27.

28.

21.

22.

23.

24.

17.

18.

19.

20.

13.

14.

15.

16.

9.

10.

11.

12.

5.

6.

7.

8.

1.

2.

3.

4.

45.

46.

47.

48.

41.

42.

43.

44.

49.

50.

51.

52.

37.

38.

39.

40.

33.

34.

35.

36.

1

2

8

8

1

1

2

1

1

1

2

4

1

1

3

2

1

1

2

4

1

2

4

1

1

2

1

2

2

2

3

1

1

20

32

4

4

3

3

12

1

2

2

20

8

8

2

32

4

13

4

124

25-0072

25-0077

25-0082

25-0085

25-0095

25-0100

25-0101

25-0102

25-0105

30-0054

30-0055

32-1800

40-0017

40-16081

40-1614

40-1617

14-7068

20-0046

20-0048

20-0049

20-0050

20-0051

20-0052

20-0053

20-0054

20-0057

20-0060

20-0065

20-0066

20-0071

20-0193

25-0066

40-1636

40-1654

40-1667

40-1703

40-1850

40-1920

40-1950

40-1961

40-1970

40-1981

44-1700

45-1666

46-1625

48-0012

49-16201

51-0300

51-2836

51-4000

56-0085

59-1057

TITLE

CASTING, LEVEL PAD

SUPPORT, IDLER SPROCKET

DRIVE LEG, APC

DETENT, APC

SUPPORT, MOTOR, APC

GUIDE, CHAIN, APC

TENSIONER BLOCK

PALLET

CLAMPING RAIL

IDLER SPROCKET

JOURNAL, IDLER SPROCKET

FRICTION BLOCK

PALLET STOP, APC

WIPER, APC

BASE, MACHINED

SHIELD, SPLASH, LOW PROFILE

LEG, APC

PALLET, SKIRT, REAR

SWITCH BRACKET, CHAIN, LOW

SWITCH BRACKET, ARM #1

PALLET DRIP PAN

BRACKET, WIPER

SWITCH BRACKET ARM #2

SWITCH BRACKET, CHAIN, HIGH

PALLET SKIRT, FRONT

CHAIN ASSEMBLY, APC

SLIP CLUTCH ASSEMBLY

SHUTTLE MOTOR, 507-01-110AH

FHCS, 5/16-18 X 3/4”

BHCS, 6-32 X 5/16”

SHCS, 1/4-20 X 1 1/4

FHCS, 1/4-20 X 1”

SHCS, 3/8-16 X 1 1/4

SHCS, 1/2-13 X 1”

SHCS, 5/16-18 X 1 1/4

FHCS, 10-32 X 1/2

SHCS, 10-32 X 3/8”

FHCS, 1/4-20 X 5/8

SHCS, 10-32 X 3/4

SHCS, 3/8-16 X 2”

FHCS, 1/4-28 X 1”

FBHCS, 1/4-20 X 1/2

SSS, CUP PT. 3/4-10 X 4:”

WASHER, FLAT 1/2 I.D.

NUT, HEX, BLACK OX, 1/4-20

DOWEL PIN, 12mm X 30 mm LG.

BHCS, 10-32 X .38

BUSHING, DRILL .6260 I.D.

BEARING, RADIAL, #60052RS

BEARING, RADIAL12 X 32 X 10MM

RETAINING RING 5100-100

BUMPER, PALLET

96-8100

ASSEMBLY DRAWINGS

311

ASSEMBLY DRAWINGS

June 1998

312

VF-1 Base

96-8100

June 1998

ASSEMBLY DRAWINGS

96-8100

VF-1 Column

313

ASSEMBLY DRAWINGS

June 1998

314

VF-1 Saddle

96-8100

June 1998

ASSEMBLY DRAWINGS

96-8100

VF-1 Leadscrew

315

ASSEMBLY DRAWINGS

June 1998

316

96-8100

June 1998

ASSEMBLY DRAWINGS

96-8100

317

ASSEMBLY DRAWINGS

June 1998

318

96-8100

June 1998

ASSEMBLY DRAWINGS

96-8100

319

ASSEMBLY DRAWINGS

June 1998

320

96-8100

June 1998

ASSEMBLY DRAWINGS

96-8100

VF-8 Base

321

ASSEMBLY DRAWINGS

June 1998

322

VF-8 Column

96-8100

June 1998

ASSEMBLY DRAWINGS

96-8100

VF-8 Saddle

323

ASSEMBLY DRAWINGS

June 1998

324

VF-6 Base

96-8100

June 1998

ASSEMBLY DRAWINGS

96-8100

VF-6 Column

325

ASSEMBLY DRAWINGS

June 1998

326

VF-6 Saddle

96-8100

June 1998

ASSEMBLY DRAWINGS

96-8100

327

ASSEMBLY DRAWINGS

June 1998

328

96-8100

June 1998

ASSEMBLY DRAWINGS

96-8100

329

ASSEMBLY DRAWINGS

June 1998

330

VF Series Spindle 7.5 K

96-8100

June 1998

ASSEMBLY DRAWINGS

96-8100

20 Pocket Tool Changer

331

ASSEMBLY DRAWINGS

June 1998

332

VF-3 Base

96-8100

June 1998

ASSEMBLY DRAWINGS

96-8100

VF-3 Column

333

ASSEMBLY DRAWINGS

June 1998

334

VF-3 Saddle

96-8100

June 1998

ASSEMBLY DRAWINGS

96-8100

335

ASSEMBLY DRAWINGS

June 1998

336

96-8100

June 1998

ASSEMBLY DRAWINGS

96-8100

337

ASSEMBLY DRAWINGS

June 1998

338

96-8100

June 1998

ASSEMBLY DRAWINGS

96-8100

339

ASSEMBLY DRAWINGS

June 1998

340

VF-3/4 Gearbox Assembly 15 HP

96-8100

June 1998

ASSEMBLY DRAWINGS

96-8100

341

ASSEMBLY DRAWINGS

June 1998

342

VF-3/4 Gearbox Assembly HT10K

96-8100

June 1998

ASSEMBLY DRAWINGS

96-8100

343

ASSEMBLY DRAWINGS

June 1998

344

VF-3/4 Gearbox Assembly HT10K TSC

96-8100

June 1998

ASSEMBLY DRAWINGS

96-8100

345

ASSEMBLY DRAWINGS

June 1998

346

VF-Series Hydraulic Couterbalance System

96-8100