haas 96-0189 Service Manual

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any other party automatically voids the factory warranty.

June 6, 2013

HAAS SERVICE AND OPERATOR MANUAL ARCHIVE

Horizontal Service Manual 96-0189 RevL English June 2005

• 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 qualied and knowledgeable about the processes.

• Only authorized personnel with the proper training and certication 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

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COMMON ABBREVIATIONS

AC Alternating Current AMP Ampere APC Automatic Pallet Changer APL Automatic Parts Loader ASCII American St andard Code for Information Interchange A T C Automatic T ool Changer A TC FWD Automatic T ool Changer Forward A TC REV Automatic T ool Changer Reverse AWG American Wire Gauge BHCS Button Head Cap Screw B T British T ooling (Common usage) CA D Computer Assisted Design CAM Computer Assisted Manufacturing (Assisted Machining) CAT - 5 Category 5 Cable CB Circuit Breaker C C Cubic Centimeter CC W Counter Clock Wise CF M Cubic Feet per Minute CN C Computerized Numeric Control CNCR SPINDLE Concurrent Spindle with axis motion C R C Cyclic Redundancy Check digit C R T Cathode Ray Tube C T Caterpillar T ooling CT S Clear T o Send CW Clock Wise DB Draw Bar D C Direct Current DGNOS Diagnostic DHCP Dynamic Host Configuration Protocol DIR Directory DN C Direct Numerical Control DO S Disk Operating System DT E Data T erminal Equipment ENA CNVR Enable Conveyor EOB End Of Block EOF End Of File EPROM Erasable Programmable Read Only Memory E-STOP Emergency S top FHCS Flat Head Cap Screw F T Foot FU Fuse FWD Forward GA Gauge HH B Hex Head Bolts HP Horse Power HS Horizontal Series of Machining Centers I D Inside Diameter IGBT Isolated Gate Bipolar Transistor I N Inch IOPCB Input Output Printed Circuit Board LAN Local Area Network LB Pound LE D Light Emitting Diode

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LO CLNT Low Coolant LOW AIR PR Low Air Pressure L VPS Low Voltage Power Supply MB Megabyte (1 million) MCD RL Y BRD M -Code Relay Board MD I Manual Data Input MEM Memory M- FI N M -code Finished MM MilliMeter MO CON Motor Control MO TI F Motor Interface MSG Message MSHCP Metric Socket Head Cap Screw N C Numerical Control N C Normally Closed NO Normally Open O D Outside Diameter OPER Operator P Pocket P ARAM Parameter PCB Printed Circuit Board PGM Program PO R Power On Reset POSIT Positions PROG Program PSI Pounds per Square Inch PS T Pallet Schedule T able PWM Pulse Width Modulation RAM Random Access Memory RET Return REV CNVR Reverse Conveyor RJ H Remote Jog Handle RPDBDN Rotary Pallet Draw Bar Down RPDBUP Rotary Pallet Draw Bar Up RPM Revolutions Per Minute RT S Request To Send R X D Receive Data S Spindle S peed SD IS T Servo Distribution PCB SFM Surface Feet per Minute SHCS Socket Head Cap Screw SI O Serial Input/Output SKBIF Serial Key Board Inter Face PCB SMTC Side Mount T ool Changer SP Spindle T T ool Number T C T ool Changer T I R Total Indicated Runout T N C T ool Nose Compensation TR P Tool Release Piston TS Tail Stock TS C Thru the Spindle Coolant T XD Transmit Data VD I Verein Deutscher Ingenieure VMC Vertical Machining Center WAN Wide Area Network

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1. TROUBLESHOOTING

This section is intended for use in determining the solution to a known problem. Solutions given are intended to give the individual servicing the CNC a pattern to follow in, first, determining the 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. Y ou 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 centerdrill 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 .

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1.1 GENERAL M ACHINE O PERATION

MACHINE N OT R UNNING

Machine cannot be powered on

• Check input voltage to machine (see "Electrical Service").

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

• Check overvoltage fuses (see "Electrical Service").

• Check wiring to POWER OFF button on front control panel.

• Check wiring to AUT O OFF relay to IOPCB.

• Check connection between 24V transformer and K1 contactor .

Machine can be powered on, but turns off by itself

• Check Settings #1 and #2 for Auto Of f T imer or Of f at M30.

• Check AC power supply lines for intermittent supply.

• Check low voltage power supply for intermittent supply .

• Check wiring to POWER OFF button on front control panel.

• Check connection between 24V transformer and K1 contactor .

• Check Parameter 57 for Power Off at E-STOP.

Machine turns on, keyboard beeps, but no LCD display

• Check for power connections to LCD from IOPCB.

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

• Check video cable from VIDEO PCB to LCD.

• Check for lights on the processor .

• Replace LCD (see "Electrical Service").

Machine turns on, LCD works, but keyboard keys do not work

• Check keyboard cable (700) from VIDEO to KBIF PCB.

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VIBRATION

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

Machine vibrates while jogging the axis with the hand wheel

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

The machine vibrates excessively in a cut

This can be caused by a number of factors as 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/Ball Screws", and "Gearbox and Spindle Motor" sections.

ACCURACY

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

• Ensure that the machine has been sufficiently warmed up before cutting parts. This will eliminate mispositioning errors caused by thermal growth of the ballscrews (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 machine.

• 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.

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

Machine will not interpolate a round hole.

• Check that the machine is level (see "Installation" section of the Reference manual).

• Check for backlash ("Servo Motors/Ballscrews" section).

Bored holes do not go straight through the workpiece.

• Check that the machine is level (see "Installation" section of the Reference manual).

• Check for squareness in the Z axis.

Machine bores holes out-of-round.

• Check that the machine is level (see "Installation" section of the Reference manual).

• Check the sweep of the machine (see "Spindle Sweep Adjustment" section).

Bored holes are out of round or out of position.

• Check for thermal growth of the ballscrew (see "Thermal Growth" section).

• The spindle is not parallel to the Z axis. Check the sweep of the machine (see "S pindle Sweep Adjustment")

Machine mis-positions holes.

• Check for thermal growth of the ballscrew (see "Thermal Growth" section).

• Check that the machine is level (see "Installation" section of the Reference manual).

• Check for backlash (see "Servo Motors/Ballscrews" section).

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

Machine leaves large steps when using a shell mill.

• Check that the machine is level (see "Installation" section of the Reference manual).

• Check the sweep of the machine (see "Spindle Sweep Adjustment" section).

• Cutter diameter too large for depth of cut.

FINISH

Machining yields a poor finish

• Check for gearbox vibration.

• Check for backlash ("Accuracy/Backlash")

• Check the condition of the tooling and the spindle.

• Check for spindle failure.

• Check the condition of the axis motors.

• Check that the machine is level (See the Installation section of the Reference manual).

THERMAL G ROWTH

A possible source of accuracy and positioning errors is thermal growth of the ballscrew . As the machine warms up, the ballscrews 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 p arts in one setup, or machining one part with multiple setups.

NOTE: The ballscrew 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 Xaxis ballscrew 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.

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2. Jog to an offset location on the t able (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 of fset). Cursor to X and press P AR T 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 G1 10 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 ballscrews to warm up to the correct temperature and stabilize. Once the machine is at temperature, the ballscrews won't expand any further, unless they're allowed to cool down. A warm-up program should be run after each time the machine is left idle.

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1.2 SPINDLE

NOT T URNING

Spindle not turning

• If there are any alarms, refer to "Alarms" section.

• Check that the spindle turns freely when machine is off.

• Command spindle to turn at 1800 RPM and check spindle drive display . If display blinks “bb”, check spindle orientation switch ("Spindle Orient ation"). If spindle drive does not light the RUN LED, check forward/reverse commands from IOPCB ("Electrical Service").

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

• If spindle is still not turning, replace MOCON PCB ("Electrical Service").

• If spindle is still not turning, replace spindle drive ("Electrical Service").

NOTE: Before installing a replacement spindle, the cause of the previous failure must

be determined.

NOISE

Check the tooling; balanced tooling will run smoother; possible reducing the noise. Check for misalignment between the motor and the spindle. If misalignment is noted, loosen the motor mount-

ing bolts, run the spindle at 1000 rpm and then tighten the mounting bolts. Remove the coolant union and run the spindle, if the spindle runs quiter the coolant union may need replacing.

OVERHEATING

Run program #O02021 with the air pressure to the spindle at 30 psi. Program time is approximately 2 hours. If possible run the program overnight by changing M30 to M99 so it can repeat. Adjust spindle speed override depending on maximum spindle speed of machine: Set at 100% for 8,000 RPM machines; Set at 120% for 12,000 RPM machines.

N100 N200 N1000 N2000 S750M3 M97 P1000 L15 S7500M3; S10000M3; G04 P600.; M97 P2000 L15 G04 P30.; G04 P30.; S2500M3; M30; S500 M3; S500M3; G04 P600.; G04 P150.; G04 P150.; S5000M3; M99; M99; G04 P900.; %

• If at any time during this procedure the spindle temperature rises above 150 degrees, start the

procedure over from the beginning and follow the steps below . If the temperature rises above 150° a second time, contact your dealer .

NOTE: Once run-in program is complete reset the air pressure back to 25psi. prior

to checking spindle temperature.

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

• Check for correct amount of lubrication.

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

carefully.

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• Ensure that the correct oil is being used (refer to "Maintenance Schedule").

STALLING / LOW 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, and run very hot and very loud. Investigate machining problems before concluding that the problem exists with the spindle or spindle drive.

SPINDLE D RIVE

Vector Drive

T o properly troubleshoot the V ector Drive, use the following questions as a guide:

• What alarms are generated?

• When does the alarm occur?

• Is the Vector Drive top fault light on?

• Is there a fault light on any of the servo amplifiers?

• Does the alarm reset?

• Does the spindle motor turn at all?

• Does the spindle turn freely by hand?

• Have the C-axis parameters been confirmed?

• What is the input voltage to the vector drive unit?

• What does the DC Bus voltage measure? (320 VDC to 345 VDC)

• Does the DC Bus voltage displayed on the diagnostic page match the measured DC Bus voltage?

All of the questions above must be answered. The DC Bus voltage should be between 320 VDC to 345 VDC with the machine powered up but not running. If the voltage is not in this range, adjust the taps on the main line transformer until this voltage range is achieved. There is a possibility the drive is faulty , but low Bus volt age can also be caused by a shorted REGEN load or a shorted amplifier.

If the DC Bus voltage is below 50 VDC and never goes any higher, perform Steps 1-6.

1. With the machine powered up, is the green “POWER-ON” L.E.D. lit? If not, replace the Vector Drive unit.

2. Power down the machine. Disconnect the REGEN load (terminals 1 and 2 on the Vector Drive unit) and measure the resistance from each wire-to-chassis ground (open) and between the wire leads. The resistance should measure 6 ohms. If not, replace the REGEN load or cabling.

3. Disconnect cable 490 at terminals 2 and 3 of the V ector Drive and from the servo amplifiers. With a multimeter in the diode mode, place the red meter lead to the +HV terminal and the black meter lead to the -HV terminal of each amplifier. The meter should read open.

4. Reverse the leads: Place the red meter lead on the -HV terminal and the black lead on the +HV terminal. The meter should read .7 ohms in both instances. If not, replace the faulty amplifier .

5. Measure the resistance between terminals 1 and 3 of the V ector Drive. The meter should read greater than 100K ohms. If not, the Vector Drive is faulty.

6. If the green “POWER-ON” L.E.D. was lit (from Step 2), leave both 490 cables (2 and 3) disconnected from the drive and power up the machine.

a. Does the DC Bus voltage come up? If not, the Vector Drive is faulty . b. Measure the voltage between terminals 1 and 3. The voltage should be 300

VDC or more. If not, the Vector Drive is faulty.

If both ‘a’ and ‘b’ check out okay, there is a problem with either the amplifiers or the REGEN load.

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If the fault occurs upon acceleration -or- the spindle accelerates slowly -or- the spindle makes noise, do the following:

7. Disconnect the output cables to the spindle motor. Turn on the machine and press <RESET>. Do not command the spindle to turn. With a volt meter, measure the DC volt age between each output phase (terminals 9, 10, and 1 1) to the 320V RTN (terminal 3). The meter should read 165 VDC in each case, else one phase is faulty .

8. Measure the resistance across the motor wires from phase to phase and from each phase to chassis. The meter should read .1 ohms phase-to-phase and open phase-to-chassis.

If the fault occurs upon deceleration or acceleration just as the spindle reaches its specified speed, or if an overvoltage alarm (119) occurred, do the following:

9. Disconnect the REGEN load resistors (terminals 1 and 2) and measure the resistance from each wire lead-to-chassis ground and between the wire leads. The meter should read open lead-toground, and 8.6 ohms between the leads.

10. Measure the resistance from terminal 1 to terminal 3. If the resistance is less than 100K, the drive is faulty.

1 1. With the REGEN load left disconnected, power-up the machine and command a spindle speed of

700 RPM (300 RPM for lathes in high gear). Press <RESET> while monitoring the DC voltage between terminal 1 and terminal 3. The voltage should read 330 VDC and then drop to less than 50 VDC momentarily . If not, that drive is faulty . If the volt age at RESET was okay and the alarm was resettable, the REGEN load should be replaced even if the resistance appears to be

ORIENTATION

Spindle loses correct orientation

• Check alarm history . Look for S pindle Z Fault, or Spindle Reference Missing alarms. If these alarms exist, there may be a defective spindle encoder, or a broken ground or shield connection.

• Check parameters.

• Check for a mechanical slip at the contact points of all components between the spindle encoder.

TOOLS S TICKING I N T APER

This problem may occur after loading a cold tool into a hot spindle (a result of thermal expansion of the tool holder inside the spindle taper). It may also occur due to heavy milling, milling with long tooling, or cuts with heavy vibration. This also is the result of thermal expansion.

If sticking only occurs during these situations, check your application to ensure proper machining techniques are being used; check the feeds and speeds for the tools and material being used. If a tool is pulled out of the extractors due to a tool stuck in the taper then the unclamp switch is not adjusted correctly or the switch could be bad.

NOTE: In a proper working system the spindle will pop slightly during a tool change.

This popping is normal provided it does not create flex in the double arm or the need to remove the tool with a mallet.

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• Check the condition of the tooling, verifying the taper on the tooling is ground and not turned. Look

for damage to the taper caused by chips in the taper or rough handling. If the tooling is suspected, try to duplicate the symptoms with known-to-be-good tooling.

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

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

• Duplicate the cutting conditions under which the deflection occurs, but do not execute an

automatic tool change. Try to release the tool using the tool release button. If sticking is observed, the deflection is not caused by improper ATC adjustment, but is a problem in the spindle head on the machine.

• Ensure the spindle is not running too hot (140°F [60°C] or above).

• Check air supply. Max air pressure drop of 10 psi [69 kilopascals] during a tool change is allowed.

• Are the correct pull studs being used?

Tool Holder / Spindle Fretting

Is fretting present on the tool holder or spindle? Fretting is the result of sideways movement of a tool holder in the spindle. Fretting can leave a wave pattern on

the mating surfaces and will affect the fit and finish of both the tool holder and the spindle.

• If light fretting is present, check the application to ensure proper machining techniques are being

used; check the feeds and speeds for the tools and material being used.

• Light fretting and rust may be cleaned from the tool holder with a fine scotchbrite hand pad and

solvent. If scotchbrite is used, clean the tool holder and spindle taper thoroughly after use with an alcohol pad. Apply a thin coat of light oil to the taper of the tool holder . Grease the pull stud.

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1.3 SERVO M OTORS / BALL S CREWS

NOT O PERATING

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

Servo motor is not functioning

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

• Encoder is faulty or contaminated (Alarms 139-142, 153-156). Replace motor assembly on brushless machines.

• Open circuit in motor (Alarms103-106). Replace motor assembly ("Axis Motor").

• Motor has overheated, resulting in damage to the interior components (Alarms 135-138, 176). Replace motor assembly ("Axis Motor").

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

• Check for broken or loose coupling between the servo motor and the ball screw. Replace or repair the coupling ("Axis Motor")

• Check for a damaged ball screw, and replace if necessary ("Ball Screw" section).

NOISE

Ball 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 ball screws or bearing sleeves without due consideration; they

are extremely durable and reliable. Verify that problems are not due to tooling, programming, or fixturing problems.

Servo motor noise

• Disconnect the servo motor from the ball screw and rotate by hand. If the noise persists, replace the motor assembly("Axis Motor" section).

• Noise is caused by bearings. Rolling, grinding sound is heard coming from the motor. If bearings are making a consistently loud sound, replace the motor.

Ball screw noise

• Ensure oil is getting to the ball screw through the lubrication system. Check for a plugged metering valve.

• Check for damage to the bearing sleeve.

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

adjusted.

• Run the axis back and forth. The motor will get very hot if the bearing sleeve is damaged. If so, turn the axis by hand and feel for roughness in the ball screw. Loosen the clamp nuts at both ends of the ball screw. If the symptom disappears, replace the bearing sleeve. Be certain to check for damage to the ball screw shaft where the bearing sleeve is mounted. If the noise persists, the ball screw is damaged and must be replaced. When replacing the ball screw in an older machine, always replace the bearing sleeve with the an angular contact design bearing sleeve.

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• Check the ball screw for misalignment. If incorrect, perform alignment procedure in "Ball Screw" section.

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

NOTE: Customer complaints of Ball Screw noise may not indicate a bad ball screw.

Ball screws from different manufacturers produce varying levels of noise. Often machines are built with two or more different brands of ball screws in the same machine. If complaints are generated about one axis screw in comparison to another, it is possible that the screws are simply sourced from different manufacturers.

ACCURACY / BACKLASH

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

Poor positioning accuracy

• Check parameters for that axis.

• Check for backlash in the ball screw; see the following steps.

INITIAL PREPARATION -

Turn the machine ON. Zero return the machine and jog the column to the approximate center of its travel in the X and Y directions. Move the Z-axis to its full travel forward.

CHECKING X-AXIS:

1. Set up a dial indicator and base on the mill table as shown in Fig. 1.3-1.

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

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Figure 1.3-1. Dial indicator in position to check X-axis.

• Zero the dial indicator.

• Press the MDI key on the control panel.

• Press the HANDLE JOG key on the control panel.

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

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

4. Repeat Step 3 in the negative (-) direction.

TOTAL DEVIATION BETWEEN THE DIAL INDICATOR AND THE CONTROL PANEL DISPLAY SHOULD NOT EXCEED .0002.

An alternate method for checking backlash is to place the dial indicator as shown in Fig. 1.3-1 and manually push the mill column to the left and right while listening for a 'clunk'. The dial indicator should return to zero after releasing the column.

NOTE: The servo motors must be on to check backlash by this method.

5. If backlash is found, refer to "Backlash - Possible Causes" in this section.

CHECKING Y-AXIS:

1. Set up a dial indicator and base on the mill table as shown in Fig. 1.3-2.

Figure 1.3-2. Dial indicator in position to check Y -axis.

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

• Zero the dial indicator.

• Press the MDI key on the control panel.

• Press the HANDLE JOG key on the control panel.

The “Distance to go” display in the lower right hand corner of the screen 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.

4. Repeat Step 3 in the negative (-) direction.

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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. 1.3-2 and manually push up and down on the spindle head while listening for a 'clunk'. The dial indicator should return to zero after releasing the spindle head.

NOTE: The servo motors must be on to check backlash by this method.

5. If backlash is found, refer to "Backlash - Possible Causes" in this section.

CHECKING Z-AXIS:

1. Set up a dial indicator and base on the mill table as shown in Fig. 1.3-3.

Figure 1.3-3. Dial indicator in position to check Z-axis.

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

• Zero the dial indicator.

• Press the MDI key on the control panel.

• Press the HANDLE JOG key on the control panel.

The “Distance to go” display in the lower right hand corner of the screen 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 (+) Z direction. Jog back to zero (0) on the display. The dial indicator should read zero (0) ± .0001.

4. Repeat Step 3 in the negative (-) direction.

An alternate method for checking backlash is to place the dial indicator as shown in Fig. 1.3-3 and manually push the Z-Axis forward and back while listening for a ‘clunk’. The dial indicator should return to zero after releasing the axis.

NOTE: The servo motors must be on to check backlash by this method.

5. If backlash is found, refer to "Backlash - Possible Causes" in this section.

BACKLASH - POSSIBLE CAUSES:

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

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• Loose SHCS attaching the ball nut to the nut housing. Tighten the SHCS as described in "Mechanical Service" section.

• Loose SHCS attaching the nut housing to the column, head, or saddle, depending on the axis. Tighten the SHCS as described in "Mechanical Service".

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

• Loose motor coupling. Tighten as described in "Mechanical Service".

• Broken or loose flex plates on the motor coupling.

NOTE: The coupling cannot be serviced in the field and must be replaced as a unit

if it is found to be defective.

• Loose SHCS attaching the bearing sleeve to the motor housing or top of column. Tighten as described in "Ball Screw" section.

• Defective thrust bearings in the bearing sleeve. Replace the bearing sleeve as outlined in "Bearing Sleeve" section.

• Loose SHCS attaching the axis motor to the motor housing. If the SHCS are found to be loose, inspect the motor for damage. If none is found, tighten as described in "Axis Motor" section. If damage is found, replace the motor.

• Incorrect backlash compensation number in Parameter 13, 27, or 41.

• Worn ball screw .

EC-400 A-Axis Backlash Adjustment (Full Forth)

1° indexer instructions are different, see the instructions at the end of this section.

1. Remove all parts and fixtures from the platter .

2. Check and record backlash near the outer edge of the platter face, using approximately 15-20 ft./lbs. The factory specification is 0.0003” to 0.0007”.

NOTE: Check backlash in each of the four quadrants (every 90°).

3. Remove the (4) 10-32 BHCS that retain the worm housing cover. Place a drip p an beneath the black bearing housing cover to catch any gear oil (keep this pan in place for Step 4). Remove the bearing housing cover. It may be necessary to apply channel lock pliers to the bearing housing in order to remove it; if this is necessary , use a rag to prevent marring.

4. Note the position of the dimple located on the flange of the bearing housing. Mark this position on an adjacent part of the casting for reference. Remove the four 5/16-18 cap screws. Do not pull the housing out or gear oil will pour out of the housing. Put two (2) screws part way in housing holes and turn housing with lever.

5. Index the bearing housing one set of holes. Move to the next set of holes by rotating the hole set upwards (towards the platter) - This may be CC or CCW . Bolt the bearing housing flange down. Torque the bolts to 25 ft./lbs. Check the backlash in each of the four quadrants. The factory specification is 0.0003” to 0.0007”.

If necessary , repeat S teps 4 and 5.

6. Replace the bearing housing cover. Replace the side cover sheetmetal and reatt ach with the (4) BHCS removed in Step 3.

7. Remove the oil filler pipe plug. If the oil level covers less than half of the sight glass, then add as follows in step 8.

8. Refill the gear case with Mobil SHC-630 gear oil to the midpoint of the oil level eye.

9. Reinstall the oil fill pipe plug form step 7.

Troubleshooting

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A-axis backlash adjustment for optional 1° indexer:

The facegear must be disengaged before checking backlash. First raise the platter by applying air to the lift piston with Haas tool number T -2150. Disconnect the A-axis and connect tool T -2150 as shown on drawing T -

2150. Toggle air to the lift piston with the regulator set between 20 to 40 PSI [138-276 kilopascals]. Check backlash at each quadrant (every 90°). Backlash on the 1° indexer option is .0007”-.0015” (nonstandard). Adjust as necessary . See the previous adjustment description.

VIBRATION

Excessive Servo Motor Vibration

• 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").

• Check all parameters of the suspected axis against the parameters as shipped with the machine. If there are any differences, correct them and determine how the parameters were changed. P ARAMETER 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 FAUL T 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 ground. If the motor is open or shorted, replace.

OVERHEATING

Servo motor overheating

• If a motor OVERHEA T 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 ball screw for binding ("Accuracy/Backlash" section). If the motor is binding by itself, replace in accordance with "Axis Motor" section.

FOLLOWING E RROR

Following Error alarms occur on one or more axes sporadically

• Check DC bus voltage on "Diagnostics" page 2. V erify 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 section of the Reference manual.

• Check motor wiring for shorts.

• Replace driver card ("Electrical Service").

• Replace servo motor ("Axis Motor").

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BALL S CREWS - VISUAL I NSPECTION

The three main causes of Ball Screw failure are:

Loss of Lubrication Contamination Machine Crash

Wear of the nut balls and the screw threads is generally a non-issue under proper operating conditions. Each type of suspect cause will leave telltale signs on the Ball Screw itself.

Loss of Lubrication:

The lubrication system of the machine provides a layer of oil for the Ball Screw components to operate on, eliminating metal-to-metal contact. Should a problem with the lubrication system develop, that failure will accelerate all wear issues.

1. Dry metal-to-metal contact following lube breakdown will create intense heat at the contact points. The Nut balls will weld to the nut races due to the heat and pressure of the preload. When movement of the Ball Screw continues, the welds will be broken, ripping off particles of both the balls and the races. This loss of diameter will reduce the preload, reducing machine accuracy . Ball Screws with this type of wear, but no screw surface marring, can be rep aired by the factory .

2. A second cause of wear of the Ball Screws is material fatigue. Material fatigue typically occurs at the end of the Ball Screw service life. Signs of material fatigue include black, contaminated coolant, pitting of the screw surface, loss of preload, and metal flakes on the Ball Screw . Ball Screws suffering from material fatigue are not repairable.

Contamination:

Contamination of the lubrication and/or coolant systems of the machine will produce problems with the Ball Screws.

Check the condition of the lube on the Ball Screw threads.

1. If the lube is wet and clean, this indicates a properly functioning lube system.

2. If the lube is thick and dark, but free of metal chips, the lube itself is old and must be changed out. The entire system should be cleaned of the old lube.

3. If the lube is wet and black, the lube system has been contaminated by metal particles. Inspect the Ball Screws for wear.

Contamination of the lube and/or coolant systems can be caused by a wearing Ball Screw , or by metal chips entering the systems through open or loose way covers. Check all way covers and seals for excessive clearances.

Machine Crash:

A hard machine crash can cause a Ball Screw to lock up. The static overload created during a machine crash can break apart the ball-nut balls, denting the thread surfaces. Turning the nut by hand will result in an obvious grinding feeling and/or sound.

1. Check the screw for straightness.

2. Look for ball dents at the ends of the screw length. These indents will be a sure sign of a hard machine crash. The inertia of the table is transferred, due to the sudden stop, directly to the balls inside the ball nut, creating impressions on the screw surface.

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BALL S CREW C LEANING

In most cases, a thorough cleaning of the suspect Ball Screw will resolve “bad screw” issues, including noise complaints.

1. Manually jog the ball nut to one end of the screw.

2. Visually inspect the screw threads. Look for metal flakes, dark or thick lube, or contaminated coolant: See the “Ball Screws - Visual Inspection - Contamination” section.

3. Use alcohol, or other approved cleaning agents, to wash the screw.

CAUTION! Do not use detergents, degreasers, or solvents to clean Ball Screws or their

4. Jog the ball nut to the other end of its travel. If metal flakes are now present on the screw threads, you may have wear issues.

5. Re-lubricate screw threads before returning the machine to service.

DRIVE F AULT / OVERCURRENT

components. Do not use water-based cleaners, as they may cause rust.

Y-axis motor overcurrent.

• Alarm not cleared

• Check Y axis parameters

• Check the ball screw for binding

• Check motor and cable for shorts

• Check amplifier

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1.4 PALLET C HANGER

EC-400 PALLET C HANGER OVERVIEW

When the automatic pallet changer (APC) is at rest, the pallet is clamped, the pallet at the load station is at home position, and the APC door is closed. The H-frame “Down” solenoid is on, the safety solenoid is on, and the H-frame is down with the H-frame lock pin engaged in the bumper mount. The APC servo has been zero returned, using the APC home sensor .

When a pallet change is commanded the following events occur in this order:

1. H-frame down switch is checked to verify down status.

2. Z-axis rapids, if necessary, to a position specified by the grid of fset & p arameter 64.

3. A-axis rapids, if necessary, to position specified by grid offset & parameter 224 (this may involve a raise & lower of the pallet).

4. The lifting and lowering of the A-axis platter is monitored by a sensor assembly located on the bottom of the A-axis, on indexer style machines. There are no sensors monitoring the A-axis platter position on machines with the full 4

axis option.

5. The A-axis is allowed to rotate, once the platter lif t sensor is triggered.

6. When the A-axis moves to the home position and lowered, the platter down sensor is triggered and the platter lift sensor is turned off.

7. Power is turned on to the pallet clamp/unclamp solenoid located at the rear of the machine.

8. The clamp air pressure is released from the clamp side of the receiver piston and 100 PSI of air is applied to the unclamp side of the receiver piston.

9. The clamp plate rises.

10. When the clamp plate moves approximately .400" it will trigger the pallet unclamp sensor . The sensor sends a signal to the CNC control, that the clamp plate is in the unclamp position. A sensor assembly located on the bottom of the A-axis monitors the clamp plate position.

1 1. APC door switch & load station lock switch are checked.

12. The H-frame down solenoid & safety solenoid turn off.

13. The H-frame up solenoid turns on.

14. Air pressure in the air cylinder rotates the top cam, by rot ating the seal housing. The bottom cam does not rotate.

16. The cage & 3 balls rotate at half speed of the cam, forcing the cams to separate.

17. The top cam raises the H-frame by lifting upward on the hub, using the tapered bearing as a thrust bearing.

18. The H-frame engages and raises both pallets as it is raised.

19. The APC shaft does not rise. The hub slides up the shaf t on the 4 ball bearings. The flat tang of the apc shaft slides inside a slot in the cycloid hub.

20. The H-frame Up-switch checks H-frame up status. As the H-frame rises, the lock pin comes out of the hole in the bumper mount, so the H-frame can rotate.

21. Once the H-frame up switch indicates up, the air blast solenoid is turned on, and sends air blowing thru the air blast assembly at the top of the receiver.

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22. The servomotor rotates the H-frame and pallets 180 deg., by driving through the gearbox, torque tube, & hub, while the apc shaft, cycloid hub, and part of the gearbox remain stationary .

The servomotor rotates with the assembly .

23. The H-frame down switch gets a momentary false signal as it rot ates past the t ang on the APC shaft approximately mid stroke, which the software ignores.

24. The safety solenoid, which is off, prevents the H-frame from suddenly lowering in the event of a power failure by blocking the vent port of the h frame up solenoid.

25. When it has rotated 180 degrees, the servomotor stops, and holds position. The encoder on the servomotor determines the rotational position.

26. The H-frame up solenoid is turned off.

27. The H-frame down solenoid and safety solenoids are turned on, pressurizing the other side of the air cylinder while venting the side previously pressurized.

28. The top cam is rotated back to its original position, allowing the H-frame and p allets to lower . As the H-frame lowers, a lock pin under the H-frame drops into a hole in the bumper mount. It keeps the H-

frame from being moved while the servo power is off.

29. The pallet in the machine is lowered onto the receiver and the pallet on the load station is lowered onto the index-disc pallet-pins.

30. Power is turned off to the clamp/unclamp solenoid and air blast solenoids located at the rear of the machine.

31. The unclamp air pressure is exhausted from the unclamp side of the receiver piston and air blast is turned off while simultaneously applying 100 PSI of air pressure to the clamp side of the receiver piston.

32. The clamp plate moves down to clamp the pallet. The clamp plate will move approximately .400" and clamp the pallet. It will trigger the pallet clamp sensor , indicating that the pallet is clamped. The clamp plate position is monitored by a sensor assembly located on the bottom of the A axis.

33. The load station lock plate prevents the load station pallet from falling off if it is rocked severely while loading parts.

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EC-300 PALLET C HANGER

Introduction

Clamp Plate

Table Clamp Springs

Clamp Piston

Air Unclamp Exhaust

Unclamped

Operation

Note: Pallet is pulled down by clamp plate. The table trips the clamp switch, not the clamp plate

1. T able Indexes into position based on servo control parameters.

• Clamp plate is in un-clamp position; it is held there by air pressure compressing the springs.

• Clamp status switch plunger is away from the Normally Open (NO) proximity switch.

2. When ta0ble is in position, the solenoid valve actuates to pressurize the clamp side of the piston. A combination of air pressure and spring force combine to clamp the table (approximately 10,000 pounds of clamp force depending on air pressure.

• The table lowers and contacts the clamp st atus switch plunger . The plunger is pushed down and trip s the normally open (NO) status switch to close contacts.

3. To unclamp, the solenoid switch shuttles to exhaust the clamp side and pressurize the unclamp side of the piston. The unclamp air pressure must compress the clamp springs to raise the clamp plate. For the first portion of the travel the springs between the table and the H-frame aid in raising the clamp plate.

•At the top of piston travel the clamp status switch plunger raises (it is pushed up by a spring) and comes clear of the proximity switch. The NO switch is now open and the table is ready to index.

Air Clamp Pressure

Springs and air clamp

Switch Normally Open

Clamped

Table Clamp Status Under Different Conditions

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Page 24

Table Clamp

A. Condition is clamped when machine is normally powered off or when first powered on or when table index is completed.

Power On

Sol

Pressure

Safety Valve

Sol

Power On

Blocked

B. Condition when machine is unclamped

• Note: Same condition applies if table is unclamped and the machine is emergency stopped in the middle of a table index. The table remains unclamped.

No Power

Safety Valve

Pressure

Port Plugged

Sol

No Power

C. Condition when the table is unclamped and then power is lost.

• Main valve shuttles to clamp the table but the safety valve also loses power and blocks the exhaust port on the clamp side of the piston. This prevents the clamp plate from clamping immediately . The clamp plate will slowly move to its clamp position.

Troubleshooting

1. Failure - Clamp switch wires cut Result The control see the switch as open at all times. The table can index into position and clamp. The

control will not see the switch close therefore it assumes that the pallet is not clamped; an alarm will generate. Comment This is a safe condition; there is no threat of injury or machine damage. However , the machine will

not function until the switch is replaced.

2. Failure - The clamp status plunger rod is stuck in clamp position (broken rod, broken switch, stuck rod). The same scenario if an errant piece of metal keeps the switch tripped closed.

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Troubleshooting

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Result The clamp plate unclamps, raising the pallet. The machine is ready to rotate the pallet, but the control does not receive a signal that the table has raised. Without the signal the control thinks the pallet is clamped. After a period of time an alarm will be generated.

Comment - This is a safe condition; there is no threat of injury or machine damage. However the machine will not function until the plunger problem is corrected.

3. Failure Table index (pallet change) starts and then is E-stopped in the middle of indexing Result the clamp plate remains in the unclamp position. Comment This is a safe condition. To resume machining, clear the alarms and Zero Return all axes. The

machine will automatically home all axes and the clamp plate will clamp the table.

4. Failure - T able Indexer (p allet change) starts and then the machine is E-stopped and powered off. Result The clamp plate remains unclamped because the exhaust port on the unclamp side of the piston is

blocked (closed). In other words the clamp plate is being pressurized in order to clamp, but as the exhaust port is blocked this prevents the pallet from being clamped.

Comment This is initially a safe condition, however , due to leakage on the exhaust side of the piston the clamp plate will eventually move to its fully clamped position. It is not safe to leave the table partially over the table locator teeth. It should be rotated fully off of the clamp plate. This can be done by manually rotating the pallet changer.

5. Clamp valve solenoid loses power or burns up while machine is running and table is clamped. Result Table remains clamped upon attempting to unclamp the clamp plate will not rise and the clamp status

switch will show the table as “clamped”. The machine will generate an alarm. Comment This is a safe condition. The table will remain clamped. Machine will not function until solenoid is

replaced.

6. Failure The solenoid on the safety valve burns out or loses power when the table is clamped and the machine is operating.

Result The machine will continue to function normally . It will clamp and unclamp without incident. In the event the machine is E-Stopped in the middle of a t able index, the clamp plate remains unclamped. If power is lost or the machine is powered off during a table index the clamp plate will clamp.

Comment A failed safety circuit valve is not detect able. This is an unsafe condition as it is found only when the machine has already crashed.

7. Failure Table clamped and machine loses air pressure Result The low air-pressure alarm will reach its time limit and alarm-out the machine. If air is lost while the

machine is cutting, the table will remain clamped via the clamp springs. Comment The clamp springs are adequate to prevent the table from moving grossly off of the locating fingers.

8. Failure Table unclamped and the machine loses air during a pallet change. Result The low air pressure alarm will not alarm out the machine until it has reached its time limit. At the time

of air loss the clamp plate will lower to the clamped position via the clamp springs. Comment This is a dangerous condition. If the table is partially on or partially off of the clamp plate; potential

damage to the indexer can result. If the table is heading towards the clamp plate and the clamp plate lowers due to loss of air, a crash will result.

Troubleshooting

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1.5 AUTOMATIC T OOL C HANGER (ATC)

Refer to the alarm description when problems arise with the ATC See “Spindle” section for additional trouble shooting information.

CRASHING

Crashing of the ATC is usually a result of operator error. The most common A TC crashes is the p art or fixture on the mill table crashes into long tooling or into the ATC double arm during a tool change

• Inspect the pocket involved in the crash for damage and replace parts as necessary .

• The machine will normally home the Z-axis as part of the tool change sequence. Check Parameter 209 bit "TC Z NO HOME", and ensure it is set to zero.

SIDE M OUNT T OOL C HANGER R ECOVERY F LOW C HART

TOOL CHANGE RESTORE

SIDEMOUNT

pressing “TCR” button

if alarms

exist?

IS THERE A TOOL

IN THE ARM

OR THE SPINDLE

(Y/N)?

WILL THE ARM

PREVENTANY TOOL IN

THE SPINDLE OR THE POCKET FROM BEING

REMOVED (Y/N)?

THE TOOL MAY FALL DURING THE TOOL RECOVERY

PROCESS. PLACE SOMETHING SOFT UNDER TOOL

TO CATCH IT. DO NOT USE YOUR HANDS TO CATCHTHE TOOL.

PRESS ‘Y’ TO CONTINUE THE PROCESS

cnc waits for ‘Y’ before continuing

USE THE FOLLOWING COMMANDS UNTIL YOU CAN REMOVE

ALL THE TOOLS FROM THE SPINDLE AND THE ARM

CAROUSEL CAN BE MOVED WITH RIGHT AND LEFT ARROWS

ATCFWD. OR REV.- ROTATEARM FWD. OR REV.

TOOL RELEASE - TOGGLE TOOL UN/CLAMP

UP OR DOWN ARROW - MOVES PKT UP OR DOWN

ORIENT SPINDLE - SPINDLE ORIENTATION

NOTE IF YOU WANT TO MOVE THE SPINDLE UP OR DOWN,

THE ARM MUST BE ATORIGIN, AND YOU MUST EXIT

TL CHANGER RECOVERY

ARE YOU FINISHED USING COMMANDS (Y)?

cnc waits for ‘Y’ before continuing

ALARMS EXIST, THEY MUST BE CLEARED. PRESS ‘Y’ TO CONTINUE, THEN ‘RESET’ TO CLEAR ALARMS THEN RETRY

arm at origin?

ATORIGIN,

CONTINUE TO PKT

RESTORE (Y)?

The “atc fwd/rev” can

still move arm at this

time.

cnc waits for ‘Y’ before

continuing

carousel between

pockets?

RESTORING POCKETS, PLEASE WAIT

CHECK CURRENT CAROUSEL POCKET, ENTER CURRENT POCKET NUMBER, THEN PRESS THE ‘ENTER’KEY.

SIDEMOUNT MILL TOOL RECOVERY SCREEN TEXT = UPPER CASE ACTIONS - DECISIONS = LOWER CASE S = SITUATION M = NEXT MODE

PRESS LEFT OR RIGHTARROW KEY TO MOVE CAROUSEL OR PRESS ‘WRITE’

TO CONTINUE WITH AUTOMATIC RECOVERY cnc waits for ’write’ before continuing

TOOL CHANGE RECOVERY COMPLETE! PRESS ‘Y’TO CONTINUE PLEASE UPDATE POCKET & TOOL PAGE

carousel between

pockets?

offset page with pockets displayed

move to next

pocket

END

orient spindle

pressed

REMOVE ALL TOOLS FROM ARM AND SPINDLE

USE TOOL RELEASE BUTTON WHILE HOLDING TOOL TO

REMOVE ANY TOOL FROM SPINDLE

DEPRESS TOOL-CLAMP-RELEASE STUD ON ARM WHILE

HOLDING TOOL AND SLIDE TOOL OUT. NOTE THERE IS

ATOOL-CLAMP-RELEASE STUD FOR EACH END OF ARM

ARE ALL THE TOOLS REMOVED (Y)?

cnc waits for ‘Y’ before continuing

arm at origin?

96-0189 rev L June 2005

USE ATC FWD/REV TO ROTATE ARM TO ORIGIN

ABOUT TO ORIENT THE

SPINDLE CAUTION! THIS MAY

DAMAGE THE TOOLARM IF

SPINDLE INTERFERES WITH ITS

MOTION PRESS ‘O’ TO ORIENT,

‘N’TO CANCEL

‘N’or ‘O’

orient spindle

Troubleshooting

Page 27

1.6 THROUGH THE S PINDLE C OOLANT

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 warranty on new machines. Notify HAAS Service Department if machine is being used for this application.

COOLANT O VERFLOW

Check the alarm history to determine the cause of the problem before any action is taken.

Coolant pouring out of spindle head

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

• Check the purge and drain lines connected to the seal housing are intact; if not replace.

• Check the TSC coolant union. If failure is found, replace the coolant union.

• Check pre-charge pressure in accordance with TSC "Precharge 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 [2068 kilosascals]), with a standard (non-TSC) tool holder in spindle. If pump pressure is above 310 psi, reset the pump relief valve.

Excessive coolant flow out of drain line or pulsating flow through tool and drain line

• Check pre-charge pressure in accordance with TSC "Precharge Regulator Adjustment" section. Reset precharge pressure if necessary . Low pre-charge pressure will cause heavy or pulsating flow from the drain line. Check main air pressure regulator for 85 psi [241 kilopascals]. A higher supply pressure will reduce precharge pressure. Lower supply pressure will increase precharge pressure.

• 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 [2068 kilosascals]), with a standard tool holder in spindle. If pump pressure is above 310 psi [2137 kilopascals], reset the pump relief valve.

LOW C OOLANT

Alarm 151, "Low Thru Spindle Coolant"

• Check coolant tank level. Check for slow coolant drainage from the machine enclosure.

• Check the filter and intake strainer for any clogging. Read filter gauges with TSC running with no tool in spindle. Check coolant lines for any clogging or kinking. Clean or replace as needed.

• Check for overheating TSC pump motor . Three phase motors have a thermal circuit that will interrupt power to the relay coil.

• If received at start-up, check that the breaker has not tripped and that the pump is turning. Check the electrical continuity of cables.

• Check for pressure switch failure (refer to "T esting the Coolant Pressure Switch" section), and replace if necessary . Check the electrical continuity of the switch cable and the control function by monitoring the "LO CLNT" bit on the Diagnostics page (0 = pressure on, 1= pressure off). Shorting the leads should cause the bit to switch from 1 to 0. Check this before replacing the pressure switch. Leaking switches can give intermittent alarms.

• Check pump pressure with no tool in the spindle. If the pressure is less than 60 psi, replace the pump.

• May be generated if another machine alarm occurs during TSC operation.

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PRE-CHARGE F AILURE

Alarm 198, "Precharge Failure"

NOTE: This alarm only applies to the TSC system.

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

• Check if the "Tool Clamped" limit switch is sticking; replace if necessary.

• Check the "T ool Clamped" limit switch adjustment (refer to "Tool Clamp/Unclamp Switch Adjustment").

• Check for low pre-charge pressure (refer to "Precharge Regulator Adjustment" section).

• Check pre-charge solenoid for proper operation.

• May be generated if another machine alarm occurs during TSC operation.

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Troubleshooting

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1.7 ELECTRICAL T ROUBLESHOOTING

CAUTION! Before working on any electrical components, power off the machine and

wait approximately 10 minutes. This will allow the high voltage power on the brushless amplifiers to be discharged.

ELECTRICAL A LARMS

Axis Drive Fault Alarm

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

• Amplifier or MOCON is noise sensitive. If this is the case, the alarm can be cleared and the axis

will run normally for a while.

T o 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.

• 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 .

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.

Axis Overload

• The fuse function built into the MOCON has been overloaded, due to a lot of motor accel/decels, or

hitting a hard stop with the axis. This safety function protects the amplifier and motor , so find the cause and correct it. If the current program is the cause, change the program. If the axis hits a hard stop, the travel limits may be set wrong.

Phasing Error

• The MOCON did not receive the proper phasing information from the motors. DO NOT RESET the

machine if this alarm occurs. Power the machine down and back up. If the problem persists, it is probably a broken wire or faulty MOCON connectors. This problem could also be related to the Low Volt age Power Supply . Check to see if the LVPS is functioning properly.

Servo Error Too Large

• This alarms occurs when the difference between the commanded axis position and the actual

position becomes larger than the maximum that is set in the parameter .

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

Axis Z Fault or Z Channel Missing

• During a self-test, the number of encoder counts was found to be incorrect. This is usually caused

by a noisy environment, and not a bad encoder. Check all shields and grounds on the encoder cables and the motor leads that come into the amplifiers. An alarm for one axis can be caused by a bad grounding on the motor leads of another axis.

Axis Cable Fault

• During a self-test, the encoder cable signals were found to be invalid. This alarm is usually caused

by a bad cable, or a bad connection on the motor encoder connectors. Check the cable for any breaks, and the encoder connectors at the motor controller board. Machine noise can also cause this alarm, although it is less common.

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Alarm 101, "MOCON Comm. Failure"

• During a self-test of communications between the MOCON and main processor , the main proces-

sor does not respond, and is suspected to be dead. This alarm is generated and the servos are stopped. Check all ribbon cable connections, and all grounding. Machine noise can also cause this alarm, although it is less common.

Alarm 157, "MOCON Watchdog Fault"

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

Rotary CRC Error Alarm 261

• This alarm is normally the result of an incomplete software installation. To correct this error,

Change Setting 30 to any selection but OFF (note the original selection). Then go to parameter 43 and change one of the bits from 1 to 0 or vice versa and press WRITE (The bit must be changed from its original value to its alternate value). Simply changing the Setting and Parameter bit from one value to another and then back again corrects the fault, and will clear any further occurrences of the alarm. Change the bit and Setting 30 back to their original values. Press Reset to clear the alarms or cycle power to the machine.

SAVING THE M ACHINE I NFORMATION

T o review a machine’ s set-up save the parameters, settings, offsets, variables and G-code programs and alarm history to a floppy disk. To do this, insert a blank diskette, press LISTPROG , POSIT, enter the machine's serial number and press F2. The new file suffix will be “.HIS”.

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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 P AGE UP and P AGE DOWN buttons can be used to move through a large number of alarms. The CURSOR right and left buttons can be used to turn on and off the ALARM history display .

Note that tool changer alarms can be easily corrected by first correcting any mechanical problem, pressing RESET until the alarms are clear , selecting ZERO RET mode, and selecting AUTO ALL AXES. Some messages are displayed while editing to tell the operator what is wrong but these are not alarms. See the editing topic for those errors.

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

101 COMM. FAILURE WITH MOCON/MOCON MEMOR Y F AUL T During a self-test of communications between the MOCON and main processor the main processor does not respond, and one of them is possibly bad. Check cable connections and boards. This alarm could also be caused by a memory fault, which was detected on the MOCON.

102 SERVOS OFF Indicates that the servo motors are off, the tool changer is disabled, the coolant pump is off, and the spindle motor is stopped. Caused by EMERGENCY STOP, motor fault, or power failure.

103 X SERVO ERROR TOO LARGE Too much load or speed on X-axis motor. The difference between the motor position and the commanded position has exceeded Parameter 9 X-axis Max Error. 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 Too much load or speed on Y-axis motor. The difference between the motor position and the commanded position has exceeded Parameter 23. 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.

105 Z SERVO ERROR TOO LARGE Too much load or speed on Z-axis motor. The difference between the motor position and the commanded position has exceeded Parameter 37. 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.

106 A SERVO ERROR TOO LARGE Too much load or speed on A-axis motor. The difference between the motor position and the commanded position has exceeded Parameter 51. 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.

107 EMERGENCY OFF EMERGENCY STOP button was pressed. Servos are also turned off. Af ter the E-STOP is released, the RESET button must be pressed at least twice to correct this; once to clear the E-STOP alarm and once to clear the Servo Off alarm. This alarm will also be generated if there is a low-pressure condition in the hydraulic counterbalance system. In this case, the alarm will not reset until the condition has been corrected.

108 X SERVO OVERLOAD Excessive load on X-axis motor. This can occur if the load on the motor over a period of several seconds or even minutes is large enough to exceed the continuous rating of the motor. The servos will be turned off when this occurs. This can be caused by running into the mechanical stops. It can also be caused by anything that causes a very high load on the motors.

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109 Y SERVO OVERLOAD Excessive load on Y-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. It can also be caused by anything that causes a very high load on the motors.

110 Z SERVO OVERLOAD Excessive load on Z-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. It can also be caused by anything that causes a very high load on the motors.

111 A SERVO OVERLOAD Excessive load on A-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. It can also be caused by anything that causes a very high load on the motors.

112 NO INTERRUPT Electronics fault. Call your dealer. 113 SHUTTLE IN FAULT Tool changer is not completely to the right. During a tool changer operation the tool in/out

shuttle failed to get to the in position. Parameters 62 and 63 can adjust the time-out times. This alarm can be caused by anything that jams the motion of the slide or by the presence of a tool in the pocket facing the spindle. A loss of power to the tool changer can also cause this. Check relays K9-K12 and fuse F1 on IOPCB.

114 SHUTTLE OUT FAULT Tool changer is not completely to the left. During a tool changer operation the tool in/out shuttle failed to get to the in position. Parameters 62 and 63 can adjust the time-out times. This alarm can be caused by anything that jams the motion of the slide or by the presence of a tool in the pocket facing the spindle. A loss of power to the tool changer can also cause this. Check relays K9-K12 and fuse F1 on IOPCB.

115 TURRET ROTATE FAULT 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. Check relays K9-K12 and fuse F1 on IOPCB.

116 SPINDLE ORIENTATION FAULT Spindle did not orient correctly. During a spindle orientation function, the spindle rotated but never achieved proper orientation. This can be caused by failure of encoder, cables, belts, MOCON or vector drive.

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

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

119 OVERVOLTAGE 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 persists, an automatic shutdown will begin after the interval specified by parameter 296.

120 LOW AIR PRESSURE Air pressure dropped below 80 PSI for a period defined by Parameter 76. The LOW AIR PR alarm will appear on the screen as soon as the pressure gets low, and this alarm appears after some time has elapsed. Check your incoming air pressure for at least 100 PSI and ensure that the regulator is set at 85 PSI.

121 LOW LUBE OR LOW PRESSURE Way lube is low or empty or there is no lube pressure or too high a pressure. Check tank at rear of mill and below control cabinet. Also check connector on the side of the control cabinet. Check that the lube lines are not blocked.

122 REGEN OVERHEAT The regenerative load temperature is above a safe limit. This alarm will turn off the 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 persists, an automatic shutdown will begin after the interval specified by parameter 297. It can also be caused by a high start/stop duty cycle of spindle.

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123 SPINDLE DRIVE FAULT Failure of spindle drive, motor or regen load. This can be caused by a shorted motor, overvoltage, overcurrent, undervoltage, failure of drive or shorted or open regen load. Undervoltage and overvoltage of DC bus are also reported as alarms 160 and 119, respectively.

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

125 SHUTTLE FAULT Tool shuttle not initialized at power on, CYCLE START or spindle motion command. This means that the tool shuttle was not fully retracted to the Out position.

126 GEAR FAULT Gearshifter is out of position when a command is given to start a program or rotate the spindle. This means that the two speed gear box is not in either high or low gear but is somewhere in between. Check the air pressure, the circuit breaker CB4 for the solenoids, and the spindle drive. Use the POWER UP/RESTART button to correct the problem.

127 NO TURRET MARK Tool carousel motor not in position. The AUTO ALL AXES button will correct this but be sure that the pocket facing the spindle afterwards does not contain a tool.

128 SUPER TRAVEL ENABLED ON MUL TIPLE AXES T wo or more axes are enabled for super travel. Only one axis is allowed to have super travel capability. Super travel is enabled when a tool change offset parameter, is greater than or less than normal travel limits. Check the Max Travel and Tool Change Offset parameter values for the X and Y axes.

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

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

131 TOOL NOT CLAMPED When clamping or powering up the machine, the Tool Release Piston is not Home. There is a possible fault in the air solenoids, relays on the I/O 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 the Power Interface (POWIF) card on power supply assembly, relays on the I/O assembly, and the main contactor K1.

133 SPINDLE INOPERATIVE Spindle does not respond when spindle motion is commanded. This can be caused by failure of encoder, cables, belts, MOCON or vector drive.

134 TOOL CLAMP FAULT While UNCLAMPING, the tool did not release from spindle when commanded. Check air pressure and solenoid circuit breaker CB4. This fault can also be caused by maladjustment of the drawbar assembly.

135 X-AXIS MOTOR OVERHEAT Servo motor overheat. The temperature sensor in the motor indicates over 150 degrees F (65 deg. C). This can be caused by an extended overload of the motor such as leaving the slide at the stops for several minutes.

136 Y-AXIS MOTOR OVERHEAT Servo motor overheat. The temperature sensor in the motor indicates over 150 degrees F (65 deg. C). This can be caused by an extended overload of the motor such as leaving the slide at the stops for several minutes.

137 Z-AXIS MOTOR OVERHEAT Servo motor overheat. The temperature sensor in the motor indicates over 150 degrees F (65 deg. C). This can be caused by an extended overload of the motor such as leaving the slide at the stops for several minutes.

138 A-AXIS MOTOR OVERHEAT Servo motor overheat. The temperature sensor in the motor indicates over 150 degrees F (65 deg. C). This can be caused by an extended overload of the motor such as leaving the slide at the stops for several minutes.

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139 X MOTOR Z FAULT Encoder marker pulse count failure. This alarm usually indicates that the encoder has been damaged and encoder position data is unreliable. This can also be caused by loose encoder connectors.

140 Y MOTOR Z FAULT Encoder marker pulse count failure. This alarm usually indicates that the encoder has been damaged and encoder position data is unreliable. This can also be caused by loose encoder connectors.

141 Z MOTOR Z FAULT Encoder marker pulse count failure. This alarm usually indicates that the encoder has been damaged and encoder position data is unreliable. This can also be caused by loose encoder connectors.

142 A MOTOR Z FAULT Encoder marker pulse count failure. This alarm usually indicates that the encoder has been damaged and encoder position data is unreliable. This can also be caused by loose encoder connectors.

143 SPINDLE ORIENTATION LOST Spindle orientation lost during a tool change operation. This can be caused by failure of encoder, cables, belts, MOCON or vector drive.

144 TIMEOUT - CALL YOUR DEALER T ime allocated for use prior to payment exceeded. Call your dealer. 145 X LIMIT SWITCH Axis hit limit switch or switch disconnected. The stored stroke limits should stop the slides

before they hit the limit switches. Verify the value of parameter 125 Grid Offset and check the wiring to the limit switch and connector P5 at the side of the main cabinet. Can also be caused by a loose encoder shaft at the back of the motor or coupling of motor to the screw.

146 Y LIMIT SWITCH Axis hit limit switch or switch disconnected. The stored stroke limits should stop the slides before they hit the limit switches. Verify the value of parameter 126 Grid Offset and check the wiring to the limit switch 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.

147 Z LIMIT SWITCH Axis hit limit switch or switch disconnected. The stored stroke limits should stop the slides before they hit the limit switches. Verify the value of parameter 127 Grid Offset and check the wiring to the limit switch 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.

148 A LIMIT SWITCH Normally disabled for rotary axis. 149 SPINDLE TURNING A signal from spindle drive indicating that the spindle drive is stopped is not present while a

tool change operation is going on. 150 Z AND TOOL INTERLOCKED Tool changer not at home and either the Z or A or B axis (or any combination) is not

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

151 LOW THRU SPINDLE COOLANT For machines with Through the Spindle Coolant only. This alarm will shut off the coolant spigot, 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. Verify proper pump and machine phasing. If no problems are found with any of these, and none of the coolant lines are clogged or kinked, call your dealer.

152 SELF TEST FAIL Control has detected an electronics fault. All motors and solenoids are shut down. This is most likely caused by a fault of the processor board stack. Call your dealer.

153 X AXIS Z CH MISSING Z Reference signal from encoder was not received as expected. Can be caused by loose connections, encoder contamination, or parameter error.

154 Y AXIS Z CH MISSING Z Reference signal from encoder was not received as expected. Can be caused by loose connections, encoder contamination, or parameter error.

155 Z AXIS Z CH MISSING Z Reference signal from encoder was not received as expected. Can be caused by loose connections, encoder contamination, or parameter error.

156 A AXIS Z CH MISSING Z Reference signal from encoder was not received as expected. Can be caused by loose connections, encoder contamination, or parameter error.

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157 MOCON WATCHDOG FAULT The self-test of the MOCON has failed. Call your dealer. 158 VIDEO/KEYBOARD PCB FAILURE During power-on tests, the control has detected a problem in either the

keyboard or the video memory. Call your dealer. 159 KEYBOARD FAILURE Keyboard shorted or button pressed at power on. A power-on test of the membrane

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

160 LOW VOLTAGE The line voltage to control is too low. This alarm occurs when the AC line voltage drops more than 10% below nominal.

161 X AXIS DRIVE FAULT Current in X servo motor beyond limit. Possibly caused by a stalled or overloaded motor. The servos are turned off. This can be caused by running the axis into a mechanical stop. A short in the motor or a short of one motor lead to ground can also cause it.

162 Y AXIS DRIVE FAULT Current in Y servo motor beyond limit. Possibly caused by a stalled or overloaded motor. The servos are turned off. This can be caused by running the axis into a mechanical stop. A short in the motor or a short of one motor lead to ground can also cause it.

163 Z AXIS DRIVE FAULT Current in Z servo motor beyond limit. Possibly caused by a stalled or overloaded motor. The servos are turned off. This can be caused by running the axis into a mechanical stop. A short in the motor or a short of one motor lead to ground can also cause it.

164 A AXIS DRIVE FAULT Current in A servo motor beyond limit. Possibly caused by a stalled or overloaded motor. The servos are turned off. This can be caused by running the axis into a mechanical stop. A short in the motor or a short of one motor lead to ground can also cause it.

165 X ZERO RET MARGIN TOO SMALL This alarm will occur if the home/limit switches move or are misadjusted. This alarm indicates that the zero return position may not be consistent from one zero return to the next. The encoder Z channel signal must occur between 1/8 and 7/8 revolution of where the home switch releases. This will not turn the servos off but will stop the zero return operation.

166 Y ZERO RET MARGIN TOO SMALL 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.

167 Z 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.

168 A ZERO RET MARGIN TOO SMALL This alarm will occur if the home/limit switches move or are misadjusted. This alarm indicates that the zero return position may not be consistent from one zero return to the next. The encoder Z channel signal must occur between 1/8 and 7/8 revolution of where the home switch releases. This will not turn the servos off but will stop the zero return operation.

169 SPINDLE DIRECTION FAULT Problem with rigid tapping hardware. The spindle started turning in the wrong direction.

171 APC-P ALLET CLAMP TIMEOUT The pallet in the mill did not clamp in the time allowed. Check for foreign objects under the pallet and between the pallet and the clamp plate. Verify there is an adequate supply of air pressure and air volume. Check air solenoids for sticking and air release ports for clogging. Check the pallet position switch for correct operation, the switch and wiring for damage, and pallet alignment. Check the pallet clamp mechanism for correct operation. After determining the cause and correcting the problem, run M50 P1 in MDI to recover the pallet changer and then continue operation. Parameter 320 specifies the pallet clamp timeout period.

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172 APC-PALLET UNCLAMP TIMEOUT The pallet in the mill did not unclamp in the time allowed. Check for foreign objects between the pallet and the clamp plate. V erify there is an adequate supply of air pressure and air volume. Check air solenoids for sticking and air release ports for clogging. Check the pallet position switch for correct operation, the switch and wiring for damage and pallet alignment. Check the pallet clamp plate for damage. After determining the cause and correcting the problem, run M50 P1 in MDI to recover the p allet changer and then continue operation. Parameter 321 specifies the unclamp timeout period.

173 SPINDLE ENCODER Z CH MISSING The Z channel pulse from the spindle encoder is missing for hard tapping synchronization.

174 TOOL LOAD EXCEEDED The tool load limit is set and the load limit for a tool was exceeded in a feed. 175 GROUND FAULT DETECTED A ground fault condition was detected in the 115V AC supply. This can be caused by a

short to ground in any of the servo motors, the tool change motors, the fans, or the oil pump. 176 OVERHEAT SHUTDOWN An overheat condition persisted longer than the interval specified by parameter 297 and

caused an automatic shutdown. 177 OVERVOLTAGE SHUTDOWN An overvoltage condition persisted longer than the interval specified by parameter

296 and caused an automatic shutdown. 178 DIVIDE BY ZERO! There are some parameters that are used as a divisor and therefore must never be set to zero.

If the problem cannot be corrected by parameters, cycle power on the machine. If the alarm reoccurs, call your dealer and report the sequence of events that lead to the alarm.

179 LOW PRESSURE TRANS OIL Transmission oil is low or low pressure condition in oil lines. 180 P ALLET/FIXTURE NOT CLAMPED The Pallet/Fixture clamped input indicates that the p allet or fixture is not

clamped and it is unsafe to run the spindle, jog an axis, or start a part program by pressing CYCLE START. This could also indicate that a previous pallet change was incomplete and the pallet changer needs to be recovered.

182 X CABLE FAULT Cable from X-axis encoder does not have valid differential signals. 183 Y CABLE FAULT Cable from Y-axis encoder does not have valid differential signals. 184 Z CABLE FAULT Cable from Z-axis encoder does not have valid differential signals. 185 A CABLE FAULT Cable from A-axis encoder does not have valid differential signals. 186 SPINDLE NOT TURNING Status from spindle drive indicates it is not at speed when expected. 187 B SERVO ERROR TOO LARGE Too much load or speed on B axis motor. The difference between the motor

position and the commanded position has exceeded Parameter 159. 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. On machines with servo based tool changer chains the chain was unable to move. On Machines with servo based tool changer arms the arm was unable to move possibly due to a stuck tool.

188 B SERVO OVERLOAD Excessive load on B-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. It can also be caused by anything that causes a very high load on the motors.

189 B-AXIS MOTOR OVERHEAT 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.

190 B MOTOR Z FAULT Encoder marker pulse count failure. This alarm usually indicates that the encoder has been damaged and encoder position data is unreliable. This can also be caused by loose encoder connectors.

191 B LIMIT SWITCH Normally disabled for rotary axis.

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192 B AXIS Z CH MISSING Z reference signal from encoder was not received as expected. Can be caused by loose connections, encoder contamination, or parameter error.

193 B AXIS DRIVE FAULT Current in B servo motor beyond limit. Possibly caused by a stalled or overloaded motor. The servos are turned off. This can be caused by running the axis into a mechanical stop. A short in the motor or a short of one motor lead to ground can also cause it.

194 B ZERO RET MARGIN TOO SMALL This alarm will occur if the home/limit switches move or are misadjusted. This alarm indicates that the zero return position may not be consistent from one zero return to the next. The encoder Z channel signal must occur between 1/8 and 7/8 revolution of where the home switch releases. This will not turn the servos off but will stop the zero return operation.

195 B CABLE FAULT Cable from B-axis encoder does not have valid differential signals. 196 COOLANT SPIGOT FAILURE Spigot failed to achieve commanded location after two (2) attempts. 197 MISC. SOFTWARE ERROR This alarm indicates an error in the control software. Call your dealer. 198 PRECHARGE FAILURE During TSC operation, the precharge failed for greater than 0.1 seconds. It will shut off the

feed, spindle and pump all at once. Check all airlines and the air supply pressure. Also, check 3-phase power phasing.

199 NEGATIVE RPM A negative spindle RPM was sensed. 201 P ARAMETER CRC ERROR Parameters lost maybe by low battery. Check for a low battery and low battery alarm. 202 SETTING CRC ERROR Settings lost maybe by low battery. Check for a low battery and low battery alarm. 203 LEAD SCREW CRC ERROR Lead screw compensation tables lost maybe by low battery. Check for low battery and

low battery alarm.

204 OFFSET CRC ERROR Offsets lost maybe by low battery. Check for a low battery and low battery alarm. 205 PROGRAMS CRC ERROR Users program lost maybe by low battery. Check for a low battery and low battery alarm. 206 INTERNAL PROG ERROR Possible corrupted program. Save all programs to disk, delete all, then reload. Check

for a low battery and low battery alarm. 207 QUEUE ADVANCE ERROR Cycle power on the machine. If the alarm reoccurs, call your dealer and report the

sequence of events that lead to the alarm. 208 QUEUE ALLOCATION ERROR Cycle power on the machine. If the alarm reoccurs, call your dealer and report the

sequence of events that lead to the alarm. 209 QUEUE CUTTER COMP ERROR Cycle power on the machine. If the alarm reoccurs, call your dealer and report the

sequence of events that lead to the alarm. 210 INSUFFICIENT MEMORY Not enough memory to store users program. Check the space available in the LIST

PROG mode and possibly delete some programs.

211 ODD PROG BLOCK Possible corrupted program. Save all programs to disk, delete all, then reload. 212 PROG INTEGRITY ERROR Possible corrupted program. Save all programs to disk, delete all, then reload. Check

for a low battery and low battery alarm.

213 PROGRAM RAM CRC ERROR Electronics fault; possibly with main processor. 214 NO. OF PROGRAMS CHANGED Indicates that the number of programs disagrees with the internal variable that

keeps count of the loaded programs. Possible processor board problem. 215 FREE MEMORY PTR CHANGED Indicates that the amount of memory used by the programs counted in the system

disagrees with the variable that points to free memory. Possible processor board problem

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216 EPROM SPEED FAILURE Possible processor board problem 217 X PHASING ERROR Error occurred in phasing initialization of brushless motor. This can be caused by a bad

encoder, or a cabling error. 218 Y PHASING ERROR Error occurred in phasing initialization of brushless motor. This can be caused by a bad

encoder, or a cabling error. 219 Z PHASING ERROR Error occurred in phasing initialization of brushless motor. This can be caused by a bad

encoder, or a cabling error. 220 A PHASING ERROR Error occurred in phasing initialization of brushless motor. This can be caused by a bad

encoder, or a cabling error. 221 B PHASING ERROR Error occurred in phasing initialization of brushless motor. This can be caused by a bad

encoder, or a cabling error. 222 C PHASING ERROR Error occurred in phasing initialization of brushless motor. This can be caused by a bad

encoder, or a cabling error. 223 DOOR LOCK FAILURE In machines equipped with safety interlocks, this alarm occurs when the control senses

the door is open but it is locked. Check the door lock circuit. 224 X TRANSITION FAULT Illegal transition of encoder 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 printed circuit board.

225 Y TRANSITION FAULT Illegal transition of encoder count pulses in Y 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 printed circuit board.

226 Z TRANSITION FAULT Illegal transition of encoder count pulses in Z 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 printed circuit board.

227 A TRANSITION FAULT Illegal transition of encoder count pulses in A 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 printed circuit board.

228 B TRANSITION FAULT Illegal transition of count pulses in B 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 printed circuit board.

229 C TRANSITION FAULT Illegal transition of count pulses in C 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 printed circuit board.

231 JOG HANDLE TRANSITION FAULT Illegal transition of count pulses in jog handle encoder. This alarm usually indicates that the encoder has been damaged and encoder position data is unreliable. This can also be caused by loose connectors.

232 SPINDLE TRANSITION FAULT Illegal transition of count pulses in spindle encoder. This alarm usually indicates that the encoder has been damaged and encoder position data is unreliable. This can also be caused by loose connectors at the MOCON.

233 JOG HANDLE CABLE FAULT Cable from jog handle encoder does not have valid differential signals. 234 SPINDLE CABLE FAULT Cable from spindle encoder does not have valid differential signals. 235 SPINDLE Z FAULT Encoder marker pulse count failure. This alarm usually indicates that the encoder has been

damaged and encoder position data is unreliable. This can also be caused by loose encoder connectors.

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236 SPINDLE MOTOR OVERLOAD The spindle motor is overloaded. 237 SPINDLE FOLLOWING ERROR The error between the commanded spindle speed and the actual speed has

exceeded the maximum allowable (as set in Parameter 184). 238 AUTOMATIC DOOR FAULT The automatic door was commanded to operate, but did not complete the operation.

The door was: 1) Commanded to close but failed to contact the closed switch in the time allowed, 2) Commanded to open but failed to contact the opened switch (not all doors have an opened switch) in the time allowed, or 3) Commanded to open but did not begin moving in the time allowed. Check the door switch, the door for mechanical binding, and that the door motor and clutch are functioning correctly.

239 UNKNOWN MOCON1 ALARM Mocon has reported an alarm to the current software. The current version of software was unable to identify the alarm.

240 EMPTY PROG OR NO EOB DNC program not found, or no end of program found. 241 INVALID CODE RS-232 load bad. Data was stored as comment. Check the program being received. 242 NUMBER FORMAT ERROR-OR T OO LONG Check input file for an improperly formatted number . Number may have

too many digits or multiple decimal points. The erroneous data will be placed on the MESSAGES page as a comment with trailing question mark.

243 BAD NUMBER Data entered is not a number . 244 MISSING (...) Comment must end with a “)”. This alarm can also occur if a comment is greater than 80 characters

long. 245 UNKNOWN CODE Check input line or data from RS-232. This alarm can occur while editing data into a program

or loading from RS-232. See MESSAGE PAGE for input line.

246 STRING TOO LONG Input line is too long. The data entry line must be shortened. 247 CURSOR DA TA BASE ERROR Cycle power on the machine. If the alarm reoccurs, call your dealer and report the

sequence of events that lead to the alarm.

248 NUMBER RANGE ERROR Number entry is out of range. 249 PROG DATA BEGINS ODD Possible corrupted program. Save all programs to disk, delete all, then reload. 250 PROG DATA ERROR Possible corrupted program. Save all programs to disk, delete all, then reload. 251 PROG DATA STRUCT ERROR Possible corrupted program. Save all programs to disk, delete all, then reload. 252 MEMORY OVERFLOW Possible corrupted program. Save all programs to disk, delete all, then reload. 253 ELECTRONICS OVERHEAT The control box temperature has exceeded 135 degrees F (60 deg. C). This can be

caused by an electronics problem, high room temperature, or clogged air filter. 254 SPINDLE MOTOR OVERHEAT Motor driving spindle is too hot. The spindle motor temperature sensor sensed a

high temperature for greater than 1.5 seconds. 255 NO TOOL IN SPINDLE There is an invalid tool number in the spindle entry of the POCKET-TOOL table. The

spindle entry cannot be 0 and must be listed in the body of the table. If there is no tool in the spindle, enter the number for an empty pocket into the spindle entry. If there is a tool number in the spindle entry, make sure that it is in the body of the table and that the pocket is empty.

256 CURRENT TOOL UNKNOWN Current tool information has been lost. This is most likely due to re-initialization. It is likely that the next commanded tool change will result in a collision between the spindle and a tool in a pocket. To eliminate the possibility of a crash, perform Tool Changer Restore. Do not use Power Up/Restart as this will cause the machine to try to return a tool to the carousel.

257 PROG DATA ERROR Possible corrupted program. Save all programs to disk, delete all, then reload.

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258 INV ALID DPRNT FORMA T Macro DPRNT statement not structured properly. 259 LANGUAGE VERSION Problem with language files. Please reload foreign language files. 260 LANGUAGE CRC Indicates FLASH memory has been corrupted or damaged. 261 ROTARY CRC ERROR Rotary table saved parameters (used by Settings 30, 78) have a CRC error. 262 PARAMETER CRC MISSING RS-232 or disk read of parameter had no CRC when loading from disk or RS-232. 263 LEAD SCREW CRC MISSING Lead screw compensation tables have no CRC when loading from disk or RS-232. 264 ROTARY CRC MISSING Rotary table parameters have no CRC when loading from disk or RS-232. 265 MACRO VARIABLE FILE CRC ERROR Macro variable file has a CRC error. Possible corrupted file 266 TOOL CHANGER FAUL T Run Tool Changer recovery. 267 TOOL DOOR OUT OF POSITION This alarm will be generated on a horizontal mill during a tool change when

parameter 278 TL DR SWITCH is set to 1, and the tool carousel air door switch indicates that the door is open after it was commanded closed, or closed after it was commanded open. This alarm will most likely be caused by a stuck or broken switch.

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

269 TOOL ARM FAULT The tool changer arm is not in position. Run tool changer recovery. 270 C SERVO ERROR TOO LARGE Too much load or speed on C-axis motor. The difference between the motor

position and the commanded position has exceeded Parameter 506. 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.

271 C SERVO OVERLOAD Excessive load on C-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 alarm can be caused by anything that causes a very high load on the motors.

272 C-AXIS MOTOR OVERHEAT 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.

273 C MOTOR Z FAULT Encoder marker pulse count failure. This alarm usually indicates that the encoder has been damaged and encoder position data is unreliable. This can also be caused by loose encoder connectors.

274 C LIMIT SWITCH Axis hit limit switch or switch disconnected. The stored stroke limits should stop the slides before they hit the limit switches. Verify the value of parameter Grid Offset and check the wiring to the limit switch 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.

275 C AXIS Z CH MISSING Z Reference signal from encoder was not received as expected. Can be caused by loose connections, encoder contamination, or parameter error.

276 C AXIS DRIVE FAULT Current in C servo motor beyond limit. Possibly caused by a stalled or overloaded motor. The servos are turned off. It can also be caused by a short in the motor or a short of one of the motor leads to ground.

277 C 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.

278 C CABLE FAULT Cable from C-axis encoder does not have valid differential signals.

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279 X AXIS LINEAR SCALE Z FAULT Encoder marker pulse count failure. This alarm usually indicates that the Z Fault encoder has been damaged and encoder position data is unreliable. This can also be caused by loose scale connectors.

280 Y AXIS LINEAR SCALE Z FAULT Encoder marker pulse count failure. This alarm usually indicates that the Z Fault encoder has been damaged and encoder position data is unreliable. This can also be caused by loose scale connectors.

281 Z AXIS LINEAR SCALE Z FAULT Encoder marker pulse count failure. This alarm usually indicates that the Z Fault encoder has been damaged and encoder position data is unreliable. This can also be caused by loose scale connectors.

282 A AXIS LINEAR SCALE Z FAULT Encoder marker pulse count failure. This alarm usually indicates that the Z Fault encoder has been damaged and encoder position data is unreliable. This can also be caused by loose encoder connectors.

283 X AXIS LINEAR SCALE Z CH MISSING Broken wires or encoder contamination. All servos are turned off. This Z Channel Missing can also be caused by loose scale connectors.

284 Y AXIS LINEAR SCALE Z CH MISSING Broken wires or encoder contamination. All servos are turned off. This Z Channel Missing can also be caused by loose encoder connectors.

285 Z AXIS LINEAR SCALE Z CH MISSING Broken wires or encoder contamination. All servos are turned off. This Z Channel Missing can also be caused by loose encoder connectors.

286 A AXIS LINEAR SCALE Z CH MISSING Broken wires or encoder contamination. All servos are turned of f. This Z Channel Missing can also be caused by loose encoder connectors.

287 X AXIS LINEAR SCALE CABLE F AULT Cable from X-axis scale does not have valid differential signals. 288 Y AXIS LINEAR SCALE CABLE F AULT Cable from Y-axis scale does not have valid differential signals. 289 Z AXIS LINEAR SCALE CABLE F AULT Cable from Z-axis scale does not have valid differential signals. 290 A AXIS LINEAR SCALE CABLE FAULT Cable from A-axis scale does not have valid dif ferential signals. 291 LOW AIR VOLUME/PRESSURE DURING ATC An Automatic Tool Change was not completed due to insufficient

volume or pressure of compressed air. Check air supply line. 292 320V POWER SUPPLY FAULT Power to the servos will be turned off when this alarm occurs. Note that error code

5 on the mini power supply may occur under this condition.

293 INVALID CHAMFER OR CORNER ROUNDING DIST ANCE IN G01 Check your geometry . 294 NO END MOVE FOR G01 CHAMFER CORNER ROUNDING A chamfer or corner rounding move was requested in a

G01 command, but no end move was commanded. 295 MOVE ANGLE TOO SMALL IN G01 CORNER ROUNDING Tangent of half angle is zero. Move Angle must be greater

than 1 deg. 296 INV ALID PLANE SELECTION IN G01 CHAMFER OR CORNER ROUNDING Chamfer or corner rounding move and

end move must be in the same plane as the beginning move. 297 ATC SHUTTLE OVERSHOOT The ATC shuttle has failed to stop within the allowable standby position window

during a tool change. Check for a loose drive belt, damaged or overheated motor, sticking or damaged shuttle standby switch or shuttle mark switch, or burned gear motor control board relay contacts. Use Tool Changer Restore to recover the ATC, then resume normal operation.

298 ATC DOUBLE ARM OUT OF POSITION The ATC double arm mark switch, CW position switch or CCW position switch is in an incorrect state. Check for sticking, misaligned or damaged switches, mechanism binding, damaged motor, or debris build up. Use Tool Changer Restore to recover the ATC, then resume normal operation.

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299 ATC SHUTTLE OUT OF POSITION The ATC shuttle mark switch is in an incorrect state. Check for a sticking, misaligned, or damaged switch, mechanism binding, damaged motor, or debris build up. Use Tool Changer Restore to recover the ATC, then resume normal operation.

302 INVALID R IN G02 OR G03 Check your geometry. R must be greater than or equal to half the distance from start to end with an accuracy of 0.0010 inches (0.010 mm.).

303 INVALID X, Y OR Z IN G02 OR G03 Check your geometry . 304 INV ALID I, J OR K IN G02 OR G03 Check your geometry. Radius at start must match radius at end of arc within

0.001 inches (0.01 mm.).

305 INV ALID Q IN CANNED CYCLE Q in a canned cycle must be greater than zero. 306 INV ALID I, J, K, OR Q IN CANNED CYCL I, J, K, and Q in a canned cycle must be greater than zero. 307 SUBROUTINE NESTING TOO DEEP Subprogram nesting is limited to nine levels. Simplify your program. 309 EXCEEDED MAX FEEDRA TE Use a lower feed rate. 310 INV ALID G CODE G code not defined and is not a macro call. 311 UNKNOWN CODE Program contained a line or code that is not understood. 312 PROGRAM END End of subroutine reached before M99. Need an M99 to return from subroutine. 313 NO P CODE IN M98, M97, M96, G47 OR G65 In M96, M97, M98 or G65 must put subprogram number in P code.

G47 must have P0 for text engraving or P1 for sequential serial number.

314 SUBPROGRAM NOT IN MEMORY Check that a subroutine is in memory or that a macro is defined. 315 INVALID P CODE IN M97, M98, G47, M99 The P code must be the name of a program stored in memory without a

decimal point for M98 and must be a valid N number for M99. If G47 command, then P must be a 0 for text engraving, 1 for sequential serial numbers or ASCII value between 32 and 126.

316 X OVER TRAVEL RANGE Commanded X-axis move would exceed the allowed machine range. Machine coordinates are in the negative direction. This condition indicates either an error in the user’s program or improper offsets.

317 Y OVER TRAVEL RANGE Commanded Y-axis move would exceed the allowed machine range. Machine coordinates are in the negative direction. This condition indicates either an error in the user’s program or improper offsets.

318 Z OVER TRAVEL RANGE Commanded Z-axis move would exceed the allowed machine range. Machine coordinates are in the negative direction. This condition indicates either an error in the user’s program or improper offsets.

319 A OVER TRAVEL RANGE Commanded A-axis move would exceed the allowed machine range. Machine coordinates are in the negative direction. This condition indicates either an error in the user’s program or improper offsets.

320 NO FEED RA TE Must have a valid F code for interpolation functions. 321 AUTO OFF ALARM Occurs in debug mode only. 322 SUB PROG WITHOUT M99 Add an M99 code to the end of program called as a subroutine. 323 ATM CRC ERROR Advanced Tool Management (ATM) variables lost maybe by low battery. Check for a low battery

and low battery alarm. 324 DELAY TIME RANGE ERROR P code in G04 is greater than or equal to 1000 seconds (over 999999 milliseconds).

This alarm can also be generated by entering an invalid M95 time format. 325 QUEUE FULL Cycle power on the machine. If the alarm reoccurs, call your dealer and report the sequence of

events that lead to the alarm.

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326 G04 WITHOUT P CODE Put a Pn.n for seconds or a Pn for milliseconds. 327 NO LOOP FOR M CODE EXCEPT M97, 98 L code not used here. Remove L Code. 328 INVALID TOOL NUMBER Tool number must be between 1 and the value in Parameter 65. 329 UNDEFINED M CODE That M code is not defined and is not a macro call. 330 UNDEFINED MACRO CALL Macro name O90nn not in memory. A macro call definition is in parameters and was

accessed by user program but that macro was not loaded into memory.

331 RANGE ERROR Number too large. 332 H AND T NOT MATCHED This alarm is generated when Setting 15 is turned ON and an H code number in a

running program does not match the tool number in the spindle. Correct the Hn codes, select the right tool, or turn off Setting 15.

333 X AXIS DISABLED Parameter has disabled this axis. 334 Y AXIS DISABLED Parameter has disabled this axis. 335 Z AXIS DISABLED Parameter has disabled this axis. 336 A AXIS DISABLED An attempt was made to program the A-axis while it was disabled (DISABLED bit in Parameter

43 set to 1), or invisible (INVIS AXIS bit in Parameter 43 set to 1), or a program commanded the A-axis while it was the outside rotary table (ROTARY INDEX button feature, MAP 4TH AXIS bit in Parameter 315 set to 1).

337 GOTO OR P LINE NOT FOUND Subprogram is not in memory, or P code is incorrect. P Not Found. 338 INV ALID IJK AND XYZ IN G02 OR G03 There is a problem with circle definition; check your geometry. 339 MUL TIPLE CODES Only one M, X, Y, Z, A, Q etc. allowed in any block, only one G codes in the same group. 340 CUTTER COMP BEGIN WITH G02 OR G03 Select cutter compensation earlier. Cutter compensation must begin

on a linear move.

341 CUTTER COMP END WITH G02 OR G03 Disable cutter compensation later . 342 CUTTER COMP P ATH TOO SMALL Geometry not possible. Check your geometry . 343 DISPLA Y QUEUE RECORD FULL Cycle power on the machine. If the alarm reoccurs, call your dealer and report

the sequence of events that lead to the alarm.

344 CUTTER COMP WITH G18 & G19 Cutter compensation only allowed in XY plane (G17). 346 M CODE DISABLED A There was an M80 or M81 commanded. These commands are not allowed if Setting 51

DOOR HOLD OVERRIDE is OFF, the SAFETY CIRCUIT ENABLED, or the Parameter 251 is set zero. Also check Setting 131 for Auto Door and Parameter 57 for DOOR STOP SP. B. There was an M17 or M18 commanded in program restart. These commands are illegal in program restart.

347 INVALID OR MISSING E CODE All 5-axis canned cycles require the depth to be specified using a positive E code. 348 MOTION NOT ALLOWED IN G93 MODE This alarm is generated if the mill is in Inverse Time Feed mode, and a

G12, G13, G70, G71, G72, G150, or any Group 9 motion command is issued. 349 PROG STOP WITHOUT CANCELING CUTTER COMP An X/Y cutter compensation exit move is required before a

program stop. 350 CUTTER COMP LOOK AHEAD ERROR There are too many non-movement blocks between motions when cutter

compensation is being used. Remove some intervening blocks. 351 INVALID P CODE In a block with G103 (Block Lookahead Limit), a value between 0 and 15 must be used for the P

code.

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352 AUX AXIS POWER OFF Aux C, U, V, or W axis indicate servo off. Check auxiliary axes. Status from control was OFF.

353 AUX AXIS NO HOME A ZERO RET has not been done yet on the aux axes. Check auxiliary axes. 354 AUX AXIS DISCONNECTED Aux axes not responding. Check auxiliary axes and RS-232 connections. 355 AUX AXIS POSITION MISMATCH Mismatch between machine and aux axes position. Check aux axes and

interfaces. Make sure no manual inputs occur to aux axes.

356 AUX AXIS TRAVEL LIMIT Aux axes are attempting to travel p ast their limit s. 357 AUX AXIS DISABLED Aux axes are disabled. 358 MUL TIPLE AUX AXIS Can only move one auxiliary axis at a time. 359 INVALID I, J OR K IN G12 OR G13 Check your geometry . 360 TOOL CHANGER DISABLED Check Parameter 57. 361 GEAR CHANGER DISABLED Check Parameter 57. 362 TOOL USAGE ALARM Tool life limit was reached. To continue, hi-light the Usage count in the Current Com-

mands Tool Life display and press ORIGIN. Then press RESET.

363 COOLANT LOCKED OFF Override is off and program tried to turn on coolant. 364 NO CIRC INTERP AUX AXIS Only rapid or feed is allowed with aux axes. 365 P DEFINITION ERROR P value not defined, or P value out of range. An M59 or M69 must have a P value between

the range of 1100 and 1155. If using G154 command, then P value must be between 1 and 99.

366 MISSING I, K OR L IN G70, G71 OR G72 Check for missing values. 367 CUTTER COMP INTERFERENCE G01 cannot be done with tool size. 368 GROOVE TOO SMALL Tool too big to enter cut. 369 TOOL TOO BIG Use a smaller tool for cut. 370 POCKET DEFINITION ERROR Check geometry for G150. 371 INV ALID I, J, K OR Q Check G150. 372 TOOL CHANGE IN CANNED CYCLE Tool change not allowed while canned cycle is active. 373 INVALID CODE IN DNC A code found in a DNC program could not be interpreted because of DNC restrictions. 374 MISSING XYZA IN G31 OR G36 G31 skip function requires an X, Y, Z, or A move. 375 MISSING Z OR H IN G37 G37 automatic tool length measurement function requires H code, Z value, and tool

offset enabled. X, Y, and A values not allowed.

376 NO CUTTER COMP IN SKIP Skip G31 and G37 functions cannot be used with cutter compensation. 377 NO SKIP IN GRAPH/SIM Graphics mode cannot simulate skip function. 378 SKIP SIGNAL FOUND Skip signal check code was included but skip was found when it was not expected. 379 SKIP SIGNAL NOT FOUND Skip signal check code was included but skip was not found when it was expected. 380 X, Y, A OR G49 NOT ALLOWED IN G37 G37 may only specify Z-axis and must have tool offset defined.

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381 G43, G44 NOT ALLOWED IN G36 OR G136 Auto work offset probing must be done without tool offset. 382 D CODE REQUIRED IN G35 A Dnn code is required in G35 in order to store the measured tool diameter. 383 INCH IS NOT SELECTED G20 was specified but settings have selected metric input. 384 METRIC IS NOT SELECTED G21 was specified but settings have selected inches. 385 INVALID L, P, OR R CODE IN G10 G10 was used to changes offsets but L, P, or R code is missing or invalid. 386 INV ALID ADDRESS FORMAT An address A...Z was used improperly. 387 CUTTER COMP NOT ALLOWED WITH G103 If block buffering has been limited, Cutter Compensation cannot be

used. 388 CUTTER COMP NOT ALLOWED WITH G10 Coordinates cannot be altered while Cutter Comp is active. Move the

G10 outside of Cutter Comp enablement.

389 G17, G18, G19 ILLEGAL IN G68 Planes of rotation cannot be changed while rotation is enabled. 390 NO SPINDLE SPEED S code has not been encountered. Add an S code. 391 FEA TURE DISABLED An attempt was made to use a control feature not enabled by a parameter bit. Set the

parameter bit to 1. 392 B AXIS DISABLED An attempt was made to program the B-axis while it was disabled (DISABLED bit in Parameter

151 set to 1) or invisible (INVIS AXIS bit in Parameter 151 set to 1), or a program commanded the B-axis while it was the outside rotary table (ROTARY INDEX button feature, MAP 4TH AXIS bit in Parameter 315 set to 1).

393 INV ALID MOTION IN G74 OR G84 Rigid Tapping can only be in the Z minus G74 or G84 direction. Make sure that the distance from the initial position to the commanded Z depth is in the minus direction.

394 B OVER TRAVEL RANGE B-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.

395 NO G107 ROT ARY AXIS SPECIFIED A rotary axis must be specified in order to perform cylindrical mapping. 396 INVALID G107 ROTARY AXIS SPECIFIED The rotary axis specified is not a valid axis, or has been disabled. 397 AUX AXIS IN G93 BLOCK This alarm is generated if a G-code block specifies any form of interpolated motion that

involves BOTH one or more of the regular axes (X, Y, Z, A, B, etc...) AND one or more of the auxiliary axes (C, U, V, W).

398 AUX AXIS SERVO OFF Aux. axis servo shut off due to a fault. 400 SKIP SIGNAL DURING RESTART A skip signal G-code (G31, G35, G36, G37, G136) was found during program

restart. 401 INVALID T ANGENT IN GROUP 1 CORNER ROUNDING OR CHAMFERING The point or angle calculated has yielded

invalid results in automatic chamfering or corner rounding. This can be for one of the following reasons: 1) Tangent of angle was too close to zero. 2) Cosine of angle was invalid. 3) Hypotenuse of calculated right triangle was shorter than side. 4) Calculated point did not line on arc or line. Check your geometry.

402 POSSIBLE CORRUPTED FILE The parameters being loaded do not match the expected number of parameters. This can be due to the loading of an older or newer parameter file than the system binary, or the file is corrupted.

403 TOO MANY PROGS Cannot have more than 500 programs in memory. 404 RS-232 NO PROG NAME Need name in programs when receiving ALL; otherwise has no way to store them. 405 RS-232 ILLEGAL PROG NAME Check files being loaded. Program name must be Onnnn and must be at begin-

ning of a block.

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406 RS-232 MISSING CODE Bad data was received. Check your program. The program will be stored but the bad data is turned into a comment.

407 RS-232 INVALID CODE Check your program. The program will be stored but the bad data is turned into a comment.

408 RS-232 NUMBER RANGE ERROR Check your program. The program will be stored but the bad data is turned into a comment.

409 FILE INVALID N CODE Bad parameter or setting number. Positive number must exist after the ‘N’ character, and cannot be longer than 5 digits.

410 FILE INVALID V CODE Bad parameter or setting value. Positive or negative number must exist after the ‘V’ character, and cannot be longer than 10 digits.

411 RS-232 EMPTY PROG Check your program. Between % and % there was no program found. 412 RS-232 UNEXPECTED END OF INPUT Check Your Program. An ASCII EOF code was found in the input data

before program receive was complete. This is a decimal code 26. 413 RS-232 LOAD INSUFFICIENT MEMORY Program received does not fit. Check the space available in the LIST

PROG mode and possibly delete some programs.

414 RS-232 BUFFER OVERFLOW Data sent too fast to CNC. Computer sending data may not respond to X-OFF. 415 RS-232 OVERRUN Data sent too fast to CNC. 416 RS-232 PARITY ERROR Data received by CNC has bad parity. Check parity settings, number of data bits and

speed. Also check your cables. 417 RS-232 FRAMING ERROR Data received was garbled and proper framing bits were not found. One or more

characters of the data will be lost. Check parity settings, number of data bits and speed. 418 RS-232 BREAK Break condition while receiving. The sending device set the line to a break condition. This might

also be caused by a simple break in the cable.

419 INV ALID FUNCTION FOR DNC A code found on input of a DNC program could not be interpreted. 420 PROGRAM NUMBER MISMATCH The O code in the program being loaded did not match the O code entered at

the keyboard. Warning only.

421 NO V ALID POCKETS Pocket Table is full of dashes. 422 POCKET TABLE ERROR If the machine has a 50 taper spindle, there must be 2 dashes between L’s. L’s must be

surrounded by dashes.

423 X SCALE/SCREW MISMATCH Scale induced correction exceeds one motor revolution. 424 Y SCALE/SCREW MISMATCH Scale induced correction exceeds one motor revolution. 425 Z SCALE/SCREW MISMATCH Scale induced correction exceeds one motor revolution. 426 A SCALE/SCREW MISMATCH Scale induced correction exceeds one motor revolution. 427 INTERRUPT OVERRUN The control detected an interrupt overrun condition. An interrupt occurred before the

previous interrupt was completed. Call your dealer.

429 DISK DIR INSUFFICIENT MEMORY CNC memory was almost full when an attempt was made to read the directory. 430 FILE UNEXPECTED END OF INPUT Ending % sign not 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.

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431 FILE NO PROG NAME Need name in programs when receiving ALL; otherwise has no way to store them. 432 FILE ILLEGAL PROG NAME Check files being loaded. Program must be Onnnn and must be at the beginning of a

block.

433 FILE EMPTY PROG Check your program. Between % and % there was no program found. 434 FILE LOAD INSUFFICIENT MEMORY Program received does not fit. Check the space available in the LIST PROG

mode and possibly delete some programs. 435 DISK ABORT Could not read disk. Possible corrupted or unformatted disk. Try a known good disk. Also caused

by dirty drive heads. Use an appropriate cleaning kit. 436 DISK FILE NOT FOUND Could not find file. Possible corrupted or unformatted disk. Try a known good disk. Also

caused by dirty drive heads. Use an appropriate cleaning kit. 457 AUX AXIS IS ENABLED One or more auxiliary axes are enabled. For the macro variables 750 and 751 to work the

auxiliary axes must be disabled. Make sure Setting 38 is 0.

471 OUT OF TOOLS The life of all tools in the Advanced Tool Management group has expired. 472 A TM F AULT Indicates an error related to the Advanced Tool Management feature. ATM software encountered a

group which does not exist. Usually it can be fixed by adding the corresponding group. 501 TOO MANY ASSIGNMENTS IN ONE BLOCK Only one assignment macro assignment is allowed per block. Divide

block into multiple blocks. 502 [ OR = NOT FIRST TERM IN EXPRESSN An expression element was found where it was not preceded by [ or =,

that start expressions. 503 ILLEGAL MACRO V ARIABLE REFERENCE A macro variable number was used that is not supported by this control,

use another variable. 504 UNBALANCED BRACKETS IN EXPRESSION Unbalanced brackets, [ or ], were found in an expression. Add or

delete a bracket. 505 VALUE STACK ERROR The macro expression value stack pointer is in error. Cycle power on the machine. If the

alarm reoccurs, call your dealer and report the sequence of events that lead to the alarm. 506 OPERAND STACK ERROR The macro expression operand stack pointer is in error. Cycle power on the machine.

If the alarm reoccurs, call your dealer and report the sequence of events that lead to the alarm. 507 TOO FEW OPERANDS ON STACK An expression operand found too few operands on the expression stack. Cycle

power on the machine. If the alarm reoccurs, call your dealer and report the sequence of events that lead to the alarm.

508 DIVISION BY ZERO A division in a macro expression attempted to divide by zero. Re-configure expression. 509 ILLEGAL MACRO V ARIABLE USE See MACROS section for valid variables. 510 ILLEGAL OPERAT OR OR FUNCTION USE See MACROS section for valid operators. 511 UNBALANCED RIGHT BRACKETS Number of right brackets not equal to the number of lef t brackets. 512 ILLEGAL ASSIGNMENT USE Attempted to write to a read-only macro variable. 513 V ARIABLE REFERENCE NOT ALLOWED WITH N OR O Alphabetic addresses N and O cannot be combined with

macro variables. Do not declare N#1, etc. 514 ILLEGAL MACRO ADDRESS REFERENCE Alphabetic addresses N and O cannot be combined with macro

variables. Do not declare N#1, etc.

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515 TOO MANY CONDITIONALS IN A BLOCK Only one conditional expression is allowed in any WHILE or IF-THEN block.

516 ILLEGAL CONDITIONAL OR NO THEN A conditional expression was found out side of an IF-THEN, WHILE, or M99 block.

517 EXPRSN. NOT ALLOWED WITH N OR O A macro expression cannot be used with N or O. Do not declare O[#1], etc.

518 ILLEGAL MACRO EXPRSN REFERENCE A macro expression cannot be used with N or O. Do not declare O[#1], etc.

519 TERM EXPECTED In the evaluation of a macro expression an operand was expected but not found. 520 OPERATOR EXPECTED In the evaluation of a macro expression an operator was expected but not found. 521 ILLEGAL FUNCTIONAL P ARAMETER An illegal value was p assed to a function, such as SQRT[ or ASIN[. 522 ILLEGAL ASSIGNMENT VAR OR VALUE A variable was referenced for writing. The variable referenced is read only . 523 CONDITIONAL REQUIRED PRIOR TO THEN A THEN was encountered and a conditional statement was not

processed in the same block. 524 END FOUND WITH NO MA TCHING DO An END was encountered without encountering a previous matching DO.

DO-END numbers must agree.

525 VAR. REF. ILLEGAL DURING MOVEMENT Variable cannot be read during axis movement. 526 COMMAND FOUND ON DO/END LINE A G-code command was found on a WHILE-DO or END macro block. Move

the G-code to a separate block. 527 = NOT EXPECTED OR THEN REQUIRED Only one assignment is allowed per block, or a THEN statement is

missing. 528 PARAMETER PRECEDES G65 On G65 lines, all parameters must follow the G65 G-code. Place parameters after

G65.

529 ILLEGAL G65 PARAMETER The addresses G, L, N, O, and P cannot be used to pass parameters. 530 TOO MANY I, J, or K’S IN G65 Only 10 occurrences of I, J, or K can occur in a G65 subroutine call. Reduce the I, J,

or K count. 531 MACRO NESTING TOO DEEP Only four levels of macro nesting can occur. Reduce the number of nested G65

calls.

532 UNKNOWN CODE IN POCKET P A TTERN Macro syntax is not allowed in a pocket p attern subroutine. 533 MACRO V ARIABLE UNDEFINED A conditional expression evaluated to an UNDEFINED value, i.e. #0. Return T rue

or False. 534 DO OR END ALREADY IN USE Multiple use of a DO that has not been closed by an END in the same subroutine.

Use another DO number. 535 ILLEGAL DPRNT STATEMENT A DPRNT statement has been formatted improperly, or DPRNT does not begin

block.

536 COMMAND FOUND ON DPRNT LINE A G-code was included on a DPRNT block. Make two separate blocks. 537 RS-232 ABORT ON DPRNT While a DPRNT statement was executing, the RS-232 communications failed. 538 MA TCHING END NOT FOUND A WHILE-DO statement does not cont ain a matching END statement. Add the proper

END statement.

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539 ILLEGAL GOTO Expression after GOTO not valid. 540 MACRO SYNT AX NOT ALLOWED A section of code was interpreted by the control where macro statement syntax

is not permitted.

541 MACRO ALARM This alarm was generated by a macro command in a program. 542 OPERATION NOT AVAILABLE This operation is not compatible with FNC mode. 600 U OVER TRAVEL RANGE Commanded U-axis move would exceed the allowed machine range. Machine coordi-

nates are in the negative direction. This condition indicates either an error in the user’s program or improper offsets. 601 V OVER TRAVEL RANGE Commanded V-axis move would exceed the allowed machine range. Machine coordi-

nates are in the negative direction. This condition indicates either an error in the user’s program or improper offsets. 602 W OVER TRAVEL RANGE Commanded W-axis move would exceed the allowed machine range. Machine

coordinates are in the negative direction. This condition indicates either an error in the user’s program or improper offsets.

603 U LIMIT SWITCH Axis hit limit switch or switch disconnected. The stored stroke limits should stop the slides before they hit the limit switches. Verify the value of parameter 373 Grid Offset and check the wiring to the limit switch 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.

604 V LIMIT SWITCH Axis hit limit switch or switch disconnected. The stored stroke limits should stop the slides before they hit the limit switches. Verify the value of parameter 409 Grid Offset and check the wiring to the limit switch 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.

605 W LIMIT SWITCH Axis hit limit switch or switch disconnected. The stored stroke limits should stop the slides before they hit the limit switches. Verify the value of parameter 445 Grid Offset and check the wiring to the limit switch 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.

608 INVALID Q CODE A Q address code used a numeric value that was incorrect in the context used. In M96 Q can reference only bits 0 to 63. Use an appropriate value for Q.

609 U SERVO ERROR TOO LARGE Too much load or speed on U-axis motor. The difference between the motor position and the commanded position has exceeded Parameter 362. 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.

610 V SERVO ERROR TOO LARGE Too much load or speed on V-axis motor. The difference between the motor position and the commanded position has exceeded Parameter 398. 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.

611 W SERVO ERROR TOO LARGE Too much load or speed on W-axis motor. The difference between the motor position and the commanded position has exceeded Parameter 434. 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.

612 U SERVO OVERLOAD Excessive load on U-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. It can also be caused by anything that causes a very high load on the motors.

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613 COMMAND NOT ALLOWED IN CUTTER COMP At least one command in the highlighted block cannot be executed while cutter compensation is active. Block Delete characters (‘/’) and M codes such as M06, M46, M50 and M96 are not allowed. Your program must have a G40 and a cutter compensation exit move before these can be commanded.

614 V SERVO OVERLOAD Excessive load on V-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. It can also be caused by anything that causes a very high load on the motors.

615 W SERVO OVERLOAD Excessive load on W-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. It can also be caused by anything that causes a very high load on the motors.

616 U-AXIS MOTOR OVERHEAT Servo motor overheat. The temperature sensor in the motor indicates over 150 degrees F (65 deg. C). This can be caused by an extended overload of the motor such as leaving the slide at the stops for several minutes.

617 V-AXIS MOTOR OVERHEAT Servo motor overheat. The temperature sensor in the motor indicates over 150 degrees F (65 deg. C). This can be caused by an extended overload of the motor such as leaving the slide at the stops for several minutes.

618 W-AXIS MOTOR OVERHEAT Servo motor overheat. The temperature sensor in the motor indicates over 150 degrees F (65 deg. C). This can be caused by an extended overload of the motor such as leaving the slide at the stops for several minutes.

620 C AXIS DISABLED Parameters have disabled this axis 621 C OVER TRAVEL RANGE C-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. 622 TOOL ARM FAULT This alarm is generated by the tool changer if the arm is not at the Origin position or the arm

motor is already running when a tool change process is started. 625 CAROUSEL POSITIONING ERROR This alarm is generated by the tool changer if the conditions are not correct

when:

• The carousel or tool arm was started and illegal conditions are present, for example: The carousel or arm motor

already running. The arm is not at the Origin. The tool carousel is not at TC mark, or the tool pocket is not locked.

• The tool carousel was in motion and the Tool One Mark was detected but the current pocket facing the spindle was

not at pocket one. Or the current pocket is at pocket one but Tool One Mark is not detected. 626 TOOL POCKET SLIDE ERROR This alarm is generated by the tool changer. It is generated if the tool pocket has

not moved to its commanded position (and settled) within the total time allowed by parameters 306 and 62. 627 ATC ARM MOTION This alarm is generated by the sidemount disk type tool changer. It is generated if the tool arm

failed to move within the time specified by Parameter 309 ARM START TIMEOUT or if the tool arm failed to move to the designated position, such as origin, clamp or unclamp within the time specified by Parameter 308 ARM ROTATE TIME, or if the tool pocket failed to move up or down within the time specified by Parameter 306 POCKET UP/DN DELAY.

628 ATC ARM POSITIONING ERROR This alarm is generated by the tool changer if:

• The arm was being moved from the ORIGIN position to the CLAMP position and it coasted past the MOTOR STOP

point, or could not get to the CLAMP point.

• The arm was being moved from the CLAMP position to the UNCLAMP position and it coasted past the MOTOR

STOP point or could not get to the UNCLAMP point (same physical point as CLAMP).

• The arm was being moved back to the ORIGIN position and it coasted past the MOTOR STOP point or could not get

to the ORIGIN point. 629 APC-PIN CLEAR/HOME SWITCH FAULT A pin clear switch was contacted when all pallets were at their home

positions. The most likely cause is debris on a switch. Check for accumulation of debris on the pin clear switches and the pallet home switches. Check switches and their electrical wiring for damage. After correcting the condition run an M50 (with P code for the pallet to be loaded) to continue machining.

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630 APC-DOOR SW F AUL T -SWITCH NOT EQUAL T O SOLENOID The APC Door Switch indicates the door is open but the solenoid shows the door has been commanded to close. Either the door failed to close and is stuck or the switch itself is broken or stuck. Also, the door switch wiring may have a fault. Check switch then cable. After correcting the condition, run an M50 to continue machining.

631 P ALLET NOT CLAMPED Vertical Mills: APC-Pallet not clamped or home. Do not attempt to move X or Y axes of the mill until the APC is in a safe condition. One pallet is at home but the other pallet is neither clamped nor at home. Locate the unclamped pallet and return to home if possible. If drive pin is engaged or pallet is partially clamped, go to the lube/air panel at rear of mill and continuously press both white buttons in center of solenoid air valves while assistant pulls the pallet off the receiver. After correcting the condition, run an M50 to continue machining.

Horizontal Mills: RP-Pallet is not clamped. The RP pallet change was not completed or the pallet was not clamped properly when a spindle command was given. After correcting the condition, run an M50 to continue machining.

632 APC-UNCLAMP ERROR The pallet did not unclamp in the amount of time allowed. This can be caused by a bad air solenoid, a blocked or kinked airline, or a mechanical problem. After correcting the condition, run an M50 to continue machining.

633 APC-CLAMP ERROR The pallet did not clamp in the amount of time allowed by parameter 316. This alarm is most likely caused by the mill table not being in the correct position. This can be adjusted using the setting for the X position (#121, #125) as described in the ‘Installation’ section. If the pallet is in the correct position but not clamped, push the pallet against the hard stop and run M18. If the pallet is clamped, but not correctly, run an M17 to unclamp, push the pallet to the correct position, and run an M18 to clamp the pallet. Less common causes could be that the slip clutch is slipping, the motor is at fault, or an airline is blocked or kinked. After correcting the condition, run an M50 to continue machining.

634 APC-MISLOCATED P ALLET A pallet is not in the proper place on the APC. The pallet must be pushed back against the hard stop by hand. After correcting the condition, run an M50 to continue machining.

635 APC-PAL NUM CONFLICT REC & CH Pallet Number Conflict Receiver and Pallet Changer: The pallet number in memory does not agree with the actual pallet in use. Run an M50 to reset this variable.

636 APC UNLOAD-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. After correcting the condition, run an M50 to continue machining.

637 APC UNLOAD-SWITCH MISSED PAL 2 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 from another mechanical problem, such as clutch slippage. After correcting the condition, run an M50 to continue machining.

638 APC-DOOR NOT OPEN The automatic door did not open (in the allowable time), or may have fallen during an APC function. This can be caused by a bad air solenoid, a blocked or kinked airline, or a mechanical problem. After correcting the condition, run an M50 to continue machining.

639 APC-DOOR NOT CLOSED The automatic door did not close (in the allowable time), when necessary after an APC function has been performed. This can be caused by a bad air solenoid, a blocked or kinked airline, or a mechanical problem. After correcting the condition, run an M50 to continue machining.

640 APC-MISSING PALLET @ REC Pallet change sequence was halted because receiver switch was not activated. Pallet is either unclamped or not on the receiver. Ensure the pallet is correctly located on receiver (against hard stop) then run M18 to clamp the pallet. After correcting the condition, run an M50 to continue machining.

641 APC-UNKNOWN CHAIN LOCATION Neither chain location switch is tripped, so the control cannot locate the chain position. This can occur if a pallet change is interrupted for any reason, such as an alarm or an E-STOP. To correct this problem, the pallets and chain must be moved back into a recognized position, such as both pallets home or one pallet home and one on the receiver. The chain position adjustment tool must be used to rotate the chain into position. The pallets must be pushed into place by hand. After correcting the condition, run an M50 to continue machining.

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642 642 APC-PIN CLEAR SWITCH FAULT – One of the pallet changer pin clear switches was contacted unexpectedly. The most likely cause is debris on a switch. Also check the pin clear switches for damage and their electrical wiring for damage. After correcting the condition run an M50 to continue machining.

643 LOW BRAKE OIL A-AXIS The oil level in the air/oil booster, supplying hydraulic pressure to the A-axis brake, is low. The booster is located on the front of the machine’s table. Access the booster fill fitting and add Mobile DTE 24 oil to bring the oil level to the high oil level line marked on the booster. If the alarm reoccurs within 90 days contact your Haas Dealer for service.

644 APC-LOW AIR PRESSURE A low air pressure condition was detected during pallet changer operation. Check that the air supply is 100 PSI, minimum. Check that the air supply line is the correct diameter. Check that the mill pressure regulator is set to 85 PSI. If this alarm continues to occur, check the entire pressurized air system for any abnormal air leakage.

645 RP-P ALLET JAMMED, CHECK FOR OBSTRUCTION The pallet changer has not rotated away from it s original position (CW/CCW) in a reasonable time, or has not achieved its final position (CW/CCW) in a reasonable time, or has not been permitted to lower to the fully down position. After correcting the condition, run an M50 to continue machining.

646 RP-CW/CCW SWITCH ILLEGAL CONDITION Both of the switches that sense the rotational position of the pallet changer are indicating the impossible condition that the pallet changer is rotated CW and CCW at the same time. Only one switch should be tripped at a time. Check the function of the rotational sense switches, their connectors, and their wiring. After correcting the condition, run an M50 to continue machining.

647 RP-UP/DOWN SWITCH ILLEGAL CONDITION, LIFT CYLINDER The switches that sense the lifted and lowered position of the pallet changer are indicating the impossible condition that the pallet changer is both lifted and lowered at the same time. Check the function of the lift and lower sense switches, check the adjustment of the top switch, check both switch electrical connections and their wiring. After correcting the condition, run an M50 to continue machining.

648 RP-MAIN DRAWBAR LOCKED IN P ALLET CLAMPED POSITION The drawbar has not tripped the unclamp sense switch in a reasonable amount of time. Check to see that the motor is plugged in at the connector panel in the rear of the machine and at the motor through the access panel; check the function of the main drawbar motor (does it turn or try to turn); check the condition of the drive belt, check power supply to the motor; check the relays that supply power to the motor, check the condition of the current limiting resistors. After correcting the condition, run an M50 to continue machining.

649 RP-MAIN DRAWBAR LOCKED IN P ALLET UNCLAMPED POSITION The drawbar has not come of f the unclamp sense switch in a reasonable amount of time. Check to see that the motor is plugged in at the connector panel in the rear of the machine and at the motor through the access panel; check the function of the main drawbar motor (does it turn or try to turn); check the condition of the drive belt, check power supply to the motor; check the relays that supply power to the motor, check the condition of the current limiting resistors. After correcting the condition, run an M50 to continue machining.

650 RP-P ALLET NOT ENGAGING RP MAIN DRA WBAR This alarm occurs when the Pull S tud cannot properly engage the Ball Pull Collet. If this happens, the Ball Pull Collet has been pushed down into the Collet Housing and pallet clamping is not possible. Check alignment of the ‘H’-frame with the adjustable Hard Stops. Check the Pallet Pull Studs and the RP-Main Drawbar Ball Collet for damage or obstruction. Remove any debris that may have entered the Collet. Check that the six balls in the collet float within the holes. If lift to the H-frame has been lost following a collet jammed condition, orientation of the pallet is not guarantied. Check orientation of the pallet as well. Zeroing of the A Axis is not safe if lift has been lost. It may be necessary to remove workpiece from the pallet. After correcting the condition, run an M50 to continue machining.

651 Z AXIS IS NOT ZEROED The Z axis has not been zeroed. In order to continue Tool Change Recovery the Z axis must be zeroed. Once the Z axis has been zeroed, continue with Tool Change Recovery.

652 U 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.

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653 V 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.

654 W 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.

655 U CABLE FAULT Cable from U-axis encoder does not have valid differential signals. 656 V CABLE FAULT Cable from V-axis encoder does not have valid differential signals. 657 W CABLE FAULT Cable from W-axis encoder does not have valid differential signals. 658 U PHASING ERROR Error occurred in phasing initialization of brushless motor. This can be caused by a bad

encoder, or a cabling error. 659 V PHASING ERROR Error occurred in phasing initialization of brushless motor. This can be caused by a bad

encoder, or a cabling error. 660 W PHASING ERROR Error occurred in phasing initialization of brushless motor. This can be caused by a bad

encoder, or a cabling error. 661 U TRANSITION FAULT Illegal transition of count pulses in U 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 printed circuit board.

662 V TRANSITION FAULT Illegal transition of count pulses in V 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 printed circuit board.

663 W TRANSITION FAULT Illegal transition of count pulses in W 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 printed circuit board.

664 U AXIS DISABLED Parameter has disabled this axis. 665 V AXIS DISABLED Parameter has disabled this axis. 666 W AXIS DISABLED Parameter has disabled this axis. 667 U AXIS LINEAR SCALE Z FAULT Encoder marker pulse count failure. This alarm usually indicates that the Z Fault

encoder has been damaged and encoder position data is unreliable. This can also be caused by loose scale connectors.

668 V AXIS LINEAR SCALE Z FAULT Encoder marker pulse count failure. This alarm usually indicates that the Z Fault encoder has been damaged and encoder position data is unreliable. This can also be caused by loose scale connectors.

669 W AXIS LINEAR SCALE Z FAULT Encoder marker pulse count failure. This alarm usually indicates that the Z Fault encoder has been damaged and encoder position data is unreliable. This can also be caused by loose scale connectors.

670 TT or B OVER TRAVEL RANGE Commanded TT or B-axis move would exceed the allowed machine range. Machine coordinates are in the negative direction. This condition indicates either an error in the user’s program or improper offsets.

671 TT or B LIMIT SWITCH Axis hit limit switch or switch disconnected. The stored stroke limits should stop the slides before they hit the limit switches. Verify the value of parameter 481 Grid Offset and check the wiring to the limit switch 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.

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673 TT or B SERVO ERROR TOO LARGE Too much load or speed on TT or B-axis motor. The dif ference between the motor position and the commanded position has exceeded Parameter 470. 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.

674 TT or B SERVO OVERLOAD Excessive load on TT or B-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 or by a very high load on the motors. If this alarm occurs on a machine with a VF-SS-type tool changer, the most likely cause is a tool over 3 pounds not identified as ‘heavy’ in the tool table.

675 TT or B-AXIS MOTOR OVERHEAT 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.

676 TT or B MOTOR Z FAULT Encoder marker pulse count failure. This alarm usually indicates that the encoder has been damaged and encoder position data is unreliable. This can also be caused by loose encoder connectors.

677 TT or B AXIS Z CH MISSING Z Reference signal from encoder was not received as expected. Can be caused by loose connections, encoder contamination, or parameter error.

678 TT or B AXIS DRIVE FAULT Current in TT or B servo motor beyond limit. Possibly caused by a stalled or overloaded motor. The servos are turned off. This can be caused by running the axis into a mechanical stop. A short in the motor or a short of one motor lead to ground can also cause it.

679 TT or B ZERO RET MARGIN TOO SMALL This alarm will occur if the home/limit switches move or are misadjusted. This alarm indicates that the zero return position may not be consistent from one zero return to the next. The encoder Z channel signal must occur between 1/8 and 7/8 revolution of where the home switch releases. This will not turn the servos off but will stop the zero return operation.

680 TT or B CABLE FAULT Cable from TT or B-axis encoder does not have valid differential signals. 681 TT or B PHASING ERROR Error occurred in phasing initialization of brushless motor. This can be caused by a

bad encoder, or a cabling error. 682 TT or B TRANSITION FAULT Illegal transition of count pulses in B 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 .

683 TT or B AXIS DISABLED Parameter has disabled this axis. 684 TT or B AXIS LINEAR SCALE Z FAULT Encoder marker pulse count failure. This alarm usually indicates that the Z

Fault encoder has been damaged and encoder position data is unreliable. This can also be caused by loose scale connectors.

685 V MOTOR Z FAULT Encoder marker pulse count failure. This alarm usually indicates that the encoder has been damaged and encoder position data is unreliable. This can also be caused by loose encoder connectors.

686 W MOTOR Z FAULT Encoder marker pulse count failure. This alarm usually indicates that the encoder has been damaged and encoder position data is unreliable. This can also be caused by loose encoder connectors.

687 U MOTOR Z FAULT Encoder marker pulse count failure. This alarm usually indicates that the encoder has been damaged and encoder position data is unreliable. This can also be caused by loose encoder connectors.

688 U AXIS Z CH MISSING Z Reference signal from encoder was not received as expected. Can be caused by loose connections, encoder contamination, or parameter error.

689 V AXIS Z CH MISSING Z Reference signal from encoder was not received as expected. Can be caused by loose connections, encoder contamination, or parameter error.

690 W AXIS Z CH MISSING Z Reference signal from encoder was not received as expected. Can be caused by loose connections, encoder contamination, or parameter error.

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691 U AXIS DRIVE FAULT Current in U servo motor beyond limit. Possibly caused by a stalled or overloaded motor. The servos are turned off. This can be caused by running the axis into a mechanical stop. A short in the motor or a short of one motor lead to ground can also cause it.

692 V AXIS DRIVE FAULT Current in V servo motor beyond limit. Possibly caused by a stalled or overloaded motor. The servos are turned off. This can be caused by running the axis into a mechanical stop. A short in the motor or a short of one motor lead to ground can also cause it.

693 W AXIS DRIVE FAULT Current in W servo motor beyond limit. Possibly caused by a stalled or overloaded motor. The servos are turned off. This can be caused by running the axis into a mechanical stop. A short in the motor or a short of one motor lead to ground can also cause it.

694 ATC SWITCH FAULT Conflicting switch states detected, such as shuttle at spindle and shuttle at chain simultaneously or tool pocket up and down simultaneously. Check for damaged or sticking switches, damaged wiring, or debris build up. Use Tool Changer Restore to recover the ATC, then resume normal operation.

695 ATC DOUBLE-ARM CYLINDER TIME OUT The A TC double arm did not complete extending or retracting within the time allowed by Parameter 61. Check for proper spindle orientation, correct alignment of the double arm with the chain or spindle, adequate air supply, mechanism binding, air leakage, excessive tool weight, debris build up, adequate chain tension, correct chain guide strip adjustment, and interference between the tool holder set screw and the chain or tool gripper. Use Tool Changer Restore to recover the ATC, then resume normal operation.

696 ATC MOTOR TIME OUT The ATC shuttle motor or double arm motor failed to complete the commanded movement within the time allowed by Parameter 60. Check for mechanism binding, correct motor and switch operation, damaged gear motor control board relays, damaged electrical wiring, or blown fuses on the gear motor control board. Use Tool Changer Restore to recover the ATC, then resume normal operation.

697 A TC MOTOR FAULT The ATC shuttle motor or double arm motor was on unexpectedly. Use Tool Changer Restore to recover the ATC, then resume normal operation.

698 A TC PARAMETER ERROR The ATC type cannot be determined. Check Parameter 278, bit 10, HS3 HYD TC, or Parameter 209, bit 2, CHAIN TC, as appropriate for the installed tool changer. Use Tool Changer Restore to recover the ATC, then resume normal operation.

791 COMM. FAILURE WITH MOCON2 During a self-test of communications between the MOCON2 and main processor the main processor does not respond. Check cable connections and boards. This alarm could also be caused by a memory fault, which was detected on the MOCON2.

792 MOCON2 WATCHDOG FAULT The self-test of the MOCON2 has failed. Call your dealer . 799 UNKNOWN MOCON2 ERROR Mocon2 has reported an alarm to the current software. The current version of

software was unable to identify the alarm. 900 A PARAMETER HAS BEEN CHANGED When the operator alters the value of a parameter, alarm 900 will be added

to the alarm history. When the alarm history is displayed, the operator will be able to see the parameter number and the old value along with the date and time the change was made. Note that this is not a resetable alarm; it is for information purposes only.

901 P ARAMETERS HAVE BEEN LOADED BY DISK When a parameter file has been loaded from disk, alarm 901 will be added to the alarm history along with the date and time. Note that this is not a resetable alarm; it is for information purposes only.

902 P ARAMETERS HAVE BEEN LOADED BY RS232 When a parameter file has been loaded from RS-232, alarm 902 will be added to the alarm history along with the date and time. Note that this is not a resetable alarm; it is for information purposes only.

903 CNC MACHINE POWERED UP When the machine is powered up, alarm 903 will be added to the alarm history along with the date and time. Note that this is not a resetable alarm; it is for information purposes only.

904 ATC AXIS VISIBLE The tool changer axis must be invisible for tool change operations with the HS tool changers. Set Parameter 462, bit 18, INVIS AXIS to 1. This will make the tool changer axis invisible and tool changes will be allowed.

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905 NO P CODE IN M14, M15, M36 In M14, M15, M36 must put pallet number in a P code. 906 INVALID P CODE IN M14, M15, M36 OR M50 The P code must be the pallet number of a valid pallet without a

decimal point, and must be a valid integer number. 907 APC UNLOAD-SWITCH MISSED PAL 3 Pallet #3 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.

908 APC UNLOAD-SWITCH MISSED PAL 4 Pallet #4 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.

909 APC-PROGRAM NOT LISTED There is no program name in the Pallet Schedule Table for the loaded pallet. To run a program for the loaded pallet, enter the program name into the Program Name column of the Pallet Schedule Table, for the pallet you want to operate on, or remove the M48 from the subprogram you want to use. Verify that the program and the pallet are compatible.

910 APC-PROGRAM CONFLICT The subprogram you are trying to run is not assigned to the loaded pallet. Another program is assigned to this pallet in the Pallet Schedule Table. Either enter the program name that you want to run into the Program Name column of the Pallet Status Table or, remove the M48 from the subprogram you want to use. Verify that the subprogram and the pallet are compatible.

911 APC-PAL LOAD/UNLOAD A T ZERO One or more of the pallets on the Automatic Pallet Changer has a load or unload position set to zero. This indicates that the APC set up procedure was incomplete. Establish the correct load and unload positions for all pallets and enter the positions in the appropriate settings. See operator’s manual for the APC model and its correct setting numbers.

912 APC-NO P CODE OR Q CODE FOR M46 M46 must have a P code and a Q code. The P code must be a line number in the current program. The Q code is the number of the pallet, if loaded, that will cause a jump to the program line number.

913 APC-NO P CODE OR Q CODE FOR M49 M49 must have a Q code. The P code is the pallet number. The Q code is the status to give the pallet.

914 APC-INVALID P CODE The P code must be the name of a program stored in memory. The program name must not have a decimal point. Remove any decimal points from the program name.

915 APC-ILLEGAL NESTING G188 or M48 G188 is only legal in main program. M48 is only legal in a program listed in the Pallet Schedule Table or a first level subprogram.

916 APC-NEGATIVE P AL PRIORITY INDEX Software Error; Call your dealer. 917 APC-NUMBER OF PALLETS IS ZERO Parameter 606 must have a value if parameter 605 is not zero. Set param-

eter 606 to the number of pallets in your FMS system. 918 APC LOAD-SWITCH MISSED PAL 1 Pallet #1 did not complete its move from the APC to the receiver in the

allowable time. 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 hard stop) then run M18 to clamp the pallet. After correcting the condition, run an M50 to continue machining.

919 APC LOAD-SWITCH MISSED PAL 2 Pallet #2 did not complete its move from the APC to the receiver in the allowable time. 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 hard stop) then run M18 to clamp the pallet. After correcting the condition, run an M50 to continue machining.

920 APC LOAD-SWITCH MISSED PAL 3 Pallet #3 did not complete its move from the APC to the receiver in the allowable time. 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 hard stop) then run M18 to clamp the pallet. After correcting the condition, run an M50 to continue machining.

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921 APC LOAD-SWITCH MISSED PAL 4 Pallet #4 did not complete its move from the APC to the receiver in the allowable time. 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 hard stop) then run M18 to clamp the pallet. After correcting the condition, run an M50 to continue machining.

922 APC-TABLE NOT DECLARED Software calling invalid tables. Software Error; Call your dealer. 923 A INDEXER IS NOT A T THE PROPER INCREMENT AL POSITION The indexer has moved to a position that cannot

be seated. 924 B INDEXER IS NOT A T THE PROPER INCREMENT AL POSITION The indexer has moved to a position that cannot

be seated. 925 A INDEXER IS NOT FULLY IN THE UP POSITION The indexer is still seated. It is not completely in the up position

and cannot be rotated. Reset then rezero the indexer. 926 B INDEXER IS NOT FULL Y IN THE UP POSITION The indexer is still seated. It is not completely in the up position

and cannot be rotated. Reset then rezero the indexer. 927 ILLEGAL G1 CODE FOR ROT ARY INDEXER The rot ary indexer only does rapid G0 motion. Feed G1 motion is not

allowed. 937 INPUT LINE POWER FAULT This alarm works with the Power Failure Detection Module. This alarm will be

generated whenever incoming power to the machine falls below reference voltage value in parameter 730 and duration of time in parameter 731. Cycle the power to continue.

938 LANGUAGES LOADED Foreign languages were recently loaded into the control. 939 LANGUAGES FAILED TO LOAD Foreign languages fails to be loaded into the control. Languages either exceeded

total flash memory, or not enough flash memory available. Try deleting a language from disk. 940 SIDE MOUNT CAROUSEL ERROR This alarm is generated by the tool changer if the carousel motor is still

running when the tool pocket is unlocked and lowered prior to a tool change. If the carousel does not start to rotate after the allowed time specified by parameter 60 TURRET START DELAY or does not stop rotating after the allowed time specified by parameter 61 TURRET STOP DELAY.

941 POCKET-TOOL TABLE ERROR This alarm is generated by the tool changer if the tool specified by the program is not found in the POCKET-TOOL table, or the searched pocket is out of range.

942 CAROUSEL POSITION TIMEOUT This alarm is generated by the tool changer if the tool carousel has not moved after the allowed time or has not stopped after the allowed time specified by parameter 60 TURRET START DELAY and parameter 61 TURRET STOP DELAY, respectively.

943 UNPROCESSED QUEUE CELL IN TOOL CHANGE There is an unknown command generated in the Tool change. Please save your current program to disk and notify your dealer.

944 INDEXER OUT OF POSITION The A axis indexer is out of position. Jog the A axis to within 1 degree of a clamping position before you run a program.

945 APC-LIFT FRAME DOWN TIMEOUT The pallet changer was commanded to lower but the down position switch was not contacted before the timeout period. Check for foreign objects under the lift frame. Verify there is an adequate supply of air pressure and air volume. Verify that parameter 320 is correct. Check air solenoids for sticking and air release ports for clogging. Check pallet down position switch and wiring for damage, switch connections for positive electrical contact, and the lifting mechanism for proper operation. After determining the cause and correcting the problem, press TOOL CHANGER RESTORE to enter pallet changer recovery, recover the pallet changer, and then continue operation.

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946 APC-PALLET CLAMP TIMEOUT The pallet in the mill did not clamp in the time allowed. Check for foreign objects under the pallet and between the pallet and the clamp plate. Verify there is an adequate supply of air pressure and air volume. Check air solenoids for sticking and air release ports for clogging. Check the pallet clamped position switch for correct operation, the switch and wiring for damage, and pallet alignment. Check the pallet clamp mechanism for correct operation. After determining the cause and correcting the problem, press Tool Changer Restore to enter pallet changer recovery, recover the pallet changer, and then continue operation. Parameter 317 specifies the pallet clamp timeout period.

947 APC-PALLET UNCLAMP TIMEOUT The pallet in the mill did not unclamp in the time allowed. Check for foreign objects between the pallet and the clamp plate. Verify there is an adequate supply of air pressure and air volume. Check air solenoids for sticking and air release ports for clogging. Check the pallet clamped position switch for correct operation, the switch and wiring for damage and pallet alignment. Check the pallet clamp plate for damage. After determining the cause and correcting the problem, press Tool Changer Restore to enter pallet changer recovery, recover the pallet changer, and continue operation. Parameter 316 specifies the unclamp timeout period.

948 APC-SOFTWARE ERROR Fault in pallet changer software. Note the actions that caused this alarm. Also, record the following information: On the control panel, press PARAM DGNOS key to get the DGNOS screen. Then press P AGE UP to the PC INPUTS p age. Record the values of PC STATE, ALARM ST and ALARM. If this alarm recurs regularly call your dealer.

949 APC-AXIS VISIBLE The pallet changer axis must be invisible for the pallet changer to operate. Set the parameter bit INVIS AXIS to one for the axis that the pallet changer is installed on.

950 APC-ILLEGAL SWITCH CONDITION, LIFT FRAME The pallet changer lift frame switches indicate that the pallet changer lift frame is up and down at the same time. Verify there is an adequate supply of air pressure and air volume. Check the adjustment of the lift frame position switches and for debris on the switches. Check switch electrical connections and wiring. This may be a false alarm if the pallet changer was out of position by 90 degrees (+/- 20) when a pallet change was in progress. After correcting the cause, press Tool Changer Restore to enter pallet changer recovery, recover the pallet changer, and then continue operation.

951 APC-ILLEGAL SWITCH CONDITION, PALLET CLAMP The pallet changer clamp switches indicate that the pallet changer is clamped and unclamped at the same time. Check the adjustment of the pallet clamp switches and for debris on the switches. Check switch electrical connections and wiring. After correcting the cause, press Tool Changer Restore to enter pallet changer recovery, recover the pallet changer, and then continue operation.

952 APC-MISLOCATED LIFT FRAME The pallet changer lift frame is not in the expected position. The lift frame was either down when expected to be up, or up when expected to be down. For example, the lift frame must be up while rotating. The lift frame must be down when a pallet change starts, before clamping the pallet, before the A axis or Z axis can be jogged, or before starting a program with CYCLE START. If the pallet began to lower during rotation, check the lift mechanism for proper operation. If this alarm occurred at start of pallet change or when clamping the pallet, check for foreign objects or misalignment that prevent the frame from lowering all the way. Verify there is an adequate supply of air pressure and air volume. After correcting the cause, press Tool Changer Restore to enter pallet changer recovery, recover the pallet changer, and then continue operation.

953 APC-MISLOCATED P ALLET CLAMP The pallet changer clamp plate is not in the expected position. The clamp plate must be unclamped while the pallet changer is rotating or before the pallet is lifted. Verify there is an adequate supply of air pressure and air volume. Check operation of the clamp mechanism air solenoids. Check the pallet clamped position switch for correct operation, the switch and wiring for damage and pallet alignment. Check the pallet clamp plate for damage. After correcting the cause, press Tool Changer Restore to enter pallet changer recovery, recover the pallet changer, and then continue operation.

954 APC-INCOMPLETE PALLET CHANGE The last pallet change did not complete successfully or the mill has been initialized. Press Tool Changer Restore to enter pallet changer recovery, recover the pallet changer, and then continue operation.

955 APC-INV ALID P ALLET CHANGER TYPE Parameter 605 has an invalid pallet changer type.

956 APC-LIFT FRAME UP TIMEOUT The pallet changer was commanded to lift but the up position switch was not

contacted before the timeout period. The primary cause of this alarm is insufficient air pressure or air volume. Also, verify the pallet is unclamped and there are no obstructing objects. Check pallet up switch and wiring for damage, switch connections for positive electrical contact, and the lifting mechanism for proper operation. Verify parameter 321 is correct. After determining and correcting the problem, press Tool Changer Restore to enter pallet changer recovery, recover the pallet changer, and then continue operation.

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957 APC-SWITCH FAULT An illegal switch condition was detected. The pallet clamp switch did not function correctly. Use M17 and M18 commands to verify the input switch (input relay 26) changes state when the pallet clamps and unclamps. Check switch adjustment and check wiring for damage or unplugged connectors. The polarity of the clamp switch may be wrong. Parameter 734 is used to invert input switch polarity.

958 TOOL OFS WEAR HAS BEEN CHANGED When tool offsets have been changed, alarm 958 will be added to the alarm history along with the date and time. Note that this is not a resetable alarm; it is for information purposes only.

959 NON-INDEXER POSITION The position commanded for the A axis incremental indexer is a non-indexer position. The indexer positions are multiples of parameter 647. Parameter 647 is in thousandths of a degree. For example, a value of 2500 represents 2.5 degrees.

960 INDEXER SWITCH NOT FOUND IN TIME The A axis indexer down switch was not found within the allowed time specified by parameter 659.

961 FLOPPY OFFSET NOT FOUND This alarm is generated because FNC has lost the offset place mark it needs to correctly advance program. Try to reload program.

962 UNABLE TO RETRIEVE FILE INFORMA TION File functions are taking too long to process. T ry loading again. 963 UNABLE TO FNC FROM THIS DEVICE This device may not function from FNC. Please change setting 134 connec-

tion type to an appropriate FNC device, from the operator’s manual. 968 DOOR HOLD OVERRIDE ENGAGED Whenever setting 51 is changed to ON, alarm 968 will be added to the alarm

history along with the date and time the change was made. Note that this is not a resetable alarm; it is for information purposes only.

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

The following alarms only apply to HS Series mills with a pallet changer

1001 Index St Unlocked The index station is not in the correct orientation for a pallet change. 1002 Pallet Locked Down The pallet did not begin to lift within two seconds of command, or did not complete lifting

within six seconds. 1003 Pallets Jammed The lift cylinder has not moved from the clockwise position within three seconds, or has not

reached the counter clockwise position within twelve seconds. 1004 CW/CCW Switch Illegal Condition One or both of the switches that sense the rotational position of the pallet

changer has failed its self-test. 1007 Up/Down Switch Illegal Condition One or both of the switches that sense the lifted/lowered position of the

pallet changer has failed its self-test.

1008 Main Drawbar Locked In Up Position The main drawbar will not disengage from the pallet nut. 1009 Main Drawbar Locked In Down Position The main drawbar will not move upward to the pallet nut. 1010 Main Drawbar Switch Illegal Condition One or both of the switches that sense the up/down position of the

main drawbar has failed its self-test. 1011 Main Drawbar Unclamp Timeout The main drawbar has disengaged from the pallet nut, but did not reach the

main drawbar down switch. 1012 Main Drawbar Clamp Timeout The main drawbar has begun to travel upward, but did not reach the fully raised

position within 15 seconds.

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3. MECHANICAL SERVICE

RECOMMENDED TORQUE V ALUES FOR MACHINE FASTENERS

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

DIAMETER TORQUE

8-32 30 in. lb. 1/4 - 20 15 ft. lb. 5/16 - 18 30 ft. lb. 3/8 - 16 50 ft. lb. M10 - 100 50 ft. lb. M12 - 65 100 ft. lb. 1/2 - 13 80 ft. lb. 3/4 - 10 275 ft. lb. 1 - 8 450 ft. lb.

3.1 WAY C OVERS

X-AXIS W AY COVER R EMOVAL

Left/Right Way Cover Removal

1. Jog the X-axis to the center of travel and POWER OFF the machine.

2. T o remove the desired way cover , remove the SHCS that fasten the way covers to the table and remove the SHCS that fasten the way covers to the outside casting.

Y-AXIS W AY COVER R EMOVAL

Removal - Top

1. Jog the X-axis to the center of travel and the Y-axis all the way down.

2. POWER OFF the machine.

3. Remove the BHCS that fasten the waycover to the spindle head and the vertical guides to the column.

5. Remove the top waycover.

Install the way cover in the reverse order above however make sure that all necessary gaskets, and sealants are replaced and repaired as necessary .

Removal - Lower

1. Jog the X-axis to the center of travel and the Y-axis all the way up.

2. POWER OFF the machine.

3. Remove the three (3) BHCS that fasten the waycover to the spindle head.

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4. Remove the seven (7) BHCS on each side that fasten the vertical guides to the column.

5. Remove the lower waycover.

Install the way cover in the reverse order above however make sure that all necessary gaskets, and sealants are replaced and repaired as necessary .

Z-AXIS W AY C OVER

Right Way Cover

Removal

1. Jog the Z-axis (receiver) all the way in the +Z direction (away from the spindle).

2. POWER OFF the machine.

3. Remove the 14 BHCS that fasten the front of the waycover to the receiver.

4. Remove the 14 BHCS that fasten the rear of the waycover to the column.

5. Remove the waycover.

Installation

1. POWER ON the machine.

2. Replace the waycover. The end with the smallest section goes toward the receiver.

3. Fasten the column end using fourteen (14) BHCS.

4. Fasten the receiver end using fourteen (14) BHCS.

Left Way Cover

Removal

1. Jog the Z-axis (receiver) all the way in the -Z direction (toward the spindle).

2. Rotate the H-frame 45° counter clockwise.

3. Remove the thirteen (13) BHCS that fasten the rear way cover to the receiver assembly .

4. Remove the rear waycover through the door.

Install the way cover in the reverse order above however make sure that all necessary gaskets, and sealants are replaced and repaired as necessary .

EC-300 X-AXIS W AY C OVER A DJUSTMENT

The front of the column on either side of the spindle, is covered by heavy shades kept taut by spring loaded canisters. If the shades should need adjusting, refer to the following procedure.

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Shades

1 Clamp the shaft at the flat with clamping pliers or other such clamping device to hold the shaft

when adjusting of the spring tension.

2. Loosen the set screw so that the spring tension may be adjusted.

3. Rotate the shaft one complete revolution against the force of the spring (counter clockwise for the left canister and clockwise for the right canister). Retighten the set screw .

4. Check the tension of the shade. Repeat this process as needed for proper tension one revolution at a time. Do not overtighten the spring.

EC-300 Y-AXIS W AY COVER

Upper Way Cover Removal

1. Handle jog the X-axis to center of travel. Handle jog the Y -axis down fully.

2. POWER OFF the machine.

3. Remove the twenty six (26) FHCS that attach the vertical guides to the way cover.

5. Remove the six (6) BHCS that the attach the upper way cover to the spindle head and the lower way cover.

20X 1/4-20 UNC

x 1-1/4 SS FHCS

6X 1/4-20 UNC

x 2-1/2 SS FHCS

Upper Y-Axis

Waycovers

P-Cool

Assembly 4X Lockwasher 4X BHCS

6X BHCS

Lower Y-Axis

Waycovers

Waycover Guide

Rails

2X Holding Bar

Holding Bar

Y-Axis Waycovers

2X Guide Rail

6X Spacer

5X Guide Bar

Front Bar

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Installation

1. Install the four SHCS at the top of the way cover . Slide the way cover up and down to ensure that it moves freely .

2. Slide the way cover down until the bottom flange goes under the spindle head cover and fasten it with four (4) BHCS.

3. Fasten the left and right vertical guides using twenty six (26) FHCS.

Lower Y-Axis Way Cover Removal

1. Handle jog the X-axis to center of travel. Handle jog the Y -axis up fully.

2. POWER OFF the machine.

3. Remove the twenty six (26) SHCS that attach the left and right vertical guides and remove.

4. Remove the four (4) FHCS that attach the top of the lower Y-axis way cover to the spindle head casting. Collapse the way cover down fully .

5. Remove the way cover from the bottom.

Installation

1. Install the four SHCS at the bottom of the way cover , and tighten evenly .

2. Slide the bottom of the way cover up and down to ensure it moves freely .

3. Slide the top flange of the waycover under the spindle head cover plate and fasten it to the spindle head cover and upper waycover using four (4) BHCS.

4. Replace the left and right vertical guides using twenty six (26) BHCS.

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3.2 SPINDLE M OTOR R EPLACEMENT

Removal

1. Remove the rear enclosure panel.

2. Disconnect the electrical cable to the fan.

3. At the rear of the spindle and motor shroud, remove the four (4) SHCS that hold the fan mounting bracket in place. Remove the electrical and pneumatic connections from the solenoid valve assembly.

EC-400 Motor

Shroud

4X BHCS

8X BHCS

EC-300

Motor Shroud

2X Two Washers as Spacer

Fan

Cable Carrier Assembly

Fan Guard

4X SHCS

6X Hex Nut

6X Lockwasher

Spindle Motor Assembly

4X SHCS

Fan Mounting

Bracket

SHCS

4X Lockwashers

Encoder Mounting Bracket

Spindle Encoder

4. EC-400 Remove the motor shroud, which is held on with four (4) BHCS. Disconnect the encoder cable.

5. EC-300 Remove Y -axis cable carrier and bracket. Loosen the X-axis cable carrier and position away from the back of the spindle casting.

6. Remove the four (4) bolts that mount the spindle motor assembly to the column and remove the spindle motor assembly .

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Installation

1. Sweep the spindle before the motor installation is started.

2. Check the condition of the coupler hub on top of the spindle, and the condition of the coupler

3. Bring the motor towards the TRP. The couplers should engage with very little interference. It may

4. Once the coupler hubs are mated, install the bolts in that hold the motor to the spacer blocks;

5. Install the air blast (purge) bracket and solenoid on the back of the motor . Ensure the cylinder is

spider. Lif t the motor up and position it just above the TRP using a forklif t or hoist. Check the condition of the coupler hub on the motor, and align it with the coupler on the spindle. Inspect the transfer tube for damage and the O-rings for deterioration. Replace, if necessary .

Note: Insure that the transfer tube has been installed prior to motor installation.

be necessary to rotate the spindle slightly to line up the coupler hubs or rock the motor housing back and forth to square the assemblies. Do this using your hand on the spindle dogs, at the nose of the spindle.

leave them loose. Join all the motor cables to the harness of the machine. Command a spindle speed of 1000 rpm; the motor mounting bolts are to be left loose. Let the spindle run for about 5 minutes, this allows the spindle assembly to seat and will help the final alignment. Snug bolts while spindle is rotating then stop the spindle and torque the bolts.

centered over the motor shaft, adjust as necessary . Connect the air line to the solenoid 3.3 Tool Release Piston (TRP)

Shaft

Coupler Spider

Coupler Hub

O-Ring

Transfer

Tube

ShaftAdaptor

Transfer Tube and Motor Shaft Motor and Air Blast Purge Bracket

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50 TAPER T RANSMISSION AND M OTOR R EPLACEMENT

Removal

1. Lower the Z-axis travel to its full negative value (full down). Position the mill table so that it is centered on the X-axis and as close to the doors as possible (full -Y). This will allow the best working surface.

2. Clean the mill table of any grease, coolant, or chips. You will be standing on the mill table during this procedure and need firm footing.

3. Power OFF the machine. Remove all air and power service from the machine.

4. Remove the head covers. Refer to the “Head Covers Removal / Installation” section.

5. Remove the TRP assembly . Refer to the “50 T aper S pindle TRP Removal” section.

CAUTION! The TRP assembly is very heavy. When moving, ensure you have a place

to set the assembly when removed.

NOTE: Make sure you collect all washers and spacers from beneath the TRP

assembly. Keep these separated in sets.

6. Remove the TSC extension tube if the machine is equipped with Through the S pindle Coolant option. Refer to the “Through The S pindle Coolant System” section.

NOTE: The TSC union and extension shaft are reverse thread.

7. If your machine is equipped with TSC, remove the 3/16” SHCS that attach the TSC valve bracket to the right side of the motor. Let the TSC valve bracket hang off the right side of the spindle head, ensuring that the hoses do not get kinked.

8. Remove the SHCS that attach the TRP solenoid assembly to the top of the motor lift plate. Cable tie the assembly to the rear sheetmetal or column to prevent damage while removing the transmission/motor assembly .

9. Remove the quick-disconnect electrical plug panel from the rear of the motor . This is attached by four 3/16” SHCS. Gently push the plug panel behind the motor and cable tie it to the rear sheetmetal or column.

10. Remove the plug for the gear change solenoid.

1 1. Remove the Encoder-to-Transmission Shaft belt. This can most easily be accomplished by

removing the four SHCS that attach the Encoder bracket to the spindle head (located inside the spindle head cavity between the drive belts). Access the panel on front of the head casting above the spindle.

12. Remove the four large SHCS that attach the transmission mount plate to the spindle head and pull the transmission/motor assembly towards the front of the machine slightly . This proceedure will remove the tension on the drive belts.

13. Remove the Encoder belt and the drive belts.

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CAUTION! Measure the distance between the bottom of the Z-axis motor and the

ballscrew anchor mount. Cut a wood block to the proper length and put in place. This is necessary to counteract the Hydraulic Counterbalance mechanism when the transmission/motor assembly is lifted off the machine.

14. Mark and remove the power cables from the motor.

15. Attach a heavy chain to the lifting eyeholes of the top motor plate using hooks or C-clips of appropriate weight rating (approximately 250 lbs.).

16. Lift off the transmission/motor assembly.

Installation

1. Lift the transmission/motor assembly into place. The next five steps (2-6) can be performed with

2. Connect the power wires.

3. Attach the electrical plug panel to the rear of the motor . Reatt ach any Molex plugs to the panel, if

4. Slide on the drive belts.

5. Place and secure the TRP solenoid assembly to the top of the motor lift plate using the removed

6. Place and secure the TSC valve bracket to the right side of the motor lift plate using the removed

CAUTION! Before proceeding, make sure you have appropriate lifting equipment to

safely lift 250 lbs., room to maneuver it, and a stable place to set the transmission/motor assembly once it is removed.

CAUTION! Before proceeding, make sure you have appropriate lifting equipment to

safely lift 250 lbs. and room to maneuver.

the transmission/motor assembly turned slightly to ease installation of accessory parts.

removed during the previous procedure.

SHCS.

SHCS (if equipped).

7. Properly orient the transmission/motor assembly , if necessary . Insert the four SHCS that attach the transmission mount plate to the spindle head.

8. Use a Belt T ensioning Tool to tighten drive belts. Do not overtighten the drive belts!

9. Slip on the Encoder belt. Reattach the Encoder bracket.

10. Replace the TRP assembly . See “50 T aper S pindle TRP Installation”.

1 1. Replace the TSC union and extension shaft. Refer to the “Through The S pindle Coolant System”

section.

NOTE: The TSC union and extension shaft are reverse thread.

12. Lubricate any new or removed parts if necessary . Remove the wood spacer (if used). Check to make sure all connections are secure.

13. Reconnect air and power services. If equipped with TSC, check drawbar for runout. See the “Adjusting Extension Tube Runout” section.

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14. Replace sheetmetal.

15. Set spindle orientation. Refer to the “Spindle Orient ation” section.

16. Check T oolchanger function.

TOOL R ELEASE P ISTON R EPLACEMENT

Removal

1. Remove the rear enclosure panel.

2. Jog the Y-axis all the way to the top. Insert a sturdy piece of wood on the bottom of the column casting. Jog the Y-axis down until the bottom of the spindle head rests on the wood. This will prevent the spindle head from falling in the event of an accident. Power off the machine.

3. Disconnect the main air supply at the lube/air panel.

4. Remove the spindle motor as described in the Spindle Motor Removal section.

5. Remove the two (2) SHCS attaching the lower Y -axis way cover to the spindle head casting, and collapse it downward. It is easiest to reach the TRP from the front side of the machine.

6. Disconnect the TRP air lines and switch cables.

TRPAssembly

4X Lockwasher

3/8 “ Air

Hose Fitting

4X SHCS

Unclamp

Switch

1/4” Air Hose Fitting

Clamp Switch

Lockwasher

SHCS

Cable Carrier

Assembly

4X BHCS

4X Lockwasher

Spindle Motor and

Shroud Assembly

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1/4” Air Hose F

TRPAssembly

3/8 “ Air

Hose Fitting

7. Remove the four (4) SHCS holding the tool release piston assembly to the head casting.

8. Remove the entire tool release piston assembly.

Installation

1. Loosely reinstall the tool release piston with the four (4) SHCS.

2. Reconnect clamp/unclamp switch cables and TRP air lines

Unclamp

Switch

Clamp Switch

Lockwasher

4X SHCS

1/4” Air Hose

Fitting

Spindle Motor and

Shroud Assembly

3/8” Air Hose Fitting

EC-Series TRP assembly

Unclamp Switch

Clamp Switch

View Rotated for Clarity

3. Install the motor as described in the Spindle Motor Replacement section.

4. Finish tightening the four SHCS that mount the TRP to the spindle head.

5. IMPORTANT! Remove the wood brace from the spindle head.

6. Replace the rear enclosure panel.

SETTING P RE-CHARGE

1. Install an air gauge capable of reading 30 psi to the precharge assembly.

2. Press MDI DNC to get to MDI screen.

3. Type in 1 120=1 and press WRITE/ENTER, and then Press CYCLE ST ART.

4. Set the pressure regulator so that 30 psi reads on the gauge. Press the regulator knob in to lock the knob in place.

5. Press RESET.

6. Remove the gauge and replace the hose.

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3.3 SPINDLE

SPINDLE C ARTRIDGE

REMOVAL-

1. Remove the six SHCS that mount the spindle to head casting.

2. Slide the spindle out from the front side of machine.

INSTALLATION-

1. Inspect the mating surface for high spots on the spindle and spindle head casting before installing spindle.

2. Carefully install the new spindle into the bored sleeve of the head casting. Apply grease to the inside of the through bore in the spindle head. The oil drain hole must point down. Failure to do so will cause the spindle to overheat, fail, adn will void the warranty .

6X SHCS

6X Lockwasher

Spindle

Assembly

EC-400

Spindle Head

Assembly

1/4” Tube X 1/8” NPT

3. Evenly tighten the six mounting SHCS on the front side of the spindle in a cross pattern until all bolts are completely tight.

4. Reset spindle orientation and check the tool changer adjustment.

5. Refer to the "Spindle - Overheating" section of "T roubleshooting" and use the spindle run-in program. Verify that the spindle temperatures are accept able.

SPINDLE S WEEP A DJUSTMENT

EC-300 Spindle Head Assembly

1/4” Tube X 1/8” NPT

Spindle must be installed with oil drain notch in spindle lock at the bottom

NOTE: The machine must be properly leveled for the spindle sweep adjustment to be

1. Place an indicator on the table and insert a 6" precision test bar into the spindle.

2. Jog the Z-axis while indicating the bottom, and then the side, of the test bar. The readings must be within 0.0005/10" in both the Y/Z and X/Z planes, as stated in the inspection report supplied with the machine.

3. Shim the spindle, if necessary , to correct the spindle sweep to specifications. Recheck spindle sweep.

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3.4 DRAWBAR R EPLACEMENT

DRAWBAR R EPLACEMENT - IN-LINE D RIVE

The drawbar is only replaceable on the 8000 RPM spindle. The 12000 RPM spindle has a non-serviceable drawbar.

Note: 12000 spindles only: Should a spindle fail, both the spindle and drawbar are

to be replaced as a unit.

Removal

Remove the spindle as described in the Spindle Removal section.. Remove the keys from the drawbar , and remove the drawbar from the spindle.

Installation

Clean and grease the shaft and shaft adaptor . Install the drawbar unit. Install the two keys, flat side up. Use a “C” clamp to press the keys together to seat them against the drawbar. Torque the 5/16-18 retaining bolts to 30 ft-lb.

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Verify the operation of the spindle by running it. If there is excessive vibration, loosen the bolt s to the spindle cartridge and spindle head. Run the spindle at 1000 rpm and snug the bolts. Stop the spindle and tighten the bolts.

DRAWBAR R EPLACEMENT - 50 TAPER

1. Remove the head covers. Refer to the “Head Covers Removal / Installation” section.

2. Remove the tool release piston. Refer to the “50 T aper S pindle TRP Removal” section.

3. Remove the TSC extension tube if the machine is equipped with Through the S pindle Coolant option. Refer to the TSC section.

4. Remove the six bolts holding the spindle cap to the machine.

5. Remove the drawbar.

6. Thoroughly coat the replacement drawbar with grease, including the end of the shaft where the four holding balls are located.

CAUTION! Excess grease may cause the drawbar to hydraulic lock preventing the full

stroke of the drawbar.

7. If machine is equipped with Through the Spindle Coolant option, grease the O-rings.

8. Insert six new balls in the replacement drawbar and insert into the spindle shaft. Be sure that as the shaft is installed, the balls do not fall out of the bores in the drawbar .

CAUTION! Insert the drawbar gently so the O-rings are not damaged. DO NOT use a

hammer to force it.

NOTE: Carefully inspect the spindle shaft for galling or burrs inside the spindle shaft

where the end of the drawbar rides. If it is damaged, the spindle must be replaced.

9. Install the drawbar.

10. Reinstall the tool release piston.

3.5 TOOL C LAMP/UNCLAMP S WITCH ADJUSTMENT

TOOLS REQUIRED

• Right angle plate

• Machined aluminum block (2"x4"x4")

TOOL C LAMP/UNCLAMP S WITCH A DJUSTMENT - INITIAL P REPARATION

1. Remove the rear enclosure panel.

2. Secure the right angle plate in place on the table.

3. Place the machined block of aluminum against the right angle plate.

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4. POWER ON the machine.

5. Insert an empty tool holder into the spindle taper .

6. Go to HANDLE JOG mode. Choose Z-axis and set the jog increments to .01.

7. Jog the Z-axis in the negative (-) direction until the tool holder is approximately .03" from the block. At this point, stop jogging and press the TOOL RELEASE button (top left). The tool holder will come out of the taper .

NOTE: Do not jog too far in the negative (-) direction! This will cause overcurrent in the

Z-axis.

SETTING TRP HEIGHT

1. Press the MDI key and turn the jog handle to zero (0).

2. Press HANDLE JOG and set the increments to .01. Jog the Z-axis in the positive (+) direction .100".

3. Press and hold the TOOL RELEASE button, and try to move the block by hand. The block should be tight at .100" and loose at .1 10". If it 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 the block is tight.

NOTE: The increments jogged in the Z negative (-) direction are the amount of shim

that must be added to the tool release piston. Refer to the "TRP Shims" section.

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 the block is loose.

NOTE: The increments jogged in the Z positive (+) direction is the amount of shim that

must be removed from the tool release piston. Refer to the "TRP Shims" section.

TRP SHIMS

The drawbar uses a 1-piece shim which can be added or removed without having to remove the TRP assembly . Once the shims have been adjusted the TRP is reinstalled and the final torque on the bolts is 35 ft-lb.

Tool release piston assembly

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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.

1. Check the condition of the tool release bolt and the draw bar. Rep air or replace these items before setting the drawbar height.

2. To add or subtract shims, loosen the bolts that secure the retaining plate.

3. Add or subtract required shim washers (See previous section for correct amount to add or remove).

4. Tighten the retaining plate screws.

ADJUSTMENT OF S WITCHES

Unclamp Switch

1. Drawbar height must be set properly before adjusting switches. Add or subtract shim washers to the tool release piston until proper height is achieved. In-line drive machines must have the precharge pressure verified. See the previous, “Setting Pre-Charge” section.

2. Push the P ARAM/DGNOS twice to enter the diagnostic mode and confirm that DB OPN =0 and DB CLS =1.

3. Using the same set-up for setting the drawbar height, jog the Z-axis to 0.06" above from where the tool holder was resting on the aluminum block.

4. Change Parameter 76 “Low air Delay” to 45000 to eliminate a low air pressure alarm.

5. In order to limit the spindle head deflection during this next part of the procedure the air pressure will need to be reduced to lower the output force of the TRP. Reduce the air regulator to about 60 psi. Place a 0.0005” test indicator between the table and front face of spindle head to measure axial deflection when the tool release piston is energized. Press and hold the tool release button and check that the block is tight and the head deflection is between 0.002 and 0.004”. If the head deflection is too high, reduce the air pressure. If the head deflection is too low, or no deflection, increase the air pressure. Once the head deflection is between .002” and 0.004” proceed to the next step.

Indicator on Table In-Line Drive Tool Release Piston Assembly

6. Press the tool release button and hold it in. Adjust the switch in or out until the switch just trip s (DB OPN =1). Cycle the tool release several times and confirm the switch is tripping.

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7. Check the adjustment. Jog the Z-axis down until the tool is .050 above the block and confirm that DB OPN=0 when the tool release button is pressed. The switch must trip (DB OPN =1) at 0.06" above the block and not trip (DB OPN =0) at 0.05" above the block.

8. Re-adjust and repeat steps 1-6 if necessary .

9. Set the pressure regulator back to 85PSI.

10. Set parameter 76 back to the original setting.

Clamp Switch

1. If the machine is equipped with TSC, remove the seal housing before continuing. This step does not apply to In-line drives with TSC.

2. Remove the tool holder from the spindle.

3. Delete everything in MDI mode and write “#1120=1”.

4. St art with the upper switch all the way in. Place a 0.02” shim between the tool release piston adjustment bolt and the drawbar.

5. Push the P ARAM/DGNOS button twice to enter the diagnostics mode.

6. Press CYCLE ST ART .

7. If DB CLS=0 (tool Unclamp) you are done (do not check with 0.04” shim). If not, adjust the upper switch out until the switch is just un-tripped (DB CLS=0).

8. Press RESET. Replace the 0.02” shim with a 0.04” shim. Press CYCLE ST ART. See that DB CLS=1. Readjust and repeat steps 2-8 if necessary . This step is not necessary for In-Line Drive machines

Checking with the 0.04” shim assures that the switch is not backed off too far . If switch is all the way in, this check is not needed.

CAUTION! Remove the tool holder from the spindle before performing the CLAMP

switch adjustment. Failure to remove it could result in damage to the tool holder, the mill table, or cause severe personal injury.

Tool Release

Piston

Shim

Drawbar

Spindle Cartridge

Assembly

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Shim

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3.6 40 TAPER C AROUSEL SIDE M OUNT T OOL C HANGER

40 TAPER C AROUSEL REMOVAL AND I NSTALLATION

Carousel

Number Disc

ATCCover (3 Pieces)

Tool Pockets

Carousel

Number Disc

Carousel Housing

Assembly

Carousel

Cover

Base

EC-300 Side Mount Tool Changer Assembly

Carousel

Carousel Housing

ATCAssembly

Assembly

Carousel

Shaft Nut

Carousel

Tool Pockets

Pocket

Retaining

Screw

Load Position

EC-400 Side Mount Tool Changer Assembly

Special T ools Required: • Lifting Device (1000lb capacity for ATC removal)

• Spanner Wrench

• Split Tools

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Bracket

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Removal:

1. Power Off machine.

2. Unscrew the BHCS from the carousel number disc and remove.

3. Using a spanner wrench, remove nut on the center shaft of the carousel.

4. Carefully pull carousel assembly from the A TC center shaft. Lift carousel away from the machine

5. Unscrew the FHCS for each tool pocket. Remove the tool pocket holders from carousel.

Installation:

1. Carefully lift and place carousel on to the center shaft.

2. Install new carousel retaining nut on to the ATC center shaft and torque to 85 ft-lbs (place the

Carousel

and carefully avoid hitting the sheet metal covers. Place assembly in service area.

CAUTION! Be careful not to bend the tool pocket orientation tabs when storing the

carousel assembly.

locking portion of the nut towards the end of the shaft). Remove the pocket stop and slider .

Number

Disc

Carousel

Shaft Nut

Carousel

Carousel Housing

Carousel

Tool Pocket

Mounting

FHCS

Slider Position

Pocket

Stop

Mounting BHCS (8)

Tool Pockets

Top View

Pocket

Orientation

Tabs

Tool Pocket (Load Position)

Carousel Assembly Carousel and Tool Pocket Installation

3. Install each tool holder through the spindle. Attach the tool pocket to the carousel. Apply blue loctite to the Torx and torque to 15 ft-lbs (1/4-20) / 23 ft-lbs (5/16-18). Manually rotate the carousel for each tool pocket installation. Re-install the pocket stop and slider. The carousel can be rot ated by manually rotating the carousel pulley by hand.

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Carousel

Motor

Pulley locations and ATC movement

4. Re-attach the carousel number disc with the BHCS. Apply blue loctite to the BHCS and tighten.

50 TAPER C AROUSEL REMOVAL AND I NSTALLATION

CAUTION! Do not attempt to remove the carousel with the pockets installed.

1. Remove sheetmetal disc covering the carousel. Press <TOOL CHANGER RESTORE>. Press <Y> three times to enter T ool Changer Recover Mode.

2. Remove all tool changer pockets. See the 50 Taper SMTC Pocket Removal and Installation in this section.

Carousel Pulley

3. Remove the center bearing nut using Haas tool P/N 1357.

4. Remove the carousel using a suitable lifting device.

Installation

1. Using a suitable lifting device, place the carousel onto the tool changer body .

2. Use a new bearing nut and thread onto the carousel shaft. Torque to 80 ft./lbs.

3. Install pockets into the carousel following the 50 Taper SMTC Pocket Removal and Installation

4. Rotate the carousel by hand to the next pocket. Line up the pocket mounting finger with the

NOTE: The carousel can be manually rotated by turning the carousel drive motor by

hand while in <E-STOP>.

CAUTION! The carousel is extremely heavy. Ensure you have an appropriate lifting

device and straps capable of lifting the carousel weight.

section.

actuator shaft (or micro switch) on the flat spot on the carousel cam.

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TOOL C HANGER A SSEMBLY R EMOVAL / INSTALLATION

Removal:

1. Power off machine.

2. Remove all ATC assembly sheet metal covers and fasteners.

3. Remove the tool changer amphenol connection at the control box and tool pocket air line at the top of the carousel. Wrap and tie the amphenol connector to the top of the carousel cam box.

4. Insert an eyebolt into the threaded 1/2-13 hole at the top of the carousel housing. Att ach the lifting device to the eyebolt and support the A TC assembly . Remove the five carousel mounting SHCS from the A TC mounting bracket and move A TC assembly away from the column.

5. Carefully raise the ATC assembly until it is out of the machine. Avoid catching the double-arm on other machine parts.

6. Lower the ATC assembly with the back side of the cam box towards the ground.

TC Lift Bracket

EC-1600 TC Lift Bracket

SHCS

SHCS *

* EC-1600-3000 only

T ool Changer Assembly Lifting Position Tool Changer Installation

1. Power Off machine.

2. Clean mounting surfaces of the A TC mounting bracket and the A TC.

3. Align the ATC with the mounting bracket and attach with SHCS. Only snug the SHCS.

4. Reconnect the tool changer amphenol connector to the control and reattach the air line to the carousel assembly .

Horiz. ATC Mounting Bracket

6X Hex

Head Bolt

Mounting Pins *

5. Align the ATC assembly according to section on A TC alignment.

6. T orque the SHCS to 100 ft-lbs.

7. Replace all carousel sheet metal covers and fasteners. Apply blue loctite to all fasteners and tighten.

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AUTOMATIC T OOL C HANGER A LIGNMENT

Use Split Tool P/N T-2086 for 40 taper , CT type T-2088 for 50 taper , BT type

T-2087 for 40 taper , BT type T -2089 for 50 taper , CT type

This procedure is for a newly mounted ATC assembly without the double-arm installed. Perform the grid offsets and change parameter 64 to 0 according to the instructions in this manual before proceeding.

1. Power Up machine, then zero return the Z-axis.

2. Go to the Debug mode and push the tool changer restore button. Follow the instructions given.

3. Install the appropriate split tool (CT or BT).

4. Move the A TC forward until it stop s.

5. In handle jog mode, align the split tool by jogging the X and Y axes until the alignment pin goes through the split tool with as little resistance as possible.

6. Go to the POS-RAW data page and record the actual encoder steps for the X and Y axes. Put the X-axis encoder steps reading into parameter 210 and Y -axis encoder steps into p arameter 211.

7. Measure the distance between the spit tool and multiply it by the Z-axis ratio (par 33 = 83231 steps/unit).

Cam Box to Tool Pocket Alignment:

1. Remove all cam box sheet metal fasteners and covers. Place protective covers on the machine table.

2. Power Up machine. Move the Z-axis all the way toward the spindle. Set the machine control to T ool Change Recovery Mode (TCR).

3. Push the ARROW DOWN button, to activate the tool pocket down (insure proper tool pocket operation).

4. POWER OFF the machine. Disconnect the air supply line at the rear of the machine. The tool pocket will swing out once the air is disconnected.

5. At the back of the ATC assembly, reverse the two air lines going from the solenoid valve to the air cylinder. Reconnect the air supply line at the rear of the machine. (The tool pocket holder in the tool change position should retract.)

6. At the back of the ATC assembly, manually rotate the cam box pulley clockwise until the output shaft is extended and just before it begins to rotate 1800.

7. Align the double-arm to the tool pocket and the spindle with the unlocking finger buttons facing in. Place the double-arm on to the shaft and snug the lock ring on the bottom of the double-arm with the SHCS.

8. Place the split tool into the double arm end in front of the tool pocket. The split tool P/Ns for 40T are T -2084 for CT type and T -2087 for BT type; P/Ns for 50T are T -2089 for CT type or T -2088 for BT type. Depress the tool release button on the keypad and insert the split tool. Slightly push the double-arm in the clockwise direction to remove backlash in the drive assembly .

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Radial Alignment of Double Arm to Carousel:

1. Rotate the cam box pulley counter-clockwise to raise the double-arm into the split tool. Visually check the centerline alignment of the split tool to the centerline of the tool pocket.

2. In order to adjust the radial alignment of the split tool to the double arm, loosen the lock ring SHCS and adjust the double-arm.

3. If the double arm is not aligned in the Y -axis with the centerline of the split tool, loosen the four cam box SHCS and insert a pry-bar between the slots. Adjust the cam box until the centerline of the split tool is aligned with the centerline of the tool pocket.

4. Torque the cam box SHCS to 80 ft-lbs.

Double-Arm

Radial

Alignment

Double-Arm

Finger Center

Carousel

Tool Pocket

Center

Cam Box / Double Arm Alignment, fr ont view.

Tool Release

Button (2)

Checking Parallelism of Double-arm to Table:

13. Rotate the cam box pulley clockwise to lower the double arm. Remove the split tool from the double arm.

14. Rotate the cam box pulley counter-clockwise to retract the double arm back to its home position.

15. Remove the air supply line from the rear of the machine. Switch the inlet and outlet airlines back to their original positions at the back of the ATC assembly. Reatt ach the air supply line (the tool pocket holder should retract to its home position).

Cam Box

Movement

Double-Arm

16. POWER ON the machine and enter TCR mode. For more information on TCR mode refer to the TCR flow chart located in the Technical Reference section.

17. Press the ATC FORWARD button until the arm extends and is parallel to the x-axis. Insert a split tool into the double arm by pressing the tool release button located near the shaft.

Place a magnetic base and indicator on to the machine table. Measure the end of the split tool to the nearest .001.”

18. Move the split tool and indicator setup to the other end of the double-arm. Measure the end of the split tool to the nearest .001.” The maximum allowable height tolerance between the two ends is .030.” Adjust the alignment as necessary. Repeat this test with the arm rotated 1800 .

19. Remove the split tool from the double-arm. Return the double-arm to the home position.

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Setting the Double-arm Extension:

20. Press the DOWN ARROW to command the tool pocket out. Place the split tool with the pull stud into the tool pocket. In TCR mode, rotate the double arm near the tool pocket.

21. Visually check the alignment of the double arm to the V -groove on the split tool. If necessary loosen the lock ring SHCS and adjust the extension of the double arm. Torque the lock ring SHCS to 15-17 ft-lbs.

22. Repeat steps 9 & 10 to re-check radial alignment.

23. Return the double-arm to the home position.

Double-Arm to Spindle Alignment:

1. ZERO RETURN the Z-axis.

2. In TCR mode, extend the double arm and re-insert the split tool into the double arm. Orient the spindle dogs for a tool change. (If the orientation has changed reset Parameter 257. Refer to section on setting spindle orientation). If spindle dogs are not aligned with the tool holder slot, manually rotate the spindle dogs.

3. Retract and extend the double-arm to move the tool in and out of the spindle. Check for alignment.

4. Check the X-axis alignment of the split tool to the spindle center.

Tool

Double-Arm

Tool Centerline

Top View

Double Arm to Spindle Center Alignment, along the Y -axis.

5. If necessary , loosen the five A TC mounting SHCS.

Spindle

Equalize Gap All Around

Spindle Centerline

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ATCCovers

ATCAssembly

Spindle

Assembly

Carousel

Number Disc

Pocket

Stop

8X BHCS

Carousel

Assembly

Double-Arm

Assembly

ATC Mounting Bracket

ATC Assembly Alignment.

6. Use a mallet to align the ATC mounting bracket. Adjust the bracket to align the split tool in the double arm to the center of the spindle in the X-axis.

7. T orque the SHCS to 80 ft-lbs.

8. Check the Y-axis alignment of the split tool to the spindle.

9. If necessary , loosen the five A TC SHCS and use a mallet to align the mounting bracket. Adjust the A TC along the mounting slots and align the tool and spindle’ s center .

10. Check the spindle tool change position. If the spindle tool change position has changed, reset Parameter 64 per the instructions in this chapter.

1 1. Return to normal operation. Insert tool holders through the spindle and perform several tool

changes. Observe the tool changer during operation and make any adjustments if necessary .

12. T orque the A TC mounting SHCS to 80 ft-lbs. Replace all cam box sheet metal covers and fasteners. Apply blue loctite to the fasteners and tighten.

EC-300 TOOL C HANGER DOOR O PEN S WITCH A DJUSTMENT

The tool changer door must be completely open before the sensor switch on the air cylinder changes its state.

1. With the machine on E-stop, disconnect the main air supply .

2. Clamped to the air cylinder with a hose clamp, is the tool changer door open switch. Move the sensor switch toward the rod end of the air cylinder until it reaches the end cap of the air cylinder.

3. Open the tool changer door all the way. W atch the diagnostic screen. Slowly slide the sensor switch back along the air cylinder until the tool changer door bit changes from 0 to 1.

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TC Door (Open)

Spring Damper

View Rotated 90

TC Door (Closed)

CCW

Hose Clamp

ToolChanger Door Open

Switch

4. Mark the spot where the bit changes to 1 and secure the switch with a hose clamp.

5. Reconnect the main air supply, and t ake the machine off of E-stop.

6. Run the tool changer door and check for speed.

7. Adjust the speed at the solenoid valve on the lube panel.

8. Check the action of the spring damper that stops the tool changer door when it opens. The tension can be adjusted by turning the adjustment screw on the back of the spring.

EC-400 TOOL C HANGER DOOR R EPLACEMENT

This procedure describes the installation of the complete door assembly . It may not be necessary to start the procedure from the beginning. Remove the damaged or inoperative parts and then rebuild the toolchanger door assembly.

Installation and Alignment

Linear Guides and Air Cylinder

1. Push the top of the linear guide towards main panel wall and tighten top bolt. Push the bottom of the linear guide towards panel wall and lightly tighten bottom bolt. Securely tighten the remaining bolts, and then tighten the top and bottom bolts. Install linear guide trucks and grease using fittings.

2. Grease shoulder bolt and slide through panel bracket, spacer , idler assembly, second spacer, and washer. Thread the bolt into the pemnut and tighten.

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3. Push air cylinder towards linear guide rail while tightening bolts.

4. Thread & tighten onto cylinder rod end.

T ool Changer Doors

5. Grease main panel face where the door guide will be mounted. Mount door guide to main panel, with the guide spacer between them using 10-32 flat-head screws.

6. Grease the edges of the door that will be sliding against main panel & door guide. Slide top door into door guide and place flange onto linear guide pad (top/right). Put the top door bracket over the door flange and position the door between the bracket and the upper linear guide truck. Push door flush against main panel and tighten the four bolts that hold the bracket to the linear guide. Check sliding motion of top door, bracket and truck, this should be smooth and uniform.

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7. Retract air cylinder rod. Place a 7/16 washer over rod aligner thread. Move top door bracket down

8. Grease main panel faces where door guides will be mounted. Mount door guides to main panel,

9. Attach the lower door bracket to bottom/left linear guide pad and leave bolts loose. Grease the

Drive Chain

10. Place chain around idler assemblies and attach one end to bottom door bracket at the hole closest

1 1 . Retract air cylinder and top door to the closed position. Move the bottom door so the top edge is

to air cylinder rod aligner. The hole in bracket should line up with rod aligner without forcing it over rod end. If not loosen air cylinder mounting bolts, reposition and then retighten the bolts. Place flat washer and split washer over rod end and tighten with a 7/16-20 nut. By hand, move the cylinder rod, door bracket and door, in and out, looking for any binding. If there is any misalignment, loosen the air cylinder mounting bolts and let it self align, then retighten the bolts.

with guide spacers sandwiched between them, via 10-32, zinc, flat head screws.

edges of the door that will be sliding against main panel & door guide. Slide door into door guides and attach to the lower door bracket. Align door so it is square to p anel prior to tightening the door bracket screws. Loosen 4 linear guide pad bolts and push door flush against main panel face and re-tighten.

to the lower idler assembly using a master link. Install jam nut onto threaded, right-handed side of the turnbuckle. Attach the opposite end of the turnbuckle to the other hole in the bottom door bracket using a second master link. Make sure chain is properly located on both idler assemblies. Tighten the chain using the turnbuckle and lock with jam nut.

even with the first bend line in the top door. Att ach chain retainer to top connect bracket and lock it into the chain.

12. Verify the operation of both doors. Move the top connect bracket back and forth with the cylinder stroke. The rod aligner should prevent any binding.

SETTING S PINDLE O RIENTATION

1. POWER UP machine. Go to P ARAMETERS. Unlock P ARAMETERS and change the value under P ARAMETER 257 to “0.”

2. Place a tool into the spindle. Enter TCR mode. Align the spindle dogs to the double-arm key (refer to Figure 3.12-13). Press the ATC FORWARD button until the double arm engages the tool (manually rotate the spindle dogs if necessary).

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3. Enter DEBUG mode. Record the encoder value under “spindle orientation position”. Refer to Figure

3.12-13.

4. Return to Parameter 257. Enter the spindle orientation value from DEBUG and lock parameters.

5. In TCR mode, press the A TC REVERSE button until the double arm is in the home position. Return to normal operation mode.

6. Manually insert tools into spindle and perform several tool changes. Observe for any misalignment.

7. Adjust the PARAMETER 257 setting value if necessary.

Double-Arm Key

Toolholder Slot

Align Spindle Dogs to Double-Arm Key and Toolholder Slot

DOUBLE A RM REMOVAL AND I NSTALLATION

Removal

1. In TCR mode, lower the double arm. POWER OFF machine.

2. Underneath the double-arm, loosen the six SHCS from the lock ring. Insert four new jack screws into the lock ring (Coat the jack screw threads and tips with moly grease).

3. Slowly tighten the jack screws in order to push the double-arm away from the lock ring. If necessary, t ap the center of the double arm from underneath with a soft mallet until the double-arm breaks free.

4. Once the double-arm is loose, pull the double arm assembly off the shaft.

Spindle Orientation Setting

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Installation

1. Place the double-arm onto output shaft. Align the double-arm to the home position, then slide the

2. Reattach the lock ring to the double-arm with eight (8) SHCS. Tighten in a star pattern to 15 ft-lbs,

Lock Ring

4X Double-Arm Jack SHCS

8X Lock Ring SHCS

Double-Arm

Removal of the Double Arm

lock ring onto the shaft.

repeat this sequence 3 times to seat the arm lock bushing. Verify the slides are correctly adjusted on the double arm with the following procedure:

With the double arm lowered, and the split tool inserted into the double arm, a 0.020 feeler gauge should fit between the slide and the tool flange O.D. The plunger should be able to rise fully to the locked position with the gauge between the split tool and the plunger.

Insert 0.020

Feeler Gauge

Plunger

Spring

Adjuster Hex

Shim

Washers

Here

Tool Holder

Adjuster

Double Arm with Cover

Slide

Plate Removed

The plunger will not return reliably to the fully raised locked position when the tool is inserted, if there is insufficient clearance. The split tool will be excessively loose in the doublearm if there is too much clearance.

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T o adjust the clearance, remove the slide and the cover by removing the cover plate and lifting the slide out at an angle. Be careful not to lose the spring. Loosen the adjuster and correct the clearance by adding or removing shims. Apply blue Locktite and retighten. Grease the spring and the slide assembly and reinstall them both. Reattach thecover plate and recheck the clearance. Both ends of the double arm are separately adjusted.

3. Re-align the double-arm to the spindle and tool pocket. Refer to double arm alignment instructions in the previous “A TC alignment” section.

40 TAPER SMTC POCKET R EMOVAL AND I NSTALLATION

Removal

1. Turn the machine on and rotate the carousel to the pocket you want to change. Remove the sheetmetal in order to gain access to pocket limit switches. Remove the sheetmetal disc covering the carousel.

2. Press <T ool Changer Restore>. Press <Y> three times.

3. Remove the four SHCS that hold the pocket stop. Remove the shoulder bolt from the back of the pocket slide.

Carousel

Tool Pocket

NOTE: The machine must be in Tool Changer Recovery Mode to perform the next step.

Cam Follower Groove

4X SHCS

Tool Pocket Stop

4. Press <v> to retract the air cylinder shaft. Manually lower the pocket and remove the pocket retaining screw . See the following figure:

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Carousel

Tool Pocket

Mounting

FHCS

Slider Position

Pocket

Stop

5. Remove the tool changer pocket by carefully maneuvering the pocket out of the carousel, taking

Installation

1. Replace the damaged pocket with a new one. Apply grease to the shaf t. Inst all the pocket slide

2. Clear all alarms. Return to T ool Changer Recovery Mode and press <^>. This will extend the air

3. Install the pocket stop, using Blue Loctite and torquing the four SHCS to 40 ft./lbs. Activate the

Pocket

Orientation

Tabs

Tool Pocket (Load Position)

care not to drop the pocket slide.

NOTE: If the carousel is to be replaced, skip to the Carousel Removal and Installation

section.

and pocket into the carousel. Apply a drop of Red Loctite to the pocket ret aining screw and install. T orque to 14 ft./lbs.

cylinder shaft. Install the pocket slide shoulder bolt, taking care not to pinch the microswitch roller. Ensure that the microswitch roller rests on the shoulder bolt head.

pocket up and down several times. Restore the machine to automatic mode and perform a tool change by pressing <MDI> and then <A TC FWD>. Check for any binding or interference of installed parts.

TOOL P OCKET S LIDER ADJUSTMENT

The slider set-screw is used to adjust the tool pockets' end-of-stroke with the circular path on the carousel housing.

1. Rotate carousel by turning the carousel cam pulley by hand.

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2. Visually check for misalignment (tool pockets should move smoothly).

3. If necessary , loosen the setscrew nut. Adjust the setscrew in or out until the tool pocket is aligned with the circular path on the carousel housing. Advance the tool pocket and observe for proper alignment.

4. Tighten setscrew lock nut.

Air Cylinder

Carousel

Tool Pocket Assembly

T ool Pocket Orientation / Set-Scr ew Adjustment

PROXIMITY S WITCH R EMOVAL / INSTALLATION

Removal

1. Power Off machine. Remove the carousel number disc and the top cover plate.

2. Remove the 1/4”NPT plug near the cam box output shaft and drain the cam box oil.

Carousel Housing

Tool Pocket Slider

Pocket in

Stored Position

Pocket in

Load

Position

Top View

Slider Adjustment Set-Screw

3. Disconnect the proximity switch connector from the bracket on the top of the assembly .

4. Loosen the double nuts retaining the proximity switch. Carefully remove the proximity switch from the cam box assembly . Refer to following figure.

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Oil Fill/Breather

Cam Box Pulley

Oil Fill Level

Tool Clamp Sensor

Trigger

Grooves

3X Proximity Sensors

4X Cam Box Mounting SHCS

Origin

Sensor

Motor Stop

Sensor

Proximity Sensor Switch Location

Installation

The proximity trigger disk inside the cam box determines the sensor operation. The sensor must be approximately .030” away from a flat surface on the disk to function properly . An L.E.D. light will come on at the back of the sensor when it is triggered.

1. Look through the sensor hole and rotate the cam box pulley by hand until the groove is not visible.

2. Screw two nuts to the threaded section of the proximity switch. Snug the two nuts together and apply thread sealant to the threads. Carefully screw the switch into the cam box. Connect the proximity switch connector to the plug on the switch bracket.

Proximity Switch Connection Bracket.

3. Power On machine. Press E-Stop.

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4. Screw the proximity sensor into the cam box an additional 1/8 turn after the L.E.D light comes on. Loosen both nuts then re-tighten the inner nut against the cam box housing. Tighten the outer nut against the inner nut.

5. Repeat this procedure for each proximity sensor switch.

6. Refill the cam box with oil (Penzgear 320) to the fill level line.

7. Check for correct operation of the tool changer and alignment. Adjust as necessary.

8. Replace the carousel disc and top cover plate. Apply blue loctite to the fasteners and tighten.

SETTING P ARAMETER 64

Caution: The EC-400 Z-axis can crash into the pallet changer actuator if Parameter

64 is not set correctly.

For Z-axis, this is the displacement from home switch to tool change position and machine zero. (Distance from Home in Inches) X (Line Encoder Constant) = Z-axis tool change position setting

Example:

.625 x 138718 = 861699

T o reset Parameter 64 (Z-axis tool change position) if an A TC assembly has been replaced or realigned.

1. Enter PARAMETERS p age and record original Parameter 64 setting value.

2. (Make sure there are no tools in the spindle head or tool pocket positions). Command the spindle head to its tool change position. Enter DEBUG and record Z-axis spindle position value.

3. Enter TCR mode. Press the DOWN ARROW , command a tool pocket down. Manually insert a tool into the tool pocket.

Plane4

Setting Parameter 64, indicator reference measurement.

4. Place a 0.0005” indicator with an extended arm base on to the machine table. Indicate the bottom of the tool with the indicator to the nearest 0.001.” Record the measurement.

5. Remove indicator from the table and the tool holder from the tool pocket. Insert the tool into the spindle head position. Place the measurement indicator under the spindle head.

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6. Enter DEBUG . Jog handle the Z-axis up or down until the end of the tool is at the same height as the measured value found when the tool was placed in the tool pocket. Record the Z-axis spindle height value.

7. T ake the difference in the spindle height values found in DEBUG mode and add the encoder count value to the original value for P ARAMETER 64 setting.

Example:

(Difference in Z-axis encoder counts) + (Old Z-axis Tool Change Setting) = New Z-axis T ool Setting

20681 + 861699 = 882380

8. Enter P ARAMETERS page. UNLOCK settings and write new setting value for Parameter 64. LOCK parameter settings.

9. Perform a tool change and observe for misalignment. Adjust the PARAMETER 64 setting if necessary.

SERVO T OOL C HANGER O FFSETS

Invisible Axis Explanation

The SMTC uses an invisible axis to control the double arm. If the axis is made visible to service or adjust it, the safety interlocks are disabled, and the automatic operation of the tool changer is prohibited. Be sure the spindle head is out of the way before rotating the double arm.

Offsets

Both the Tool Change Offset and the Grid Offset must be set before using the tool changer. The Grid Offset must be set first.

Setting the Grid Offset

The control can calculate grid offset parameters with a ‘GRID’ command. A grid of fset is an of fset that is applied to the home position of an axis so that the zero location for that axis is re-defined to be half an encoder revolution away from the home switch. It is recommended that the GRID command be used on each axis separately.

1. Zero Return all the axis

2. Turn the machine off and back on. This will un-zero all the axes.

3. Select the ALARMS screen and enter DEBUG mode.

4. Perform a ZERO SINGLE AXIS on the Tt axis. Ignore the ZERO RET MARGIN TOO SMALL alarm if it occurs. The tool arm is out of position and must be repositioned using tool change recovery , if a tool arm fault is generated.

5. Select the Positions screen, enter “GRID TT” and press ENTER. The message GRID OFSET DONE should appear and the GRID OFFSET parameters for the homed axes will have been updated. If the message “NO ZERO” appears, this indicates that none of the axes had been zeroed.

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Setting the Tool Change Offset

1. Set the Tool changer axis to “Visible”. This is done by setting bit 18 of Parameter 462 to zero.

2. Make sure the spindle head is up out of the way

3. Go to the Discrete Inputs page and look at the cambox origin display.

4. Handle jog (rate .01) the TT (B) axis until “Origin” and Motor S top” are “1”.

5. Handle jog in the positive direction, until both the “Motor Stop” and “Origin” are “0”. Switch displays to the Position page and continue jogging the axis 3-5 degrees, in the same direction, past this position.

6. Handle jog the axis in the negative direction (.01 degrees per pulse) until both “Motor Stop” and “Origin” are ”1”. Note that you cannot back up if the mark is missed. If the mark has been missed go back to step 5.

7. Go to the Pos Raw Data page. Under the “Command” header the display shows the “B” axis encoder counts. Write down the current number .

8. Go back to the Discrete Inputs page. W atch “Motor Stop” and “Origin”. Handle jog in negative direction, until one of them changes to “0” (the first one to change).

9. Go back to the Position page and write down the current number from the same column as step 7. Add both numbers and divide by 2, this is the amount of tool change offset, but with the wrong sign.

10. Return to the Discrete Inputs page and handle jog the axis back until the “Motor S top” and “Origin” are “1”. 1 1. Enter the calculated number , as a negative number in the TT axis, Parameter 487 (not the B-axis).

12. Return the axis to “Invisible”, set parameter 462 to 1, and cycle power.

13. Zero return the TT axis. The double arm should be in the middle of the home position.

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3.7 AXIS M OTORS

Please read this section in its entirety before attempting to remove or replace the axis motors.

X-AXIS M OTOR

4X SHCS

Key

Cover Plate

Coupling

X-Axis Motor

4X SHCS

4X BHCS

Key

Coupling Housing Cover

Coupling

X-Axis Motor and Ball Screw Assembly EC-300

4X BHCS

Coupling

Housing

Proximity Sensor

Wiring

Top View

Removal

1. Power ON the machine. Zero return all axes and put machine in HANDLE JOG mode.

2. Jog the Y-axis to the bottom of its travel. Jog the X-axis away from the motor.

3. Remove the rear enclosure panel.

4. POWER OFF the machine.

5. On the top of the motor housing, remove the four BHCS and remove the coupling housing cover.

6. Loosen the SHCS on the motor coupling.

7. Disconnect all wiring from the motor and remove. Be careful of the proximity sensor wires when lifting out the motor .

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8. Remove the SHCS motor mounting bolts and remove the motor from the coupling housing.

Installation

1. Inspect the motor coupling and replace it if required. 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 ball screw or motor shaft. Refer to the diagram in coupling replacement section.

2. Reconnect all wiring to the motor.

3. Align the key on the motor shaft. Slide the motor into the coupling housing, inserting the end of the ball screw into the motor coupling.

4. Reinstall and tighten down the four SHCS that hold the motor to the coupling housing.

5. Tighten the SHCS on the motor coupling at the ball screw . (Place a drop of blue Loctite® on the screw before inserting.)

6. Replace the housing cover and fasten the BHCS.

7. Replace the rear enclosure panel.

8. Check for backlash in the X-axis ball screw ("Troubleshooting" section) or noisy operation.

9. Set grid offset.

Caution: Work offsets will change.

Y-AXIS M OTOR

Removal

1. Power ON the machine. Zero return all axes and put machine in HANDLE JOG mode.

2. Remove the rear enclosure panel.

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3. Jog the X-axis until the Y-axis motor can be easily accessed from the rear.

4. Install the column shipping bolts if available, or place a block of wood on the column casting beneath the spindle head casting. Lower the spindle head (Y -axis) until it rests on the wood.

5. POWER OFF the machine.

6. EC-300 – Remove the right spindle head cover (looking at the spindle) from the inside of the machine.

7. Remove the motor coupling cover and loosen the SHCS on the motor coupling at the ball screw.

Coupling

Housing

Cover

BHCS

Bumper

8. Remove the SHCS and remove the motor from the coupling housing.

9. Disconnect all wiring from the motor.

10. Remove the motor.

Installation

1. Inspect the motor coupling and replace it if required. Visually inspect the flex plates to ensure they

Y-Axis Motor

4X SHCS

Key

Coupling

Housing

Cover

4X BHCS

4X SHCS

Y-Axis Motor

Key

Coupling

Y -axis motor and coupling EC-300 Y-axis motor and coupling EC-400

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

2. Reconnect all wiring to the motor.

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hole pattern of the coupler. If improperly aligned, the coupler will not have enough clamping force on the ball screw or motor shaft. Refer to diagram in

Coupling Replacement section.

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3. Align the key on the motor shaft. Slide the motor into the motor housing, inserting the end of the ball screw into the motor coupling.

4. Reinstall and tighten down the SHCS that hold the motor to the coupling housing.

5. Tighten the SHCS on the motor coupling at the ball screw . (Place a drop of blue Loctite® on the screw before inserting.)

6. Remove the shipping bolts from the column, or raise the Y -axis and remove the wood blocks from the column casting.

7. Replace the rear enclosure panel.

8. EC-300 – Replace the right spindle head cover

9. Check for backlash in the Y -axis ball screw (T roubleshooting section) or noisy operation.

10. Check that Parameter 21 1, "Y-Axis Tool Change Of fset", is set correctly, and adjust if necessary.

1 1 . Set the grid offset after the new motor has been installed.

Z-AXIS M OTOR

4X SHCS

REMOVAL-

4X BHCS

Motor

Coupling

Column

EC-300 Z-axis motor and ball screw assembly

Coupling

Housing Cover

Coupling Housing

EC-400 Z-axis motor and ball screw assembly

Coupling

Motor Bumper

Z-Axis Motor

Key

4X SHCS

Z-Axis Motor

4X BHCS

Receiver

Coupling Housing Cover

Key

Z-Axis

Way Cover

1. Power ON the machine. Zero return all axes and put machine in HANDLE JOG mode.

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2. EC-300 – Jog the Y -axis to the bottom of its travel. Jog the Z-axis to the back of the machine. EC-400 – Jog the Z-axis away from the spindle.

3. POWER OFF the machine.

4. EC-400 – Unbolt the Z-axis way cover from the receiver and pull it away from the receiver.

5. Remove the BHCS and the coupling housing cover plate from the coupling housing.

6. Loosen the SHCS on the motor coupling at the ball screw.

7. Disconnect all wiring from the motor.

8. Remove the SHCS and remove the motor from the coupling housing.

INSTALLATION-

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 ball screw or motor shaft. Refer to diagram in Coupling Replacement section.

2. Reconnect all wiring to the motor.

3. Align the key on the motor shaft. Slide the motor into the coupling housing, inserting the end of the ball screw into the motor coupling.

4. Reinstall and tighten down the SHCS that hold the motor to the housing.

5. Tighten the SHCS on the motor coupling at the ball screw . (Place a drop of blue Loctite® on the screw before inserting.)

6. Replace the cover plate.

7. EC-400 – Replace the Z-axis way cover.

8. Check for backlash in the Z-axis ball screw ("Troubleshooting" section) or noisy operation.

9. Set the grid offset after the new motor has been changed.

COUPLING R EPLACEMENT

REMOVAL-

1. Remove the axis motor in accordance with "Axis Motor Removal/Installation" section.

2. Completely loosen the two SHCS on the two coupling clamp rings and remove the coupling.

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haas 96-0189 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

COMMON ABBREVIATIONS

1. TROUBLESHOOTING

1.1 GENERAL M ACHINE O PERATION

MACHINE N OT R UNNING

VIBRATION

ACCURACY

FINISH

THERMAL G ROWTH

1.2 SPINDLE

NOT T URNING

NOISE

OVERHEATING

STALLING / LOW T ORQUE

SPINDLE D RIVE

ORIENTATION

TOOLS S TICKING I N T APER

1.3 SERVO M OTORS / BALL S CREWS

NOT O PERATING

NOISE

ACCURACY / BACKLASH

VIBRATION

OVERHEATING

FOLLOWING E RROR

BALL S CREWS - VISUAL I NSPECTION

BALL S CREW C LEANING

DRIVE F AULT / OVERCURRENT

1.4 PALLET C HANGER

EC-400 PALLET C HANGER OVERVIEW

EC-300 PALLET C HANGER

1.5 AUTOMATIC T OOL C HANGER (ATC)

CRASHING

SIDE M OUNT T OOL C HANGER R ECOVERY F LOW C HART

1.6 THROUGH THE S PINDLE C OOLANT

COOLANT O VERFLOW

LOW C OOLANT

PRE-CHARGE F AILURE

1.7 ELECTRICAL T ROUBLESHOOTING

ELECTRICAL A LARMS

SAVING THE M ACHINE I NFORMATION

2. ALARMS

3. MECHANICAL SERVICE

3.1 WAY C OVERS

X-AXIS W AY COVER R EMOVAL

Y-AXIS W AY COVER R EMOVAL

Z-AXIS W AY C OVER

EC-300 X-AXIS W AY C OVER A DJUSTMENT

EC-300 Y-AXIS W AY COVER

3.2 SPINDLE M OTOR R EPLACEMENT

50 TAPER T RANSMISSION AND M OTOR R EPLACEMENT

TOOL R ELEASE P ISTON R EPLACEMENT

SETTING P RE-CHARGE

3.3 SPINDLE

SPINDLE C ARTRIDGE

SPINDLE S WEEP A DJUSTMENT

3.4 DRAWBAR R EPLACEMENT

DRAWBAR R EPLACEMENT - IN-LINE D RIVE

DRAWBAR R EPLACEMENT - 50 TAPER

SETTING TRP HEIGHT

TRP SHIMS

ADJUSTMENT OF S WITCHES

3.6 40 TAPER C AROUSEL SIDE M OUNT T OOL C HANGER

40 TAPER C AROUSEL REMOVAL AND I NSTALLATION

50 TAPER C AROUSEL REMOVAL AND I NSTALLATION

TOOL C HANGER A SSEMBLY R EMOVAL / INSTALLATION

AUTOMATIC T OOL C HANGER A LIGNMENT

EC-400 TOOL C HANGER DOOR R EPLACEMENT

SETTING S PINDLE O RIENTATION

DOUBLE A RM REMOVAL AND I NSTALLATION

40 TAPER SMTC POCKET R EMOVAL AND I NSTALLATION

TOOL P OCKET S LIDER ADJUSTMENT

PROXIMITY S WITCH R EMOVAL / INSTALLATION

SETTING P ARAMETER 64

SERVO T OOL C HANGER O FFSETS

3.7 AXIS M OTORS

X-Axis Motor

Y-Axis Motor