haas 96-0284 Service Manual

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any other party automatically voids the factory warranty.

June 6, 2013

HAAS SERVICE AND OPERATOR MANUAL ARCHIVE

Electrical Service Manual 96-0284 RevH English January 2010

• 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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Haas Automation Inc.

Mill and Lathe

Service Manual

Electrical Components

January 2010

96-0284 rev H

Haas Automation Inc.

2800 Sturgis Road, Oxnard CA 93030 Tel. 888-817-4227 Fax 805-278-8561 www.HaasCNC.com

Page 3

Table of Contents

Safety .................................................................................................................................................................1

General Electrical Troubleshooting ................................................................................................................1

Machine not Running ................................................................................................................................1

electRical alaRM tRoubleshooting ...........................................................................................................2

Line Voltage Adjustments ................................................................................................................................5

ElectRical Connections .............................................................................................................................5

Fuse Replacement ............................................................................................................................................8

oveRvoltage Fuses .................................................................................................................................... 8

Front Panel ........................................................................................................................................................9

sl-10 Pendant coMPonents access ..........................................................................................................9

lcd asseMbly RePlaceMent ...................................................................................................................10

Jog handle ............................................................................................................................................. 11

PoweR on/oFF switches ..........................................................................................................................12

eMeRgency stoP switch ...........................................................................................................................12

KeyboaRd beePeR ....................................................................................................................................12

laMP on/oFF switch ................................................................................................................................ 12

switch RePlaceMent ................................................................................................................................ 12

sPindle load MeteR ................................................................................................................................13

KeyPad RePlaceMent ................................................................................................................................ 13

seRial KeyboaRd inteRFace RePlaceMent .................................................................................................14

Solenoids .........................................................................................................................................................15

tool Release Piston (tRP) aiR solenoid asseMbly (hoRiz & veRt) ........................................................15

sPindle lube aiR solenoid .......................................................................................................................16

PneuMatic chucK/tuRRet claMP/unclaMP solenoid (lathe) .....................................................................17

Smart Amplier ...............................................................................................................................................17

Smart Vector Drive ..........................................................................................................................................18

PCB Replacement ...........................................................................................................................................20

MicRoPRocessoR asseMbly ....................................................................................................................... 20

Mocon, Video/KeyboaRd, & MicRoPRocessoR ...........................................................................................20

MotoR ContRolleR (Mocon) ................................................................................................................. 20

video/KeyboaRd .......................................................................................................................................21

MicRoPRocessoR Pcb (68eco30) ..........................................................................................................21

inPut/outPut asseMbly ............................................................................................................................23

PoweR tRansFoRMeR asseMbly (t1) .........................................................................................................23

PoweR suPPly asseMb ly .......................................................................................................................... 25

low voltage PoweR suPPly ..................................................................................................................... 25

Rs-232 seRial inteRFace ......................................................................................................................... 26

Spare User M Code Interface .........................................................................................................................27

M Function Relays (M-Fin) .....................................................................................................................28

M-Fin discRete inPut .............................................................................................................................. 28

wiRing the Relays ...................................................................................................................................28

Switches ..........................................................................................................................................................28

Control Memory ..............................................................................................................................................30

Diagnostic Data ...............................................................................................................................................32

discRete inPuts/outPuts (lathe) ............................................................................................................. 32

discRete inPuts/outPuts (Mills) ..............................................................................................................34

Cable List .........................................................................................................................................................37

96-0284 rev H © Haas Automation January 2010

Table of Contents

Page 4

PCBs, Cable Locations, and Diagrams .........................................................................................................48

MicRoPRocessoR Pcb .............................................................................................................................49

seRvo systeM blocK diagRaM ..................................................................................................................50

bRushless seRvo aMPliFieR (P/n 32-5550F) ...........................................................................................51

sMaRt aMPliFieR (P/n 93-5550J (30a) 93-3551J (45a)) ....................................................................... 52

systeM blocK diagRaM - high/low voltage ............................................................................................. 53

PoweR Pcb veRsion K/l ......................................................................................................................... 54

oFFice Mill PoweR suPPly .......................................................................................................................55

i/o Pcb veRsion w, z, aa, ab ...............................................................................................................56

discRete inPuts ........................................................................................................................................59

discRete outPuts .................................................................................................................................... 62

seRial KeyboaRd inteRFace Pcb with handle Jog (34-4241d)................................................................65

video & KeyboaRd Pcb w/etheRnet & usb dRive ..................................................................................68

Mocon Pcb ......................................................................................................................................... 69

Rs-232 PoRt #1 Pcb .............................................................................................................................70

wye-delta switch asseMblies ................................................................................................................71

M code Relay boaRd............................................................................................................................... 71

hydRaulic Pcb .......................................................................................................................................72

tsc MotoR dRive/high PRessuRe coolant Pcb .....................................................................................73

haas vectoR dRive unit ..........................................................................................................................73

Quad aPc ( 32-3078a) Pcb .................................................................................................................. 74

Renishaw tool PResetteR (lathe) ............................................................................................................74

oPeRato R Pendant ................................................................................................................................... 75

ciRcuit bReaKeRs ..................................................................................................................................... 76

hoRizontal Machine contRol cabinet wiRing diagRaM.............................................................................77

veRtical Machine contRol cabinet wiRing diagRaM ................................................................................ 78

lathe contRol cabinet wiRing diagRaM ..................................................................................................79

Cables ..............................................................................................................................................................80

Alarms ............................................................................................................................................................133

Parameters ....................................................................................................................................................180

PaRaMeteR list ......................................................................................................................................180

ballscRew coMPensation (Mills) ...........................................................................................................227

electRonic theRMal coMPensation ........................................................................................................ 228

sPindle head theRMal coMPensation ..................................................................................................... 228

X-aXis theRMal coMPensation (lathes) ................................................................................................. 228

coMMon abbReviations ...........................................................................................................................228

Table of Contents

96-0284 rev H

Page 5

SAFETY

RED

WHT

BLK

OFF

Install lock-out clasp and lock with padlock to secure Circuit Breaker in the OFF position.

To avoid possible shock, make sure circuit breakers are appropriately locked off before attempting any electrical work.

CAUTION! Working with the electrical services required for the machine can be extremely

hazardous. The electrical power must be off and steps must be taken to ensure that it will not be turned on while you are working with it. In most cases this means turning off a circuit breaker in a panel and then locking the panel door. However , if your connection is different or you are not sure how to do this, check with the appropriate personnel in your organization or otherwise obtain the necessary help before you continue.

WARNING!

The electrical panel should be closed and the three screws/latches on the door should be secured at all times except during installation and service. At

those times, only qualied electricians should have access to the panel. When

the main circuit breaker is on, there is high voltage throughout the electrical panel (including the circuit boards and logic circuits) and some components operate at high temperatures. Therefore extreme caution is required.

GENERAL ELECTRICAL TROUBLESHOOTING

MACHINE NOT RUNNING

Machine cannot be powered on.

• Check input voltage to machine.

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

• Check overvoltage fuses.

• Check wiring to Power Off button on front control panel.

• Check wiring to Auto Off relay to I/O PCB.

• Check connection between 24V transformer (T5) and K1 contactor.

• Check 24V transformer (T5) bracket has jumper in correct position (measure voltage at main circuit breaker and connect jumper to corresponding connector on T5 transformer bracket).

• Check I/O PCB.

• Check Power PCB.

96-0284 rev H © Haas Automation January 2010

Electrical Service

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

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

• Check alarm history for Overvoltage or Overheat shutdown.

• Check AC power supply lines for intermittent supply.

• Check 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 I/O PCB.

• Check Parameter 57 for Power off at E-Stop.

• Check MOTIF or MOCON PCB.

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

• Check for power connections to LCD/CRT from I/O PCB (LVPS power from Power PCB for 15” monitor). Check for green Power LED at front of CRT.

• Close doors and zero return machine (possible bad monitor).

• Check video cable from Video PCB to LCD/CRT.

• Check for lights on the processor.

• Replace LCD/CRT.

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

• Check keyboard cable (700) from Video to SKBIF PCB.

• Check keypad.

• Check SKBIF PCB.

Constant E-Stop Condition (will not reset) (Vertical Machines).

• Check hydraulic counterbalance pressure, low pressure switches, and cabling.

Quad APC trouble shooting

The Quad APC uses an additional PC board to control pallets 3 and 4.

The pallet chain motor receives 160VDC from plug 6A on this board (32-3078A). The PC board receives power (115V) from the power card, which plugs into P4 on the APC board.

The solenoid for the left, air operated, automatic door plugs into P3; this cable is part of 33-6038A. Pallet 3 and 4 signals are sent through cable 33-1516, which plugs into P1. The cable’s other end plugs into the I/O board P62.

ELECTRICAL ALARM TROUBLESHOOTING

Axis Drive Fault Alarm

• Blown amplier - indicated by light at bottom of amplier when power is on. Replace the fuse in the amplier.

• Amplier or MOCON is noise sensitive. If this is the case, the alarm can be cleared and the axis will run

normally for a while.

To check an amplier, switch the motor leads and control cables between the amplier and the one next to it. If the same problem occurs with the other axis, the amplier 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.

Electrical Service

96-0284 rev H

Page 7

• Amplier faulting out for valid reason, such as overtemp, overvoltage, or +/-12V undervoltage condition. This usually results from running a servo intensive program, or unadjusted 12V power supply. Adjust voltage to correct specications or replace the 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. This may be caused by a lot of motor accel/ decels, or hitting a hard stop with the axis. This safety function protects the amplier and motor. 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 Voltage 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 amplier is blown, is not receiving the commands, or the 320V power source is dead. If the MOCON is not sending the correct commands to the amplier, 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 ampliers. An alarm for one axis can be caused by a bad grounding on the motor

leads of another axis.

Axis Cable Fault

• During self-test, 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 cause this alarm, although it is less common.

Alarm 101, “MOCON Comm. Failure”

• During self-test of communications between the MOCON and main processor, the main processor does not respond, and is suspected to be dead. This alarm is generated and the servos are stopped. Check all ribbon cable connections, and all grounding. Machine noise can also cause this alarm, although it is less common.

Alarm 157, MOCON Watchdog Fault

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

Alarm 212, Program Integrity Error/Alarm 250, Program Data Error

• If a program has been corrupted in the system or a corrupted program has been loaded into the machine, a Program Data Error (250) or Program Integrity Error (212) might occur. This occurrence can be recognized by an exclamation point (!) next to a program when turning to the list program page. Following is the common

procedure to perform when this happens.

1. Save all programs to disk except the program with the exclamation point error signal. The exclamation point (!) indicates the program that is corrupt. This will be your back-up disk to reload the programs into the

machine.

2. Delete all the programs. This should delete all the programs including the one with the “!” error signal.

3. If the program with the exclamation point (!) does not erase then the control needs to be initialized.

96-0284 rev H © Haas Automation January 2010

Electrical Service

Page 8

4. If the machine still has the program with the exclamation point or the control now refuses to load a good program, it may be necessary to clear memory and reload software.

5. If problem persists, replace main processor board.

Alarm 261, Rotary CRC Error (Horiz & Vert)

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

Press Emergency Stop.1. Turn Setting 7 to OFF. 2.

Go to Setting 30 and select HRT210. Make note of this and all following changes. 3.

Go to Parameter 43 and change the rst bit from 0 to 1. 4.

Go to setting 30 and select HRT310. 5.

Go back to Parameter 43 and change the second bit from 0 to 1. 6.

Now reverse the changes you have made. 7.

Cycle power to the machine. The alarm will now be cleared. 8.

If the alarm persists, repeat the above steps before calling for assistance.

Alarm 354, Aux Axis Disconnected (Lathe)

When this alarm is generated, do not press Reset. Turn Setting 7 Off. Enter Debug mode, then view the

Alarms/Messages page. On the Messages page, a code will appear similar to WO1. The list of codes and

their descriptions follows :

WO1 Power was just turned on or failed. Check the ribbon cables from the Aux Axis PCB to the proces-

sor for correct routing. Check for communication problems between the processor and the Aux Axis PCB.

WO2 Servo following error too large. Check the encoder for contamination or dirt. Check for an

intermittent connection at both ends of the motor cable.

WO3 Emergency Stop. The E-STOP button was pressed, or an E-STOP condition occurred.

WO4 High load. Check for binding in the tool changer gearbox and motor. Rotate the carousel by hand

and feel for any binding. Make sure the toolholders are the correct weight.

WO5 Remote RS-232 commanded off. Check the ribbon cable and the voltage to the Aux Axis PCB.

Check for 115V AC (minimum) to the Aux Axis PCB from the main transformer. Check the fuse

holder and the fuse that is protecting this circuit.

WO6 Air or limit switch or motor overheat. Check that the motor is not hot. Check for any binding in the

motor. Check for overweight tooling.

WO7 Z channel fault. Either the encoder or the cable is bad. Change the encoder rst, as it is easier to

change than the cable. If the problem persists, change the cable.

WO8 Over-current limit, stalled or PCB fault. Check for binding in the tool changer gearbox. Make sure

the belt is not too tight. Ohm out the motor cable, checking pins G to F (should be open), G to H (should be open), and F to H (should read between 2.5 and 5 ohms). Check all the connections on the Aux Axis PCB and motor cable.

WO9 Encode ES. Z channel is missing. Bad encoder or cable. See WO7.

WOA High voltage. Check the incoming voltage to the Aux Axis PCB. Incoming voltage must be 115V

AC. See WO5.

WOB Cable fault. Check the cable from the motor to the Aux Axis PCB. Check for loose connections at

each end.

Electrical Service

96-0284 rev H

Page 9

LINE VOLTAGE ADJUSTMENTS

actors

Low Voltage Power Supply

Please read this section in its entirety before attempting to adjust the line voltage.

Tools Required: Large at tip screwdriver, Digital voltmeter

NOTE: The machine must have air pressure at the air gauge, or a “Low Air Pressure” alarm

will be present on power up.

T5 Transformer

MOCON-2

(if equipped)

LCD Video/Floppy

MOCON-1

Processor

3-Phase Breaker

Power PCB

Power Amplifiers X, Y, Z, A,B&PC

Optional Servo Tool Changer Amp

SERVODRIVE ASSEMBLY

Haas Vector Drive

Wye-Delta Cont

(underneath)

I/O Board

Single Axis Brake PCB

(if so equipped)

Transformer

Control Cabinet General Overview

ELECTRICAL CONNECTIONS

Ouput Power

Ground Line

Main

Circuit

L1 L2

TB2

240VOUT

488-458V

120VOUT

457-429V

260-244V

INCOMINGLINE VOLTAGETAPS(74, 75,76)

428-403V

243-227V

TB1

402-377V

226-211V

376-354V

210-195V

Input

Power

Breaker

1. Place the main circuit breaker in the Off position and hook up the three power lines to the terminals on top of the main circuit breaker at the upper right-hand side of the electrical panel. Connect the separate ground

line to the ground bus to the left of the terminals.

NOTE: Ensure service wires go into terminal-block clamps. (Do not miss clamp and tighten

screw. Connection looks ne but machine runs poorly - servo overloads.) To check,

pull on wires after screws are tightened.

96-0284 rev H © Haas Automation January 2010

Electrical Service

Page 10

2. After the line voltage is connected to the machine, make sure that main circuit breaker is off. Turn on the power at the source. Using an accurate digital voltmeter and appropriate safety procedures, measure the voltage between all three pair phases at the main circuit breaker and write down the readings. The voltage

must be between 195 and 260V (360 and 480V for high voltage option).

NOTE: Wide voltage uctuations are common in many industrial areas; you need to know

the minimum and maximum voltage which will be supplied to the machine while it is

in operation. U.S. National Electrical Code species that machines should operate with a variation of +5% to -5% around an average supply voltage. If problems with

the line voltage occur, or low line voltage is suspected, an external transformer may be required. If you suspect voltage problems, the voltage should be checked every

hour or two during a typical day to make sure that it does not uctuate more than +5% or -5% from an average.

CAUTION! Make sure the main circuit breaker is set to off and the power is off at the supply

panel before changing the transformer connections. Make sure that all three

black wires are moved to the correct terminal block and are tight.

3. Check the connections on the transformer at the bottom-right corner of the rear cabinet. The three black

wires labeled 74, 75, and 76 must be moved to the terminal block triple which corresponds to the average voltage measured in step 2 above. There are four positions for the input power for the 260V transformer and

ve positions for the 480V transformer. The labels showing the input voltage range for each terminal position

are as shown in the previous illustration.

4. Transformer T5 supplies 24VAC used to power the main contactor. There are two versions of this transformer for use on 240 and 400V machines (32-0964B and 32-0965B, respectively). The 240V

transformer has two input connectors located on the transformer bracket, which allow it to be connected

to either a 221-240V range or 180 to 220V range. Users that have 180-240V input power should place the jumper on the appropriate connector.

The 400V transformer has three input connectors located on the transformer bracket, which allow it to be connected to either a 441-480V range, 381-440V range or 340-380V range. Users with the External High Voltage Option should place the jumper on the connector marked with the appropriate input voltage. Failure to place the jumper on the correct input connector will result in either overheating of the main contactor or failure

to reliably engage the main contactor.

A jumper must also be placed on the plate covering the T5 transformer, Measure voltage at the main circuit breaker and connect the supplied shorting plug to the corresponding connector on the T5 transformer plate.

5. Set the main circuit breaker to ON and check for evidence of problems, such as the smell of overheating components or smoke. If such problems are indicated, immediately set the main circuit breaker to OFF and

call the factory before proceeding.

T5 Transformer

441-480V

Main

Circuit

Breaker

Electrical Service

221-240V

381-440V 180-220V

MEASURE VOLTAGEATMAIN

CIRCUIT BREAKER ANDCONNECT

SUPPLIED SHORTING PLUG TO CORRESPONDING CONNECTOR

340-380V

ON THIS TRANSFORMER

T5 24VAC

WARNING:

96-0284 rev H

Page 11

Through the Spindle Coolant (TSC) pump is a three phase pump and must be phased correctly! Improper phasing will cause damage to the TSC pump and void the warranty. Refer to the TSC start up section if your machine is equipped with TSC.

6. After the power is on, measure the voltage across the bottom terminals on the main circuit breaker. It should be the same as the measurements where the input power connects to the main circuit breaker. If there are any problems, check the wiring.

7. Apply power to the control by pressing the Power On switch on the front panel. Check the high voltage buss on the Vector Drive (pin 2 with respect to pin 3 on the terminal bus at the bottom of the drive). It must be between 310 and 360V. If the voltage is outside these limits, turn off the power and recheck steps 2 and 3. If the voltage is still outside these limits, call the factory. Next, check the DC voltage displayed in the second page of the Diagnostic data on the display screen. It is labeled DC BUS. Verify that the displayed voltage matches the voltage measured at pins 2 and 3 of the Vector Drive +/- 7V DC.

If the displayed voltage exceeds the measured voltage by 12 volts or more, install a ferrite EMI lter (65-1452) to the current command cable near its connection to the vector drive. Secure with a cable tie (See photo). Recheck voltage.

WARNING!

8. Electrical power must be phased properly to avoid damage to your equipment. The Power Supply

Assembly PC board incorporates a “Phase Detect” circuit with neon indicators, shown below (disregard for single phase machines). When the orange neon is lit (NE5), the phasing is incorrect. If the green neon is lit (NE6), the phasing is correct. If both neon indicators are lit, you have a loose wire. Adjust phasing by placing the main circuit breaker in the Off position and swapping L1 and L2 of the incoming power lines at the main

circuit breaker.

PHASE DETECT

(FOR3PHASE ONLY)

PASS FAIL

NE5NE6

WARNING!

All power must be turned off at the source prior to adjusting phasing.

9. Close the door, lock the latches, and turn the power back on.

10. Remove the key from the control cabinet and give it to the shop manager.

96-0284 rev H © Haas Automation January 2010

Electrical Service

Page 12

FUSE REPLACEMENT

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

The Power PCB contains two ½-amp fuses located at the top right (FU1, FU3). If the machine is subject to a severe overvoltage or a lightning strike, these fuses may blow and turn off all power. Replace these fuses only

with the same type and ratings.

15” and Thin Pendant Machines Size Fuse Name Type Rating (amps) Voltage Location

5x20mm F1/F3 Fast Acting 1 250V PSUP pcb, upper right

VERVOLTAGE FUSES

The electrical panel will have residual voltage, even after power has been shut off and/or disconnected . Never work inside this cabinet until the small

green Power On light on the servo ampliers (servo drive assembly on brush machines) goes out. The servo ampliers/servo drive assembly is on the left

side of the main control cabinet and about halfway down. This light(s) is at the top of the circuit card at the center of the assembly. Until this light goes out, there are dangerous voltages in the assembly even when power is shut off.

1. Turn machine power off.

2. Place the main circuit breaker (upper right of electrical cabinet) in the off position.

WARNING!

Main

Switch

3. Open the cabinet door and wait until the red charge light on the servo drive assembly goes out before

beginning any work inside the electrical cabinet.

4. The two overvoltage fuses are located beside each other at the upper right of the Power Supply board. An orange light will be on to indicate the blown fuse(s). If these fuses are blown, check incoming voltage to ensure it matches the jumper setting on T5.

Electrical Service

96-0284 rev H

Page 13

PHASE DETECT

(FOR3PHASEONLY)

+5V

GND

10A230V

FAILPASS

GND

+5V

NE6

WORKLIGHT

GFI/

71 73

NE5

NE1

TSC COOLANTPUMP

TSCCOOLANT PUMP

930

COOLANT/TSC

1A250V

10A230V

POWER SUPPLYASSY

SEC

PRI

TOT5

NE3

PSUP-K

230VIN

CHIPCONVEYOR

170

AUTOOFF/CONTACTOR

740

ON/OFF

P10

5A230V

CB4

160

CHIPC230V

GND

+5V

GND

+5V

NE6

(FOR3PHASE ONLY)

PHASE DETECT

FAILPASS

71 73

NE5

NE1

1A 250V

PRI

TO T5

NE3

IOPCB

GND

+5V

+12V

P30

GND

-12V

+12V

COOLANTPUMP

92A

DELTA-WYE

LOWVOLT PS

SWDOOR FAN

MONITOR

PROBEPS

SERVOFAN

90A

AC GROUND

90C

MCD1

MCD2

LVINPUT

GND

+12V

90A

90C

94/N

+12V

-12V

+12V

LE2

LE3

+12V

-12V

TS1

MAIN115V XFRMR

ON ON ON ON ON

10A115V

115VINPUT

MAIN

XFRMR

CB2

115VSPARES

90C 90C

90C90C 90C

MOTIF

MOCON2

GND

+5V

-12V

+12V

LE1

+5V

P18

AMPS

GND

+12V

-12V

GFI

7A115V

GFI

CB6CB3 CB5

3PH115V TOIOPCB

Power Supply Board; Fuse Locations

5. Using a at tip screwdriver, turn the fuse(s) counterclockwise to remove the fuses. Replace the fuse(s) with one having the same type and rating (½ amp, type AGC, 250V).

FRONT PANEL

Please read this section in its entirety before attempting to replace any control panel component.

SL-10 PENDANT COMPONENTS ACCESS

The SL-10 pendant door hinges on the left side. Remove the two (2) screws on top of the pendant in order to

open the pendant door.

CAUTION! Do not pinch the cable as the door is closed.

96-0284 rev H © Haas Automation January 2010

Electrical Service

Page 14

LCD ASSEMBLY REPLACEMENT

CAUTION! Use an electrostatic discharge (ESD) strap on wrist when working inside the

pendant.

1. Turn the power off and disconnect power to the machine.

2. Remove the screws holding the cover on the back of the operator’s pendant. Take care to hold the cover in

place until all screws have been removed.

3. Disconnect the video out cable (J16) from the SKBIF PC board and backlight cable.

4. Remove the four (4) hex nuts and washers beginning with the bottom, then remove the LCD assembly and

set aside in a safe place.

CAUTION! Do not drop or damage the LCD when removing it from the control panel.

5. Use gloves to avoid getting ngerprints on the new LCD. Position the assembly onto the four bolts (two each on top and bottom). Place the washers and hex nuts on the bolts to hold in place. Once all washers

have been attached and nuts have been hand-tightened, tighten down completely.

Video Out to LCD Pnl

J13

SKBIF

J16

Video In

Kybd

Data

Power In

Backlight cable

to inverter board

RS-232 Data

to/from

Microprocessor

Back of Operator’s Pendant

6. Plug the keyboard cables into the new receiver board (P1) and the power supply (TB2). Plug the power cable into the power supply board (TB1) and attach the green wire to ground. Plug the data cable into the receiver board (J3).

7. Replace the back cover panel and attach with the four screws previously removed.

Some LCD panel replacement kits include a panel with the inverter and data cables connected to a piggyback

board on the panel itself, under the display shield. To properly connect such a display:

1. Power off the machine and install the new LCD panel in the control pendant. Disconnect the data and inverter cables from the piggyback board (they are accessible through the rectangular cutouts in the display shield shown in the following photo).

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Data Cable

Inverter Cable

2. Connect these cables directly to the SKBIF PCB. If the cables that came with the new display are not long

enough, reuse the cables from the old display.

3. Power on the machine and check the display. If the image is blurry, toggle the switches at SW2 on the SKBIF PCB to correct the problem.

JOG HANDLE

The Jog handle is actually a 100-line-per-revolution encoder, used to move one axis at a time. If no axis

is selected for jogging, turning the handle has no effect. When the axis moved reaches its travel limits, the handle inputs will be ignored in the direction that would exceed the travel limits. Parameter 57 bit 0 can be

used to reverse the direction of operation of the handle.

Jog Handle Replacement

1. Turn the machine power off.

2. Remove the screws holding the cover on the back of the pendant. Take care to hold the cover in place until

all screws have been removed.

3. Unplug the cable leading to the jog handle encoder.

Blank pin goes to this

side of connector

+5V

BLK

Jog Handle Encoder Jog Handle Removal Jog Handle Wiring Diagram

RED

GND WHT

+5V

RED

GRN

4. Using the 5/64” allen wrench, loosen the two screws holding the knob to the control panel and remove.

5. Remove the three screws holding the jog handle encoder to the control panel and remove.

YEL

GND WHT/ RED

BRN

WHT/

YEL

B WHT/ BRN

6. Replacement is reverse of removal. Important! The blank pin side of the connector must face as shown when reconnecting; otherwise, damage may occur to the machine.

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POWER ON/OFF SWITCHES

The Power On switch engages the main contactor. The On switch applies power to the contactor coil and the contactor thereafter maintains power to its coil. The Power Off switch interrupts power to the contactor coil and turns power off. Power On is a normally open switch and Power Off is normally closed. The maximum voltage on the Power On and Power Off switches is 24V AC and is present any time the main circuit breaker

is on.

EMERGENCY STOP SWITCH

The Emergency Stop switch is normally closed. If the switch opens or is broken, servo power is removed instantly. This will also shut off the turret, spindle drive, and coolant pump. The Emergency Stop switch will shut down motion even if the switch opens for as little 0.005 seconds. Note that if Parameter 57 bit 3 is set to 1, it will cause the control to be powered down when Emergency Stop is pressed.

You should not normally stop a tool change with Emergency Stop as this will leave the tool changer in an

abnormal position that takes special action to correct

If the lathe turret or mill tool changer (T/C) becomes jammed, the control will automatically come to an alarm state. To correct this, push the Emergency Stop button and remove the cause of the jam. Push the Reset key to clear any alarms. Push Zero Return and the Auto All Axes to reset the Z-axis and turret or T/C. Never put your hands near the turret or T/C when powered unless E-Stop is pressed.

KEYBOARD BEEPER

There is a beeper under the control panel that is used as an audible response to pressing keyboard buttons and as a warning beeper. The beeper is a one kHz signal that sounds for about 0.1 seconds when any

keypad key, Cycle Start, or Feed Hold is pressed. The beeper also sounds for longer periods when an autoshutdown is about to occur and when the “Beep at M30” setting is selected.

If the beeper is not audible when buttons are pressed, the problem could be in the keypad, keyboard interface

PCB or in the speaker. Check that the problem occurs with more than one button and check that the beeper volume is not turned down or disconnected. If lamps do not turn on, check the GFCI plug.

LAMP ON/OFF SWITCH

An on/off switch is supplied for the work lamp. It is located on the side of the operator’s pendant. The lamp uses 115V AC taken from P19 on the main power distribution board.

SWITCH REPLACEMENT

1. Turn the machine power off. Remove the screws holding the cover on the back of the pendant. Take care to

hold the cover in place until all screws have been removed.

2. Disconnect all leads to the switch connectors. Ensure all leads are properly marked for reconnecting later.

3. Unscrew the two small set screws, one on top and one on the bottom, and turn the switch counterclockwise to loosen. Separate from the front portion and pull out.

4. To replace, screw the front and rear portions together (reverse of removal) and tighten down the two small

set screws when the switch is properly positioned.

NOTE: The Power On, Power Off, and Emergency Stop switches must all have the connectors

on the bottom of the switch.

5. Reconnect all leads to the correct switch.

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SPINDLE LOAD METER

Load meter measures load on spindle motor as a percentage of rated continuous power of motor, with a slight delay between a load and actual meter reection. The eighth A-to-D input also provides a measure of spindle load for cutter wear detection. Second page of diagnostic data displays % of spindle load. Meter should agree with display within 5%. Spindle drive display #7 should also agree with load meter within 5%. There are different types of spindle drives used in the control, all are equivalent in performance but are adjusted

differently.

Spindle Load Meter Replacement

1. Turn the power off and disconnect power to the machine. Remove the screws holding the cover panel on

the back of the pendant. Take care to hold the cover panel in place until all screws are removed.

2. Disconnect the two leads at the back of the spindle load meter assembly. Ensure the two leads are properly

marked for reconnecting later.

3. Unscrew the four screws that hold the spindle load meter assembly to the control panel. Take care to hold the assembly in place until all screws have been removed. Remove the assembly.

4. Installation is reverse of removal. Ensure leads go to the correct location.

EYPAD REPLACEMENT

1. Turn the power off and disconnect power to the machine. Remove the screws holding the rear cover to the

back of the pendant. Take care to hold the cover in place until all screws are removed.

2. Unplug the keypad’s 24-pin ribbon cable from the Keyboard Interface board.

3. Remove the screws from the front of the pendant. Take care to hold the cover in place until all screws have been removed. Remove the pieces and set aside in a safe place.

4. Using a at, blunt tool, such as putty knife, pry the keypad away from the control panel. Pull the ribbon

cable through the opening in the control to remove.

5. To replace, rst put the bezel spacer in place and fasten temporarily with screws in the top corners.

96-0284 rev H © Haas Automation January 2010

Electrical Service

Page 18

Gasket

Glass

Keypad

Keypad Installation

Front Bezel

6. Insert the ribbon cable through the opening in the control panel. Expose the adhesive strip on the back of the keypad and press it into place in the upper right corner of the keypad recess. Press to the control panel to mount. Plug the ribbon cable into the Keyboard Interface board, taking care to not bend the pins.

7. Replace the front and rear cover panels and fasten with the screws that were previously removed.

SERIAL KEYBOARD INTERFACE REPLACEMENT

NOTE: Refer to “Cable Locations” for a diagram of this board.

1. Follow all precautions noted previously before working in the control cabinet.

2. Turn the main switch (upper right of electrical cabinet) to the off position.

3. Remove the four screws on the back of the control box, then remove the cover panel. Take care to hold the

panel in place until all screws have been removed.

4. Disconnect all leads to the Serial Keyboard Interface (SKBIF) board. Ensure all cables are properly labeled.

5. After all cables have been disconnected, unscrew the four screws holding the Serial KBIF board to the control box. Take care to hold the board in place until all screws have been removed. Place the screws and

standoffs aside for later use.

6. Replace the Serial KBIF board, using the four screws previously removed. Starting at the top right, attach

each screw and standoff loosely, until all are mounted, then tighten down.

7. Reconnect all cables to the Serial KBIF board at their proper locations.

8. Verify whether the machine is equipped with either a speaker or a beeper. Align the toggle switches of Switch 1 on the Serial KBIF board to their appropriate positions. Beeper operation requires that both S1 switches be set to ‘B’; speaker operation requires that both S1 switches be set to ‘S’.

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96-0284 rev H

Page 19

SOLENOIDS

Basic Air Solenoid Assembly

With TSC Feature Added

Please read this section in its entirety before attempting to replace any solenoid assemblies.

TOOL RELEASE PISTON (TRP) AIR SOLENOID ASSEMBLY (HORIZ & VERT)

Removal

1. Turn machine power on and raise spindle head to uppermost position, then turn the power off. Remove air

supply from machine.

2. Remove sheet metal at rear and/or top of machine to access the back of the spindle (Mechanical Service manual).

3. Disconnect all air lines from the air solenoid assembly (Do not remove ttings). Disconnect the two leads

from the low air pressure sensor.

4. Unscrew the air solenoid assembly from the tool release piston assembly, taking care not disturb the

position of the clamp/unclamp switches. It may be necessary to remove the tool release piston to access the

solenoid assembly.

5. Unplug the wiring leading to the plug marked on the solenoid bracket as “880 from I/O PCB to Solenoid Valves” and the plug marked “Spare”.

6. Unscrew the air solenoid from the air solenoid assembly. Remove the SHCS holding the assembly to the

bracket and remove the assembly.

Installation

1. Install the new air solenoid. Take care to not disturb the position of the clamp/unclamp switches.

2. Replace air solenoid assembly and attach to bracket with the SHCS previously removed. Tighten securely.

3. Reinstall the tool release piston assembly if removed (see Mechanical Service).

4. Reconnect the two leads to the low air preassure sensor. Reconnect wiring to plugs on solenoid bracket.

5. Ensure all air lines are reconnected to their proper ttings. Reconnect air supply to the machine, and check

for leaks.

6. Replace the sheet metal.

Air Solenoid

Assembly

400

Check Valve Switch

Pre-

Charge

Regulator

Check Valve Switch

Locations of EC-300 and EC-400 TRP Solenoids VF-Series Air Solenoid Assembly

Motor Shroud

TRP Solenoid

To TSC

Inlet

Pressure Switch

TRP Solenoid

Air Solenoid

Assembly

Check Valve Switch

Air Solenoid Assembly

Sheet Metal

Tray

TSC Solenoid

Junction Elbow

Low air pressure

sensor

Air solenoid

assembly

Disconnect

all air lines Disconnect all air lines

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Electrical Service

Page 20

SPINDLE LUBE AIR SOLENOID

Removal

1. Turn the machine power off and remove the air supply from the machine.

Pressure Gauge

Spindle Lube Solenoid

Lube/Air Panel (Rear View) Spindle Lube/Air Solenoid Assembly (Top View)

2. a. Lathe: Disconnect the lube line from the spindle lube air solenoid assembly. b. Mill: Disconnect the air lines from the spindle lube air solenoid assembly.

3. Disconnect the electrical leads from the main air line pressure switch.

4. Lathe: Unscrew the solenoid assembly pressure gauge from the assembly.

5. Unscrew the entire solenoid assembly from the T-tting.

Lube Line

Main Air Line

Pressure Switch

Installation

1. Reattach the solenoid assembly at the T-tting.

2. a. Lathe: Replace the pressure gauge on the solenoid assembly and reconnect the lube line. b. Mill: Reconnect all air lines.

3. Reconnect the electrical leads to the main air line pressure switch.

4. Restore the air supply to the machine.

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96-0284 rev H

Page 21

PNEUMATIC CHUCK/TURRET CLAMP/UNCLAMP SOLENOID (LATHE)

Removal

1. Turn machine power off and remove the air supply from the machine.

2. Pneumatic Chuck: Disconnect the two air hoses from the pneumatic chuck clamp/unclamp solenoid.

Turret: Disconnect the three air hoses from the turret clamp/unclamp solenoid (see the Turret In/Out

Adjustment), and disconnect exhaust lines.

3. Unplug the solenoid electrical lead (located on the rear of the lube air panel).

4. Remove the two SHCS holding the assembly to the bracket and remove the assembly.

Installation

1. Replace the air solenoid assembly and attach it to the bracket with the two SHCS. Tighten securely.

2. Reconnect the electrical connection to the solenoid at the switch bracket.

3 Reconnect the two (three for Turret) air lines and turret exhaust lines, ensuring that all connections are tight

and do not leak.

4. Restore the air supply to the machine.

MART AMPLIFIER

The Smart Amplier has a microprocessor incorporated in the design. This allows the amplier to detect and report detailed alarms. The software level necessary to display these new alarms is 15.02A or newer.

The Smart Amplier is backward compatible to any machine that has a Vector Drive. New Smart Ampliers and standard ampliers may be used in any combination in the machine. However, if the machine does not have at least 15.02A software or newer the specic Smart Amplier will not be displayed. The Smart Amplier and the standard amplier use the same Parameters. On non-thin pendant machines, at least two of the standard ampliers must be used.

The Smart Amplier does not have a 12VDC connector, and both the Fault (Red LED) and the Run (Green LED) are relocated. The 320VDC (H+ and H-) and the X, Y and Z-axis connections are also relocated.

96-0284 rev H © Haas Automation January 2010

Electrical Service

Page 22

The smart amplier will calibrate utilizing the microprocessor that is present in each of the Smart Ampliers at power up. When power is applied to the Control Cabinet the Fault (Red LED) will illuminate and stay illuminated for a short time (approximately 5 seconds), this is called the “A” Phase Calibration. Then both LEDs will be out for a few seconds; this is called the “B” Phase Calibration. Next the Run (Green LED) will illuminate, indicating the Smart Amplier is ready with no faults.

SMART VECTOR DRIVE

The smart vector drive features a microprocessor that allows it to detect and display specic alarms (software version 15.02A or newer only). It is backward compatible to any machine with a vector drive regardless of

software version; however, the drive-specic alarms will not display in older software. Such alarms will dis-

play in the same way as with old-style drives.

Smart vector drives installed in new machines include a cover, and the machines electrical cabinet door is cut to accommodate it. Service drives are shipped without the cover for installation in older machines. When

replacing a drive in a machine built to accommodate the cover, use the cover from the old drive. When installing a smart vector drive without the cover, install the cover plate to the front of the vector drive.

When installing with the cover, install the cover plate to the top of the vector drive.

You will also need several cables. Please see 93-32-5558A for the 40 HP drive and 93-32-5559A for the 20 HP drive.

Trouble Shooting

To properly troubleshoot the Vector 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 ampliers?

• Does the alarm reset?

• Does the spindle motor turn at all?

• Does the spindle turn freely by hand?

• Have the C-axis parameters been conrmed?

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

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96-0284 rev H

Page 23

• 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 amplier.

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 resis-

tance should be 8.6 ohms for machines with 20/15 Vector drives and HT10K mills equipped with 40/30 drives. All other machines with 40/30 drives should measure 6 ohms. If not, replace the REGEN load or

cabling.

3. Disconnect cable 490 at terminals 2 and 3 of the Vector Drive and from the servo ampliers. With a mul-

timeter in the diode mode, place the red meter lead to the +HV terminal and the black meter lead to the

-HV terminal of each amplier. 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 amplier.

5. Measure the resistance between terminals 1 and 3 of the Vector 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) disconected 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 ampliers or the REGEN load.

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 voltage between each output phase (ter-

minals 9, 10, and 11) 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 decel-

eration or acceleration just as the spindle reaches its specied 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 6

ohms between the leads for machines with 40/30 Vector drives and 8.6 ohms between the leads on ma-

chines with 20/15 Vector drives and HT10K mills.

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

faulty.

11. 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 termi-

nal 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 voltage at RESET was okay and the alarm was resettable, the REGEN load

should be replaced even if the resistance appears to be okay.

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Electrical Service

Page 24

PCB REPLACEMENT

Please read this section in its entirety before attempting to replace any PCBs

MICROPROCESSOR ASSEMBLY

The microprocessor assembly is in the control cabinet at the top left position. It contains three large boards.

They are: Microprocessor, the Video/Keyboard and the MOCON. All three boards of the processor assembly receive power from the low voltage power supply. The three PCBs are interconnected by a local buss on dual 50-pin connectors. At power-on, some diagnostic tests are performed on the processor assembly and any problems found will generate Alarms 157 or 158. In addition, while the control is operating, it continually tests itself and a self test failure will generate Alarm 152.

MOCON, VIDEO/KEYBOARD, & MICROPROCESSOR

The electrical panel will have residual voltage, even after power has been shut off and/or disconnected. Never work inside this cabinet until the small

red Charge light on the servo ampliers go out. The servo ampliers are on

the left side of the main control cabinet and about halfway down. This light is at the top of the circuit card at the center of the assembly. Until this light goes out, there are dangerous voltages in the assembly even when power is shut off.

Ground straps must be used when handling boards.

WARNING!

NOTE: Board arrangement may differ from the order of replacement that follows. Steps for

MOTOR CONTROLLER (MOCON)

Machines are equipped with a microprocessor-based brushless motor controller board (MOCON) that

replaces the motor interface in the brush type controls. It runs in parallel with the main processor, receiving axis commands and closing the loop around the axis motors.

In addition to controlling the axis and detecting axis faults, the motor controller board (MOCON) is also in charge of processing discrete inputs, driving the I/O board relays, commanding the spindle, and processing the jog handle input. It also controls 6 axes, so there is no need for an additional board for a 5-axis machine. Four LEDs are used to diagnose MOCON problems:

The RUN” LED will turn on, indicating that Mocon code was found in ROM and is being executed. This LED will turn off if a processor exception causes the Mocon code to abort execution.

replacement will only differ in which board may need to be removed before getting to the necessary board.

The “STAT” LED indicates the following (Specic to Mocon 11.00 or later software)

a. Continuously ON - Normal status. board passed all power-on tests; no problems encountered

b. Blinks 3 times - Communication with main processor failed

c. Blinks 4 times - Internal ±12V testing failed

d. Blinks 5 times - Internal watchdog circuit failed

e. Blinks rapidly - EPROM CRC failed

The “Halt” LED glows when the board is in use (processing).

The “+5” LED lights when the board has power.

MOCON Board Replacement

1. Turn machine power off and turn the main switch (upper right of electrical cabinet) to the off position.

2. Open the cabinet door enough to safely work on the electrical panel. Wait until the red charge light on the servo ampliers (servo drive assembly on brush machines) goes out before beginning any work.

Electrical Service

96-0284 rev H

Page 25

3. Disconnect all leads to the Motor Controller (MOCON) board, and ensure all cables are properly labeled.

4. After all cables have been disconnected, unscrew the standoffs, taking care to hold the board in place until all standoffs have been removed.

NOTE: If the Video/Keyboard or Processor boards need replacing, skip the next step.

5. Replace the MOCON board, attaching it to the Video/Keyboard (beneath the MOCON board) with the standoffs, and reconnect all leads (previously removed) to their proper connections.

6. If a second MOCON board is present, be sure to connect the jumper on the second MOCON board.

IDEO/KEYBOARD

The Video/Keyboard PCB generates the video data signals for the monitor and the scanning signals for the keyboard. In addition, the keyboard beeper is generated on this board. There is a single jumper on this board used to select inverse video. The video PCB connectors are:

P1 Power connector J11 SPARE J3 Keyboard (700) J12 Floppy J4 Address bus J13 Video (760)

J5 Data J14 RS422 B

J10 Floppy V+ J15 RS422 A

Video/Keyboard Replacement

1. Remove the MOCON board as previously described.

2. Disconnect all leads to the Video/Keyboard. Ensure all cables are properly labeled for reconnecting later.

3. After all cables have been disconnected, unscrew the standoffs, taking care to hold the board in place until

all standoffs have been removed.

NOTE: If the Processor board needs replacing, skip the next step.

4. Replace the Video/Keyboard, attaching it to the Processor board with the standoffs.

5. Reconnect all leads (previously removed) to their proper connections.

6. Replace the MOCON board.

MICROPROCESSOR PCB (68ECO30)

The Microprocessor PCB contains the 68ECO30 processor running at 40 MHz, one 128K EPROM; between 1MB and 16MB of CMOS RAM and betwen 512K and 1.5MB of Fast Static RAM. It also contains a dual serial port, a battery to backup RAM, buffering to the system buss, and eight system status LED’s.

Two ports on this board are used to set the point at which an NMI is generated during power down and the point at which Reset is generated during power down.

The eight LEDs are used to diagnose internal processor problems. As the system completes power up testing,

the lights are turned on sequentially to indicate the completion of a step. The lights and meanings are: RUN Program Running Without Fault Exception. (Normally On) - If this light does not come on, or goes

out after coming on, there is a problem with the microprocessor or the software running in it. Check all of the buss connectors to the other two PCBs and ensure all three cards are getting power.

PGM Program Signature Found in Memory. (Normally On) - If this light does not come on, it means that

the main CNC program package was not found in memory, or that the auto-start switch was not set. Check that Switch S1-1 is on and the EPROM is plugged in.

CRT CRT/LCD Video Initialization Complete. (Normally On) - If the light does not come on, there is a

problem communicating with the Video PCB. Check buss connectors to ensure it is getting power.

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MSG Power-on Serial I/O Message Output Complete. (Normally On) - If light does not come on, a

problem exists with serial I/O or interrupts. Disconnect anything on the external RS-232 and retest.

SIO Serial I/O Initialization Complete. (Normally On) - If this light does not come on, there is a problem

with the serial ports. Disconnect anything on the external RS-232 and test again.

POR Power-On-Reset Complete. (Normally On) - If this light does not come on, there is a problem with

the Processor PCB. Check that the EPROM is plugged in. Test the card with buss connectors off.

HALT Processor Halted in Catastrophic Fault. (Normally Dim) - If this light comes on, there is a problem

with the Processor PCB. Check that the EPROM is plugged in. Test the card with buss connectors off.

+5V +5V Logic Power Supply is Present. (Normally On) - If this light does not come on, check the low

voltage power supply and check that all three phases of 230V input power are present.

There is 1 two-position DIP switch on the Processor PCB labled S1. Switch S1-1 must be ON to auto-start the CNC operational program. If S1-1 is OFF, the PGM light will remain off. Switch S2-1 is used to enable Flash. If it is disabled it will not be possible to write to Flash.

The processor connectors are:

J1 Address buss J5 Serial port #2 (for auxiliary 5th axis) (850A) J2 Data buss J3 Power connector

J4 Serial port #1 (for upload/download/DNC) (850) J6 Battery

Processor Board Memory Retention Battery Replacement

Alarm 124 indicates an imminent battery failure. To preserve CMOS RAM contents while the machine is pow-

ered off, the 3.3V lithium battery must be replaced within 30 days of the rst alarm. To replace the battery:

1. Backup all parameters, settings, programs, offsets, history, and macro variables.

2. Haas kit 32-1010 includes a temporary battery with a jumper connector. Plug this jumper into J6 (68K PCB) or J15 (Coldre PCB). This ensures that memory contents are retained during the procedure.

NOTE: Do not remove the existing battery before the backup battery is installed, or remove

the backup before a fresh battery has been installed. This will result in complete machine memory loss, which cannot be reversed.

3. Properly ground yourself and unsolder the battery from the processor board.

4. Clean the battery contact areas and solder the new battery in place, observing correct battery orientation (the positive battery connector is marked on the board and circled in the previous photograph).

5. With the new battery in place, disconnect the backup battery jumper.

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96-0284 rev H

Page 27

Processor Board Replacement

1. Remove the MOCON board, and the Video/Keyboard as previously described.

2. Disconnect all leads to the Processor board. Ensure all cables are properly labeled for reconnecting later.

3. After all cables have been disconnected, unscrew the standoffs, taking care to hold the board in place until

all standoffs have been removed.

4. Replace the Processor board, attaching it to the electrical cabinet with the standoffs, reconnect all leads (previously removed) to their proper connections, and replace Video/Keyboard and MOCON board.

INPUT/OUTPUT ASSEMBLY

The Input/Output Assembly consists of a single printed circuit board called the I/O PCB.

The I/O PCB also contains a circuit for sensing a ground fault condition of the servo power supply. If more than 1.75 amps is detected owing through the grounding connection of the 160V DC buss, a ground fault

alarm is generated and the control will turn off servos and stop.

Relay K6 is for the coolant pump 230V AC. It is a plug-in type and is double-pole. Relays K9 through K12 are

also plug-in types for controlling the tool changer motors.

I/O Board Replacement

1. Follow all precautions noted previously before working in the electrical cabinet.

2. Disconnect all leads to the Input/Output board and move aside for removal. Ensure all cables are properly

labeled for reconnecting later.

3. Remove the board by rst removing the twelve screws that fasten it to the cabinet. Take care to hold the

board in place until all screws have been removed.

4. Replace the I/O board, attaching it to the cabinet with the twelve screws previously removed, and reconnect all leads to the I/O board. Check for any additional jumper settings per I/O release notes.

POWER TRANSFORMER ASSEMBLY (T1)

The power transformer assembly converts three-phase input power (50/60Hz) to three-phase 230V and 115V power. Two transformers are used, depending on the input voltage range. The low voltage transformer has four input connections to allow for a range of voltages from 195V RMS to 260V RMS. The high voltage transformer has ve input connections and will accept a range of voltages from 354V RMS to 488V RMS.

The 230V is used to power the spindle drive. THe 230V also supplies the power to the vector drive, which supplies 325V DC power for the axis servo ampliers. The 115V is used by the video monitor, solenoids, fans and pumps, in addition to supplying power to the main LVPS used by the control electronics.

The transformer assembly is located in the lower right hand corner of the main cabinet. Besides the high/low

voltage variations, two different power levels are available depending on the spindle motor used. The small

and large transformers have power ratings of 14 KVA and 28 KVA, respectively, and are protected by the main

circuit breaker.

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Ouput Power

Input

Power

TB2

240VOUT

488-458V

457-429V

260-244V

INCOMINGLINE VOLTAGETAPS(74, 75,76)

428-403V

243-227V

402-377V

226-211V

TB1

120VOUT

376-354V

210-195V

Polyphase Bank Transformer

Primary Connection To T1

Input power to T1 is supplied through CB1, the main circuit breaker. Three-phase 230 to T1 is connected to the rst three terminals of TB10.

Circuit breaker CB1 protects the spindle drive and shuts off all power to the control. A trip of this breaker

indicates a serious overload problem and should not be reset without investigating the cause of the trip.

Main Contactor K1

Main contactor K1 is used to turn the control on and off. The Power On switch applies power to the coil of K1 and after it is energized, auxiliary contacts on K1 continue to apply power to the coil. The Power Off switch on

the front panel will always remove power from this contactor.

When the main contactor is off, the only power used by the control is supplied through two ½ amp fuses to

the circuit that activates the contactor. An overvoltage or lightning strike will blow these fuses and shut off the main contactor.

The power to operate the main contactor is supplied from a 24V AC control transformer that is primary fused at ½ amp. This ensures that the only circuit powered when the machine is turned off is this transformer and only low voltage is present at the front panel on/off switches.

Voltage Selection Taps

There are four labeled plastic terminal blocks. Each block has three connections for wires labeled 74, 75, and

76. Follow the instructions printed on the transformer.

Secondary Connection To T1

The secondary output from T1 is 115V AC three-phase CB2 that protects the secondary of transformer T1 and is rated at 25 amps.

Optional 480V Transformer

60Hz 50Hz

Input Voltage Range Tap Input Voltage Range Tap

493-510 1 (504) 423-440 1 (504)

481-492 2 (492) 412-422 2 (492) 469-480 3 (480) 401-411 3 (480) 457-468 4 (468) 391-400 4 (468) 445-456 5 (456) 381-390 5 (456) 433-444 6 (444) 371-380 6 (444)

420-432 7 (432) 355-370 7 (432)

Power-Up Low Voltage Control Transformer (T5)

The low voltage control transformer, T5, supplies power to the coil of the main contactor K1. It guarantees that the maximum voltage leaving the Power Supply assembly when power is off is 12V AC to earth ground. It is connected via P5 to the Power PCB.

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Operator’s Work Light

Main transformer (T1) outputs 115V AC to the work light.

POWER SUPPLY ASSEMBLY

All control power passes through a power supply assembly on the upper right corner of the control cabinet.

Power PCB (PSUP)

Low voltage power distribution and high voltage fuses and circuit breakers are mounted on a circuit board called the Power PCB.

Secondary Circuit Breakers

The following circuit breakers are located on the Power supply assembly:

CB2 Controls the 115V power from the main transformer to the I/O PCB and, if tripped, will turn off all

inputs and outputs. CB2 could be tripped by a short circuit in the cables.

CB3 Controls the power to coolant pump only. It can be tripped by an overload of the coolant pump

motor or a short in the wiring to the TSC motor, or lathe hydraulic pump.

CB4 Controls the power to chip conveyor only. CB5 Controls power to the TSC coolant pump only. It can be tripped by an overload of the TSC coolant

pump motor or a short in the wiring to the motor.

CB6 Single-phase 115V protected ground fault interrupt circuit and output for the worklight.

Power PCB (PSUP) Replacement

1. Follow all precautions noted previously before working in the electrical cabinet

2. Disconnect all leads to the Power PCB (PSUP) and set aside for removal. Ensure all cables are properly

labeled for reconnecting later.

3. After all cables have been disconnected, remove the seven screws holding the Power board to the cabinet and remove the board. Take care to hold the Power board in place until all screws have been removed.

NOTE: If replacing the Low Voltage Power Supply board, please skip the next step.

4. Replace the Power board, attaching it with the seven screws previously removed. Do not forget to use the

lower left screw for a ground connection.

5. Reconnect all cables to Power board at proper location. Refer to release notes for additional information.

LOW VOLTAGE POWER SUPPLY

The low voltage power supply provides +5V DC, +12V DC, and -12V DC to all logic sections of the control. It operates from 115V AC nominal input power, and continues to operate correctly over 90 to 133V AC.

Low Voltage Power Supply (LVPS) Replacement

1. Remove the Power Distribution (Power) board as previously described.

2. Disconnect all leads to the Low Voltage Power Supply (LVPS) board. Ensure all cables are properly labeled

for reconnecting later.

3. After all cables are disconnected, unscrew the two standoffs at the bottom of the board. Unscrew the remaining two screws at the top of the LVPS board. Hold the board in place until all screws are removed.

4. Replace the LVPS board, attaching it to the cabinet with the two screws and standoffs previously removed.

5. Replace the Power board as previously described.

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RS-232 SERIAL INTERFACE

There are two connectors used for the RS-232 interface. The RS-232 connector on most PCs is a male DB25, so only one type of cable is required for connection to the controller, or between controllers. This cable must be a DB-25 male on one end and a DB-25 female on the other. Pins 1, 2, 3, 4, 5, 6, 7, 8, and 20 must be wired one-to-one. It cannot be a Null Modem cable, which inverts pins 2 and 3. To check cable type use a cable tester to check that communication lines are correct. The controller is DCE (Data Communication Equipment). This means that it transmits on the RXD line (pin 3) and receives on the TXD line (pin 2). The RS-232 connector on most PCs is wired for DTE (Data Terminal Equipment), requiring no special jumpers.

The Down Line DB-25 connector is only used when more than one controller is to be used. The rst controller’s down line connector goes to the second controller’s up line connector, etc.

Interfacing a Haas Rotary Control to the mill

The RS-232 interface sends and receives seven data bits, even parity, and two stop bits. The interface must be set correctly. The data rate can be between 110 and 19200 bits per second. When using RS-232, it is important to make sure that Parameter 26 (RS-232 Speed) and 33 (X-on/X-off Enable) are set to the same value in the controller and PC.

If Parameter 33 is set to on, the controller uses X-on and X-off codes to control reception, so be sure your computer is able to process these. It also drops CTS (pin 5) at the same time it sends X-off and restores CTS when is sends X-on. The RTS line (pin 4) can be used to start/stop transmission by the controller or the X-on/ Xoff codes can be used. The DSR line (pin 6) is activated at power-on of the controller and the DTR line (pin 20 from the PC) is not used. If Parameter 33 is 0, the CTS line can still be used to synchronize output.

When more than one Haas controller is daisy-chained, data sent from the PC goes to all of the controllers at the same time, requiring an axis selection code (Parameter 21). Data sent back to the PC from the controllers is ORed together so that, if more than one box is transmitting, the data will be garbled. Because of this, the

axis selection code must be unique for each controller.

RS-232 Remote Command Mode

Parameter 21 must be non-zero for the remote command mode to operate as the controller looks for an axis select code dened by this parameter. The controller must also be in RUN mode to respond to the interface. Since the controller powers-on in Run mode, remote unattended operation is thus possible.

RS-232 Line Noise

To minimize line noise on the serial port, reroute the cables straight up the left-hand side of the control to the

processor stack. Do not run them above the I/O PCB or up the center wire channel to the processor.

Transmission errors may be best minimized with a good common ground between the PC and CNC control.

RS-232 Loop Back Test

If you have a communications problem between Port #1 of the machine and your external computer, use the

following procedure to isolate the problem to either internal or external causes.

1. Unplug the cable from Port #1 of the Control Panel, and plug the cable tester in (port #1).

PLUG TESTER

BACK VIEW

The RS-232 Plug Tester is a 25-pin male connector with the following pins shorted.

Pins 2 & 3 and Pins 14 & 16

In order to properly perform the test, Setting 14 must be set to CTS/RTS.

2. If the machine is on, cycle the power (power down then turn back on).

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3. Press List Prog, followed by press Param Dgnos twice, then press Send RS232.

4. If the internal serial port is working, the lower left-hand part of the screen will display Serial Passed. (This means that the system, to the output of the control panel, is working. Check the cable to the computer set-up if you still have a communications problem.)

If the internal serial port is bad, the lower left-hand part of the screen will display Serial Failed. (This means there is a problem inside the control panel, or that the test connector is unplugged or missing.)

RS-232 PCB Replacement

1. Follow all precautions noted previously before working in the electrical cabinet.

NOTE: It is necessary, when replacing the RS-232 board, to work from the inside and

outside of the cabinet at the same time.

2. On the left side of the cabinet, at the top of the side panel, are two serial port connections labeled “Serial Port #1” and “Serial Port #2”. Serial Port #1 is the upper connection.

VR5

VR1

VR2

VR3

VR4

RS-232 PORT1

RS-232 PORT2*

PIN1

C5C4C3

GND

Video &

Keyboard

J13

Micro

Processor

J14

* Requires second RS-232 Board (34-4089)

RS-232

PCB

PORT1

SKBIF

RS-232 PORT2*

* Requires second RS-232 Board (34-4090)

RS-232 Wiring Diagram (with Serial Keyboard)

VR5

VR1

VR2

VR3

VR4

PIN1

C5C4C3

GND

Coldfire

Micro

Processor

J14

3. To remove the RS-232 board, unscrew the two hex screws (on the exterior of the cabinet) holding the connector to the cabinet. From the inside of the cabinet, pull the connector through the panel, and disconnect

the cable.

4. Replace the RS-232 board by rst connecting the appropriate cable to the board (850 to Serial Port #1, 850A to Serial Port #2, then inserting the board (cable side up) through the left side panel. Attach with the two hex screws previously removed. Ensure the board for Serial Port #1 is the upper connector and the board for Serial Port #2 is the lower connector.

SKBIF

SPARE USER M CODE INTERFACE

The M code interface uses outputs M21-25 and one discrete input circuit. M codes M21 through M25 will activate relays labeled M21-25. These relay contacts are isolated from all other circuits and may switch up to 120V AC at three amps. The relays are SPDT (Single Pole Double Throw).

WARNING!

Power circuits and inductive loads must have snubber protection.

The M-FIN circuit is a normally open circuit that is made active by bringing it to ground. The one M-FIN applies to all of the user M codes.

The timing of a user M function must begin with all circuits inactive (open). The timing is as follows:

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M21

for M-fin

delay

end M-fin

M-FIN Discrete Input 1009

CNC is:

Running Waiting

.05 ms

Waiting for

Running

The Diagnostic Data display page may be used to observe the state of these signals.

M FUNCTION RELAYS (M-FIN)

The I/O PC board has relays that are available to the user. M21 is already wired out to P12 at the side of the control cabinet. This is a four-pin DIN connector and includes the M-FIN signal.

NOTE: Refer to Diagnostic Data for specic machine Inputs and Outputs.

M-Code Output Relay Normally Open

NOTE: Some or all of the M21-25 on the I/O PCB may be used for factory installed options.

Inspect the relays for existing wires to determine which are in use.

1 M-FIN, Input Signal

2 Input GND

M-FIN DISCRETE INPUT

The M-FIN discrete input is a low voltage circuit. When the circuit is open, there is +12V DC at this signal. When the line is brought to ground, there is about 10 milliamps of current. M-FIN is discrete input 1009 and is wired from input 1009 on the I/O PCB (usually P10). The return line for grounding the circuit should come from that PCB. For reliability, these two wires should be routed in a shielded cable where the shield is grounded at one end only. The diagnostic display shows a “1” when the circuit is open and a “0” when it is

grounded.

WIRING THE RELAYS

Relays are marked on the I/O PCB, with their respective terminals forward of them. If the optional 8M relay board is installed, connections on the I/O PCB are unused, since they are replaced by relays on the optional board. Refer to the gure, and the Probe Option gure in the Electrical Diagrams section for terminal labeling.

SWITCHES

X, Y, Z Travel Limit Switches

Machine zero position is dened by a limit switch for each of the X, Y, and Z axes. After search for machine zero is complete, these switches are used to limit travel in the positive direction. Negative direction travel is

limited by stored stroke limits. It is not normally possible to command the servo axes past the machine zero as servo travel lookahead will decelerate and stop each motor prior to exceeding the stroke limits.

Prior to performing a Power Up/Restart or an Auto All Axes operation, there are no travel limits. You can jog into the hard stops in either direction for X, Y, or Z. After a Zero Return has been performed, the travel limits

will operate unless an axis hits the limit switch. When the limit switch is hit, the zero returned condition is reset and an Auto All Axes must be done again to ensure you can still move the servo back away from it.

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The limit switches are normally closed. When a search for zero operation is being performed, the X, Y, and Z axes will move towards the limit switch unless it is already active (open); then move away from the switch until it closes again; then continue to move until the encoder Z channel is found. This position is machine zero.

On some mills, the auto search for zero in the Z-axis is followed by a rapid move from the limit switch position

down to the tool change position, making the Z-axis a little different from the other axes. The position found

with the limit switch is not machine zero but is the position used to pull tools out of the spindle. Machine zero for Z is below this by Parameter 64. Be careful during the Z zero search and stay clear of that rapid move.

What Can Go Wrong With Switches?

Proximity switches are distance sensitive, and must be set no farther than .012” (3mm) away from an assembly or limit ag. An improperly set proximity switch will give inconsistence results, which may be

interrupted as another problem. Any time a switch is replaced ensure the proper distance is set.

• If the machine is operated with Limit Switch inputs disabled, a Low Lube and Door Open alarm is generated.

In addition, Home search will not stop at the limit switch and instead runs into the physical stops on each axis.

• If the switch is damaged and permanently open, the zero search for that axis will move in the negative

direction at about 0.5 in/min until it reaches the physical travel stops at the opposite end of travel.

• If the switch is damaged and permanently closed, the zero search for that axis will move at about 10 in/min

in the positive direction until it reaches the physical stops.

• If the switch opens or a wire breaks after the zero search completes, an alarm is generated, the servos are

turned off, and all motion stops. The control will operate as though the zero search was never performed.

Reset can be used to turn servos on, but you can jog that axis slowly.

Clamp/Unclamp Switches

There are two switches used to sense the position of the turret or tool clamping mechanism. They are both normally closed and one will activate at the end of travel during unclamping and the other during clamping. When both switches are closed, it indicates that the turret or drawbar is between positions.

The diagnostic display can be used to display the status of the relay outputs and the switch inputs.

Door Hold Switch

The switch is normally closed. When the door opens, the switch opens and the machine stops with a “Door Hold” function. When the door is closed again, operation continues normally.

If the door is open, it is not possible to start a program. Door hold will not stop a tool change operation, will not

turn off the spindle, and will not turn off the coolant pump. The door hold function can be temporarily disabled

with Setting 51, but this setting will return to Off when the control is turned off.

Tool #1 Sense Switch

The tool rotation turret has a switch activated when tool one is in position or facing toward the spindle. At

Power On this switch can indicate that tool #1 is in the spindle. If this switch is not active at power-on, the rst

tool change will rotate the turret until the switch engages and then move to the selected tool. The diagnostic

display will show the status of this input switch as “Tool #1”. A “1” indicates that tool #1 is in position.

Umbrella Tool Changer Geneva Wheel Position Mark (Vert)

The turret rotation mechanism has a switch mounted so that it is activated for about 30

Geneva mechanism. When activated, this switch indicates that the turret is centered on a tool position. This

switch is normally closed. The diagnostic display will show this status of this input switch as “TC MRK”. A “1”

indicates the Geneva wheel is in position.

of travel of the

Umbrella Tool Changer Shuttle In/Out Switches (Vert)

Two switches are used to sense the position of the tool changer shuttle and the arm that moves it. One switch

is activated when the shuttle is moved to full travel inward and one is activated when it is in full travel outward. These switches are normally closed, so that both are closed between in and out. The diagnostic display will

show the status of the input switch. A “1” indicates the associated switch is activated or open.

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Transmission High/Low Gear Position Switches

On machines with a two-speed transmission, there are two switches in the gearbox used to sense the position of the gears. One switch indicates “High” by opening and the other indicates “Low” by opening. Between

gears, both switches are closed, indicating a between-gear condition. The diagnostic display shows the status

of these switches and the Curnt Comds display shows which gear is selected. If the switches indicate that the gearbox is between gears, the display will indicate “No Gear”.

NOTE: The Transmission High/Low Gear Position Switches are located at the bottom of the

Gearbox Assembly and are difcult to reach. Removal of this assembly is necessary to replace these switches. See the Mechanical Components Service Manual, for Spindle Motor and Transmission removal.

CONTROL MEMORY

The Haas processor board contains three types of memory:

• Flash Memory - stores the binary and language les (software). Information stored only changes when the

serviceperson loads a new binary le. Flash memory retains its contents even when the power is turned off.

• Random Access Memory (RAM) - When the machine is powered up the processor board copies the binary

le and the selected language text from the ash memory into RAM, which is run from there. RAM also holds

internal information that the control needs while it is running, such as current position, displays screens, etc.

When the user selects a different language, it is copied over the last language. Information stored in RAM is

not retained when the machine is turned off.

• Battery Backed-up Random Access Memory (BBU-RAM) - This type of memory uses an on-board

battery to retain its information after the machine is turned off. If battery power is low the memory gets

corrupted, and if the battery voltage goes to zero, the memory goes blank. Battery Backed up memory holds information such as user programs, Settings, Parameters, Offsets.

Clearing Processor Memory (Coldre):

At the prompt, >, type in the following and press, “enter” to test and clear BBU Ram:

M 6000000 60FFFFF

The following message is repeatedly displayed until Reset is pressed to stop the BBU RAM memory test:

Memory test passed, press and hold reset to stop

To clear Flash Memory (Coldre Processor):

Type “FC” and press enter

The following message will be displayed:

ERASING FLASH – PLEASE WAIT… FIRST FLASH CHIP ERASED

FLASH CLEAR COMPLETE

NOTE: This ash memory clear will not erase the ColdFire monitor program

Clearing the memory in a control

At times it is necessary to clear the memory of the machine. This may have to be done to update software, or

do remove corrupted software. To do this follow the steps for the specic type of memory. The next two steps

must be followed to prepare the machine.

1. The programs, settings and other control information must be saved before clearing the memory. It may be

necessary to turn off Setting 23 to save the macro variables. The following are the les to save:

PROGRAMS (PGM) SETTINGS (SET) OFFSETS (OFS)

PARAMETERS (PAR) MACRO VARIABLES (VAR)

Disconnect the RS-232 cables, if used.

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2. Turn off the machine and then turn it back on while holding the PRGRM CONVRS button. The display will

be similar to the following:

HAAS 68030 MONITOR ddd-mmm-yy FLASH MEMORY FOUND: 1024K @ 00080000 BBU RAM FOUND: 1024 K (1024K of BBU-RAM)

68882 COPROCESSOR NOT FOUND

This example shows 1024K of ash memory at address 80000 and 1024K of BBU-RAM. Write down what the

machine has before continuing.

Clearing the BBU-RAM (68K Processor)

1. Type in “M 3000D6C 300FFFF” and press Enter. The control responds with “Memory Test Passed” written several times. The command “M3000D6C” checks and clears just a portion of the BBU-RAM. It avoids the section that contains the serial number of the machine (Setting 26). Most problems can be solved without

removing the serial number.

2. Press and Hold Reset until you see “>” displayed. If the “>” does not display, continue to step 3.

3. This step will clear the BBU-RAM completely including the machine serial number. Use the following to determine the command to clear BBU-RAM.

BBU RAM Found Board Size Command to Clear BBU-RAM

256K 256K M 3000000 303FFFF 1024K 1 megabyte M 3000000 30FFFFF 4096K 4 megabyte M 3000000 33FFFFF 8192K 8 megabyte M 3000000 37FFFFF

16384K 16 megabyte M 3000000 3FFFFFF

To Clear BBU- RAM as per the example, Type the following and press Enter:

M 3000000 30FFFFF (for 1024K)

Clearing Flash Memory:

Clearing Flash Memory will solve problems caused by fragments of code left behind from previous binary or language les. The most common problem is BAD LANGUAGE VERSION alarm. To clear the ash memory, a value is entered to tell the system where it is located. Following these steps will clear the memory or give you the message, “Undened Command”, or a similar message.

If the control displayed the amount of ash memory in step 2 of “Clearing the memory in the control”, then do one of the following depending upon how much ash Memory is found:

Enter FC 80000 200000 and press enter (for 1536K of FLASH) Enter FC 80000 280000 and press enter (for 2048K of FLASH)

Enter FC 80000 380000 and press enter (for 3072K of FLASH)

Enter FC 8000 and press enter (for 0.5MB of FLASH) Enter FC 100000 and press enter (for 1.0MB of FLASH)

Enter FC 180000 and press enter (for 1.5MB of FLASH)

If you get the message “Undened Command” (or similar) perform the following steps.

Enter FC 8000 FFFFF and press enter (to clear 80000 thru FFFFF) Enter FC 100000 17FFFF and press enter (to clear 100000 thru 17FFFF)

Enter FC 180000 1FFFFF and press enter (to clear 180000 thru 1FFFFF)

The ash memory is now cleared and software must be loaded to continue.

If the control is prior to 1997, 512K x 8 bit RAM chips are used on the processor PCB. These can be cleared

as follows:

Enter the following for 4 chips: FC 20000 9FFFF and press enter Enter the following for 5 chips: FC 20000 BFFFF and press enter Enter the following for 6 chips: FC 20000 DFFFF and press enter Enter the following for 7 chips: FC 20000 FFFFF and press enter

The ash memory is now cleared and software must be loaded to continue.

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DIAGNOSTIC DATA

The Alarm Msgs display is the most important source of diagnostic data. At any time after the machine com-

pletes its power-up sequence, it will either perform a requested function or stop with an alarm. Refer to the

Alarms chapter for their possible causes and some corrective action. If there is an electronics problem, the controller may not complete the power-up sequence and the monitor

will remain blank. In this case, there are two sources of diagnostic data; these are the audible beeper and the LEDs on the processor PCB. If the audible beeper is alternating a ½ second beep, there is a problem with the main control program stored in EPROMs on the processor PCB. If any of the processor electronics cannot be accessed correctly, the LEDs on the processor PCB will or will not be lit.

If the machine powers up but has a fault in one of its power supplies, it may not be possible to ag an alarm condition. If this happens, all motors will be kept off and the top left corner of the monitor will display a Power Failure Alarm message, and all other functions of the control will be locked out.

When the machine is operating normally, a second push of the Param/Dgnos key selects the diagnostics display page. The Page Up and Page Down keys are then used to select one of two different displays. These are for diagnostic purposes only and are not normally needed. The diagnostic data consists of 32 discrete input signals, 32 discrete output relays and several internal control signals. Each can have the value of 0 or 1.

There are also up to three analog data displays and an optional spindle rpm display.

ISCRETE INPUTS/OUTPUTS (LATHE)

Discrete Inputs # Name # Name

1000 Tool Turret Unlock 1016 Spare 1001 Tool Turret Lock 1017 Spare 1002 Spare 1018 Spare 1003 Low Coolant 1019 Spare 1004 Automatic Door 1020 Low hyd pressure 1005 Spindle In Hi Gear 1021 T.S. Foot Switch 1006 Spindle In Low Gear 1022 Probe Not Home 1007 Emergency Stop 1023 Spare 2b 1008 Door Switch 1024 Tool Unclamp Rmt* 1009 M Code Finish 1025 Low Phasing 115V 1010 Over Voltage 1026 B F End of Bar 1011 Low Air Pressure 1027 Bar Feeder Fault 1012 Low Lube Press. 1028 Ground Fault 1013 Regen Overheat 1029 G31 Block Skip 1014 Spare 1030 B F Spindle Intlk

1015 Spare 1031 Conveyr Overcrnts

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Discrete Outputs # Name # Name

1100 Hyd Pump Enable 1116 Move Spigot CW 1101 Spare 111 7 Move Spigot CCW 1102 Spare 1118 Pal Ready Light

1103 Spare 1119 T.S. High Pressure 1104 Spindle Brake 1120 Tool Turret Out 1105 Coolant Pump on 1121 T.S. Reverse 1106 Power Off 1122 T.S. Forward 1107 Way Lube Pump 1123 (CE) Door Locked

1108 SB Motor Load PR 1124 M21 (Auto Door Clutch) 1109 SB Motor Load Bar 1125 M22 (Parts Catcher) 1110 Auto Door Open 1126 M23 (C Axis Engage) 1111 Auto Door Close 1127 HPC Coolant

1112 Spindle Hi Gear 1128 Green Beacon On 1113 Spindle Low Gear 1129 Red Beacon On 1114 Unclamp Chuck 1130 Enable Conveyor

1115 Lock Spindle 1131 Reverse Conveyor

The second page of diagnostic data is displayed using the Page Up and Page Down keys. It contains:

Inputs 2

X-axis Z Channel X Motor Over Heat Y-Axis Z Channel Y Motor Over Heat Z-axis Z Channel Z Motor Over Heat A-axis Z Channel A Motor Over Heat B-axis Z Channel B Motor Over Heat

C-axis Z Channel C Motor Over Heat

X Home Switch X drive fault Y Home Switch Y drive fault Z Home Switch Z drive fault A Home Switch A drive fault B Home Switch B drive fault

C Home Switch C drive fault

X Cable Input S Z CH Spindle Z Channel Y Cable Input Z Cable Input A Cable Input B Cable Input

C Cable Input

The Temp-Track option displays the X and Z ballscrew temperatures on the Inputs2 diagnostics screen just above “SP Load” when Parameter 266 or 268 bit 9 “Temp Sensor” is set to 1. The following inputs and outputs pertain to the Haas Vector Drive. If it is not enabled, a value of * is displayed. Otherwise, it displays a 1 or 0.

Haas Vector Drive Name Name

Spindle Forward Spindle Fault Spindle Reverse Spindle Locked Spindle Lock Spindle Cable Fault Spindle At Speed Spindle Overheat

Spindle Stopped

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Analog Data Name Description

SP LOAD Spindle load in % SP SPEED Spindle rpm CW or CCW RUN TIME Total machine run time TOOL CHANGES Number of tool changes VER X.XXX Software version number YY/MM/DD Today’s date MDL SL- __ Model number

DC BUSS Mocon II

DISCRETE INPUTS/OUTPUTS (MILLS)

# Name # Discrete Input Name

1000 TC Changer In/SMTC Pocket Down 1023 Spare 3/APC Pin Clr #2 1001 TC Changer Out/SMTC Pocket Up 1024 Tool Unclmp Rmt* 1002 Tool One In Pos. 1025 Spare 1003 Low TSC Pressure 1026 Spare 3A/APC Pal #2 Home 1004 Tool In Position 1027 Spare 3B/APC Pal #1 Home 1005 Spindle High Gear 1028 Ground Fault 1006 Spindle Low Gear 1029 G31 Block Skip 1007 Emergency Stop 1030 Spigot Position 1008 Door Safety Switch 1031 Conveyr Overcrnt 1009 M Code Finish*/APC: APC Pal Clamp 1032 Spare 4A 1010 Over Voltage (Mini-Mill - P.S. Fault) 1033 Spare 4B 1011 Low Air Pressure 1034 Spare 5A 1012 Low Lube Press. 1035 Spare 5B 1013 Regen Over Heat 1036 Spare 6A 1014 Drawbar Open 1037 Spare 6B 1015 Drawbar Closed 1038 Spare 7A 1016 Spare 1039 Spare 7B 1017 Spare 1040 Spare 8A 1018 Spare 1041 Spare 8B 1019 Spare 1042 Spare 9A (SMTC: Motor stop) 1020 Low Trans Oil Prs 1043 Spare 9B (SMTC: Origin) 1021 Spare 1/APC Door 1044 Spare 10A (SMTC: Clamp / Unclamp)

1022 Spare 2/APC Pin Clr #1 1045 Spare 10B

Inputs are numbered the same as the connections on the inputs printed circuit board. (*): active when = 0.

# Discrete Output Name # Discrete Output Name

1100 Powered Servos 1120 Unclamp Pre-Chrg 1101 Spare 1121 HTC Shuttle Out (Air Drive Shuttle in/ APC Door) 1102 Spare 1122 Brake 5TH Axis 1103 Spare 1123 CE Door Lock 1104 Brake 4th Axis 1124 M21 1105 Coolant Pump On 1125 M22 1106 Auto Power Off 1126 M23 (Air Drive Shuttle: Move Shuttle Out) 1107 Spind. Motor Fan 1127 TSC Coolant 1108 Move T.C. In/APC Chain Dr Fwd 1128 Green Beacon On

1109 Move T.C. Out/APC Chain Dr Rev 1129 Red Beacon On

1110 Rotate T.C. CW 1130 Enable Conveyor 1111 Rotate T.C. CCW 1131 Reverse Conveyor 1112 Spindle Hi Gear 1132 M-n 1113 Spindle Low Gear 1133 Probe

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# Discrete Output Name # Discrete Output Name

1114 Unclamp Tool 1134 spare 1115 Spare 1135 spare 1116 Move Spigot CW 1136 spare 1117 Move Spigot CCW 1137 spare

1118 Pal Ready Light 1138 spare

1119 TSC Purge 1139 spare

NOTE: The following inputs and outputs change for machines equipped with an APC.

# Discrete Output Name # Discrete Output Name

1021 APC CE Door 1108 APC Chain Drive Forward 1022 APC Pin CLR #1 1109 APC Chain Drive Reverse

1023 APC Pin CLR #2 1121 PAL Clamp

1026 APC PAL #2 Home 1122 Door 1027 APC PAL #1 Home 1125 APC Motor 1046 APC Door Closed 1126 Beeper 1047 Door Open 1137 APC Chain Drive Power Enable 1048 APC Pallet Clamped 1138 Air Blast

1101 Pallet Clamped 1139 APC Beeper

The second page of diagnostic data is displayed using the Page Up and Page Down keys. It contains:

Inputs 2

Name Name Name

X Axis Z Channel X Overheat X Cable Input Y Axis Z Channel Y Overheat Y Cable Input Z Axis Z Channel Z Overheat Z Cable Input A Axis Z Channel A Overheat A Cable Input B Axis Z Channel B Overheat B Cable Input X Home Switch X Drive Fault Spindle Z Channel Y Home Switch Y Drive Fault Z Home Switch Z Drive Fault A Home Switch A Drive Fault

B Home Switch B Drive Fault

The following inputs and outputs pertain to the Haas Vector Drive. If it is not enabled, these will display a value of *. Otherwise, it will display a 1 or 0.

Spindle Forward Spindle Reverse Spindle Lock Spindle at Speed* Spindle Stopped Spindle Fault Spindle Locked Spindle Cable Fault

Spindle Over Heat

The following Discrete Inputs/Outputs 2 are available when Parameter 278 SMNT bit 1,2 or 3 (Side-Mount Tool Changer) is set and Parameter 209 MCD RLY BRD (M-Code relay board) is On.

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Discrete Inputs 2 Name Name

Spare Input 4A Spare Input 8A Spare Input 4B Serp. Shot Pin* Spare Input 5A Motor Stop Spare Input 5B Origin Spare Input 6A Clamp/Unclamp Spare Input 6B Serp. Cam Count Spare Input 7A Spare Input 11A

Spare Input 7B Spare Input 11 B

Discrete Outputs 2 Name Name

Spare Output 32 Spare Output 44 Spare Output 33 Spare Output 45 Spare Output 34 Spare Output 46 Spare Output 35 Spare Output 47

Spare Output 36 Spare Output 48 (SMTC: Serp. ATC Enable) TC MTR SW Spare Output 49 (SMTC: Serp. ATC Rev.) Spare Output 38 Spare Output 50 (SMTC: Serp. Carsl CW) Spare Output 39 Spare Output 51 (SMTC: Serp. Carsl CCW) Spare Output 40 Spare Output 52 (SMTC: Serp. Carsl Ena.) Spare Output 41 Spare Output 53 Spare Output 42 Spare Output 54

Spare Output 43 Spare Output 55

Analog Data Name Description

DC BUSS Voltage from Haas Vector Drive (if equipped) uP TEMP Displayed when Parameter 278 bit “µP Encl Temp” is set to 1) SP LOAD Spindle load in % SP SPEED Spindle rpm CW or CCW RUN TIME Machine total run time

TOOL CHANGES Number of tool changes

VER X.XXX Software version number MOCON MOCON software version YY/MM/DD Today’s date

MDL HS__ Machine model FV 2 11.0004 Floppy version (Ethernet Firmware)

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CABLE LIST

WIRE/ TERMINAL FUNCTION NAME: NUMBER

INCOMING POWER 195-260 VAC (353-488 VAC OPTIONAL)

L1 INCOMING 195-260VAC, PHASE 1, TO CB1-1 L2 INCOMING 195-260VAC, PHASE 2, TO CB1-2

L3 INCOMING 195-260VAC, PHASE 3, TO CB1-3

71 PROTECTED 195-260 VAC FROM MAIN CB1-4 TO K1-1 72 PROTECTED 195-260 VAC FROM MAIN CB1-5 TO K1-2

73 PROTECTED 195-260 VAC FROM MAIN CB1-6 TO K1-3

74 195-260 VAC FROM K1-4 TO XFORMER T1 75 195-260 VAC FROM K1-5 TO XFORMER T1

76 195-260 VAC FROM K1-6 TO XFORMER T1

77 230VAC PHASE 1 , FROM XFORMER T1 TO VECTOR/CHIP CONV 78 230VAC PHASE 2 , FROM XFORMER T1 TO VECTOR/CHIP CONV

79 230VAC PHASE 3 , FROM XFORMER T1 TO VECTOR/CHIP CONV

90 115 VAC FROM TB2 (CB2 OUTPUT) TO IOPCB P33 91 STEPPED-DOWN 115 VAC (FROM XFRMR T1) 92 STEPPED-DOWN 115 VAC (FROM XFRMR T1) 93 STEPPED-DOWN 115 VAC (FROM XFRMR T1)

94 SHIELD DRAIN

—- 115 VAC FROM XFORMER T1 TO TB1 94 STEPPED-DOWN 115 VAC (FROM XFRMR T1) 95 STEPPED-DOWN 115 VAC (FROM XFRMR T1)

96 STEPPED-DOWN 115 VAC (FROM XFRMR T1)

90A 115 VAC TO CRT 91A LEG 1 92A LEG 2

93A SHIELD DRAIN

90B 115 VAC TO HEAT EXCHANGER (CABINET DOOR FAN) 91B LEG 1 92B LEG 2

93B SHIELD DRAIN

90C 115 VAC TO CB4 91C LEG 1 92C LEG 2

93C SHIELD DRAIN

100 M-FIN 101 SIGNAL 102 COMMON

103 SHIELD DRAIN

100A MFIN OUTPUT M21 (MCD RELAY BOARD M21) 101A UNSWITCHED LEG 1 102A SWITCHED LEG 2

103A SHIELD DRAIN

110 SPARE

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120 TSC OVER TEMP THERMAL SENSOR (Vert) 121 THERMAL SENSOR SIGNAL 122 THERMAL SENSOR RETURN

123 SHIELD

140 230VAC 3PH POWER TO CHIP CONVEYOR MOTOR 141 PHASE A 230VAC 142 PHASE B 230VAC 143 PHASE C 230VAC 144 STARTING WINDING 230VAC 145 STARTING WINDING 230VAC

146 SHIELD DRAIN

140A 230VAC 3PH POWER IN CONDUIT TO CHIP CONVEYOR (Lathe) 141A PHASE A 230VAC 142B PHASE B 230VAC 143B PHASE C 230VAC

160 3PH 230VAC TO CHIP CONVEYOR CONTROLLER 161 PHASE A 230VAC 162 PHASE B 230VAC 163 PHASE C 230VAC

164 SHIELD DRAIN

170 AUTO OFF FUNCTION 171 UNSWITCHED LEG 1 172 SWITCHED LEG 2

173 SHIELD DRAIN

180 COOLANT SPIGOT DETENT SWITCH (Mill) SPARE (Lathe & Horiz) 181 SIGNAL 182 COMMON

183 SHIELD DRAIN

190 UNCLAMP FROM SPINDLE HEAD TO IOASM 191 INPUT 25

192 DIGITAL RETURN 193 SHIELD DRAIN

200 COOLANT SPIGOT MOTOR (12VDC) (Mill) SPARE (Lathe & Horiz) 201 MOTOR +

202 MOTOR -

210 DATA CABLE TO 3” FLOPPY DISK DRIVE

220 SERVO BRAKE 115VAC (Mill) 221 115VAC COMMON 222 115VAC SWITCHED

223 SHIELD DRAIN

230 5’th AXIS BRAKE (Vert & Horiz) TAILSTOCK FORWARD OPTION (Lathe)

231 115VAC COMMON 232 115VAC SWITCHED

233 SHIELD DRAIN

240 PALLETS UP & DOWN INPUTS (Vert & Horiz) BARFEEDER LOAD BAR-BARFEEDER LOAD Q (Lathe) 241 PALLETS UP (Vert & Horiz) END OF BAR (Lathe) 242 PALLETS DOWN (Vert & Horiz) LOADER OK (Lathe) 243 COMMON 244 SHIELD DRAIN

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250 VR SHUT IN / APC DOOR OPEN/ MD NIAGRA COOLANT ON (Vert option) HTC SHUTTLE/MORI MANUAL

TOOL RELEASE (Horiz) TAILSTOCK REVERSE OPTION (Lathe)

251 LEG 1 (Mill) 115 VAC (Lathe) 252 LEG 2 (Mill) 115 VAC RETURN (Lathe)

253 SHIELD DRAIN

260 K210 CABLING FOR EC (Mill) SPARE (Lathe)

261 SWITCHED LED 262 UNSWITCHED LEG

263 SHIELD DRAIN

270 K111 CABLING FOR EC (Mill) TAILSTOCK RAPID OPTION (Lathe)

271 UNSWITCHED LEG 1 (Mill) 115 VAC (Lathe) 272 SWITCHED LEG 2 (Mill) 115 VAC RETURN (Lathe)

273 SHIELD DRAIN

280 RED/GREEN STATUS LIGHT WIRING 281 RED LAMP 115VAC 282 GREEN LAMP 115VAC 283 COMMON 115VAC

284 SHIELD DRAIN

290 115VAC TO XFORMER T2 10VAC OUTPUT (Horiz) CABLE OP LIGHT + SPINDLE MOTOR FAN (Lathe) 291 LEG 1 PRIMARY (Horiz) 115 VAC (Lathe) 292 LEG 2 PRIMARY (Horiz) 115 VAC RETURN (Lathe) 293 CENTER TAPPED (GROUND) (Horiz) SHIELD DRAIN (Lathe) 294 LEG 1 SECONDARY (Horiz)

295 LEG 2 SECONDARY (Horiz)

300 115VAC TO SPINDLE MOTOR FAN/OIL PUMP/OILER 301 LEG 1 115VAC PROTECTED 302 LEG 2 115VAC PROTECTED

303 SHIELD DRAIN

310 APC #2 DOOR OPEN (Vert) PC PALLET CW/CCW (Horiz)

AUTO DOOR CLUTCH - PARTS CATCHER (Lathe)

330 230V 3PH FROM CB6 TO K2 (LATHE HYDRAULICS) 331 PHASE 1 230VAC 332 PHASE 2 230VAC 333 PHASE 3 230VAC

340 230V 3PH FROM K2 TO HYDRAULIC PUMP (LATHE) 341 PHASE 1 230VAC 342 PHASE 2 230VAC 343 PHASE 3 230VAC

350 SERVO BRAKE RELEASE 115VAC (Mill) 115VAC HYD PUMP ENABLE (Lathe) 351 LEG 1 COMMON (Mill) 115VAC (Lathe) 352 LEG 2 SWITCHED (Mill) 115VAC RETURN (Lathe)

353 SHIELD DRAIN

390 115VAC TO 4’TH AXIS BRAKE (LATHE PART DOOR) 391 LEG 1 COMMON 392 LEG 2 SWITCHED

393 SHIELD DRAIN

410 TOOL CHANGER DOOR/APC CE DOOR OPEN (Mill) TAILSTOCK FOOT SWITCH (Lathe)

411 SIGNAL (Lathe) 412 RETURN (Lathe)

413 SHIELD DRAIN

420 APC #2 PIN CLR #1 / APC #2 PIN CLR #2 / APC #2 PAL #2 HOME / APC #2 PAL #1 HOME (Vert)

MORI ARM IN/OUT - SMTC ARM CW/CCW (Horiz)

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430 APC PALLET CLAMP MD PAL UP (Mill) APL LIGHT/BF EXTENDED PUSH (Lathe)

440 AUTO DOOR OPEN (Vert) SMTC CAGE DOOR OPEN - MORI ARM OUT (Horiz) DOOR OPEN (Lathe)

450 APC #2 CE DOOR OPEN (Vert) MORI ARM CW/CCW (Horiz) STEADY REST FOOT SWITCH (Lathe)

460 APC #2 DOOR CLOSED - APC #2 DOOR OPEN (Vert) MORI SLIDE 1/2 WAY - MORI SLIDE LEFT (Horiz)

APL ROTOR MARK - APL ROTOR HOME (Lathe)

470 SMTC MOTOR STOP (Vert) SMTC SHUTTLE MARK (Horiz)

490 ALL BRUSHLESS AXIS SERVO MOTOR DRIVE POWER CABLE 491 A PHASE 492 B PHASE 493 C PHASE

494 GROUND

490A A AXIS MOTOR POWER (Vert) 320VDC FROM SPINDLE DRIVE TO AMPLIFIERS (Horiz & Lathe) 490B B AXIS MOTOR POWER (Vert) 320VDC FROM AMPLIFIER TO SERVO POWER SUPPLY (Horiz & Lathe) 490X X AXIS MOTOR POWER 490Y Y AXIS MOTOR POWER

490Z Z AXIS MOTOR POWER

491A HIGH VOLT P1/+ RED (Horiz & Lathe) 492A HIGH VOLT N/- BLACK (Horiz & Lathe) 493A SHIELD DRAIN 491B HIGH VOLT + RED (Horiz & Lathe) 492B HIGH VOLT - BLACK (Horiz & Lathe)

500 OVERTEMP SENSOR FROM SPINDLE MOTOR 501 OVERTEMP WIRE 1 502 OVERTEMP WIRE 2

503 SHIELD DRAIN

510 RELAY CARD 1 DRIVE CABLE - 16 WIRE RIBBON

520 RELAY CARD 2 DRIVE CABLE - 16 WIRE RIBBON

530 RELAY CARD 3 DRIVE CABLE - 16 WIRE RIBBON

540 RELAY CARD 4 DRIVE CABLE - 16 WIRE RIBBON

550 INPUTS CARD CABLE (MOCON P10) 34 WIRE RIBBON

570 LOW VOLTAGE BRUSHLESS AMPLIFIER POWER CABLE ASSEMBLY (Horiz & Lathe) 571 +12VDC #22 572 COMMON 573 - 12VDC #22

610 X AXIS HAAS AMPLIFIER CABLE TO MOTOR CONTROLLER BOARD

610-1 +A CHANNEL 610-2 ANALOG GROUND 610-3 +B CHANNEL 610-4 ANALOG GROUND 610-5 ENABLE 610-6 LOGIC GROUND 610-7 FAULT 610-8 LOGIC GROUND 610-9 NOT USED

610-10 SHIELD/ANALOG GROUND

620 Y AXIS HAAS AMPLIFIER CABLE TO MOTOR CONTROLLER BOARD

(SAME AS 610-1 THRU 610-10) (Mill)

630 Z AXIS HAAS AMPLIFIER CABLE TO MOTOR CONTROLLER BOARD

(SAME AS 610-1 THRU 610-10)

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640 A AXIS HAAS AMPLIFIER CABLE TO MOTOR CONTROLLER BOARD

(SAME AS 610-1 THRU 610-10) (Lathe)

640A A AXIS HAAS AMPLIFIER CABLE TO MOTOR CONTROLLER BOARD

(SAME AS 610-1 THRU 610-10) (Mill)

640B B AXIS HAAS AMPLIFIER CABLE TO MOTOR CONTROLLER BOARD

(SAME AS 610-1 THRU 610-10) (Mill)

640C C AXIS HAAS VECTOR CURRENT COMMAND CABLE TO MOTOR CONTROLLER BD.

(SAME AS 610-1 THRU 610-10) (Vert)

640C HAAS VECTOR DRIVE CURRENT COMMAND CABLE (Horiz & Lathe) 640C-1 A PHASE 640C-2 B PHASE 640C-3 ENABLE 640C-4 FAULT 640C-5 320VDC VOLTAGE MONITOR 640C-6 A PHASE RETURN 640C-7 B PHASE RETURN 640C-8 DIGITAL GROUND 640C-9 FAULT RETURN 640C-10 ANALOG GROUND

650 THREE PHASE POWER TO SPINDLE MOTOR 651 LEG 1 OF 230VAC 652 LEG 2 653 LEG 3

654 SHIELD DRAIN

650A THREE PHASE POWER TO SPINDLE MOTOR 651A LEG 1 OF 230VAC 652A LEG 2 653A LEG 3

654A SHIELD DRAIN

650B THREE PHASE POWER TO SPINDLE MOTOR 651B LEG 1 OF 230VAC 652B LEG 2 653B LEG 3

654B SHIELD DRAIN

660 X-AXIS ENCODER CABLE 660-1 LOGIC RETURN (D GROUND) 660-2 ENCODER A CHANNEL 660-3 ENCODER B CHANNEL 660-4 +5 VDC 660-5 ENCODER Z CHANNEL (OR C) 660-6 HOME/LIMIT SW 660-7 OVERHEAT SWITCH 660-8 ENCODER A* 660-9 ENCODER B* 660-10 ENCODER Z* (OR C*) 660-11 X HALL A (NOT USED) 660-12 X HALL B (NOT USED) 660-13 X HALL C (NOT USED) 660-14 X HALL D (NOT USED) 660-15 SHIELD DRAIN

660-16 (NOT USED)

670 Y-AXIS ENCODER CABLE (SAME AS 660-1 THRU 660-16) (Mill)

680 Z-AXIS ENCODER CABLE (SAME AS 660-1 THRU 660-16)

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690 A-AXIS ENCODER CABLE (SAME AS 660-1 THRU 660-16) (Vert & Lathe)

690A A-AXIS ENCODER CABLE (SAME AS 660-1 THRU 660-16) (Horiz)

690B B-AXIS ENCODER CABLE (SAME AS 660-1 THRU 660-16) (Mill)

690C C-AXIS ENCODER CABLE (SAME AS 660-1 THRU 660-16) (Mill)

700 KEYBOARD CABLE - 34 WIRE RIBBON WITH IDC (FROM VIDEO P4 TO KBIF P1)

710 APC #1 PALLET READY 1 / APC #1 PALLET READY 2 (Vert)

P-COOL/BF COLLET OPEN - BF COLLET CLOSE (Horiz) APL GRIP 1,2 (Lathe 711 FORWARD COMMAND (Vert) 712 REVERSE COMMAND (Vert) 713 RESET COMMAND (Vert) 714 COMMON (Vert)

715 SHIELD DRAIN

720 ANALOG SIGNAL FROM MOCON TO SPINDLE DRIVE TO LOAD METER (BRUSH SYSTEMS) 721 0 TO +10 VOLTS SPEED COMMAND (SPINDLE DRIVE CN1-1) 722 SPEED COMMAND REFERENCE (A GROUND) (CN1-17)

723 SHIELD DRAIN

730 POWER METER FROM SPINDLE DRIVE TO KBIF (Vert) (BRUSH SYSTEMS) 731 METER + 732 METER -

733 SHIELD DRAIN

730A POWER METER FROM KBIF TO METER (Vert) (BRUSH SYSTEMS) 733 METER + AFTER TRIM POT 734 METER - AFTER TRIM POT

734 METER - AFTER TRIM POT

730B ANALOG SIGNAL FROM SPINDLE DRIVE LOAD MONITOR (Vert) (BRUSH SYSTEMS) 731 SIGNAL 0.5V

732 GROUND

740 POWER ON/OFF CABLE TO FRONT PANEL 741 POWER ON SWITCH LEG 1 (24 VAC) 742 POWER ON SWITCH LEG 2 #24 N.O. 743 POWER OFF SWITCH LEG 1 (24 VAC) 744 POWER OFF SWITCH LEG 2 #24 N.C.

745 SHIELD DRAIN

750 JOG-CRANK DATA CABLE (REM JOG SIDE CONNECTION)

750-1 LOGIC RETURN (D GROUND) 0VDC 750-2 ENCODER A CHANNEL 750-3 ENCODER B CHANNEL 750-4 +5 VDC 750-5 NC (Vert) JUMPER TO 750-1 (0 VDC) (Horiz & Lathe) 750-6 X-AXIS 750-7 Y-AXIS 750-8 N/C (Vert) ENCODER A* CHANNEL (Horiz & Lathe) 750-9 N/C (Vert) ENCODER B* CHANNEL (Horiz & Lathe) 750-10 N/C (Vert) JUMPER TO 750-4 (+5 VDC) (Horiz & Lathe) 750-11 Z-AXIS 750-12 A-AXIS 750-13 X 10 750-14 X 1 750-15 SHIELD DRAIN

750-16 N/C (Vert) NOT USED (Horiz & Lathe)

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750A JOG HANDLE DATA CABLE (Horiz & Lathe) 751A +5 VDC 752A 0 VDC 753A ENCODER A CHANNEL 754A ENCODER B CHANNEL 755A SHIELD DRAIN

750B JOG HANDLE DATA CABLE (Horiz) 750B-1 +5 VDC JOG HANDLE 750B-2 0VDC 750B-3 JOG HANDLE A CHANNEL 750B-4 JOG HANDLE A* CHANNEL 750B-5 JOG HANDLE B CHANNEL

750B-6 JOG HANDLE B* CHANNEL

760 MONITOR VIDEO DATA CABLE (FROM VIDEO P3 TO CRT)

770 EMERGENCY STOP INPUT CABLE 771 SIGNAL (INPUT 8)

772 RETURN (D GROUND) (65) 773 SHIELD DRAIN

770A SECOND E-STOP INPUT / COUNTERBALANCE (Horiz) / BARFEEDER OPTION (Lathe)

771A SIGNAL

772A RETURN (D GROUND) 773A SHIELD DRAIN

770B THIRD E-STOP INPUT FOR APC (REMOTE CONTROL PANEL) (Vert)

790 APC PIN CLR #1 / MD OP DOOR OPEN - APC PIN CLR #2 / MD OP DOOR CLOSED (Vert)

PALLET CHANGER CW/CCW (Horiz) SPARE INPUTS PROBE HOME OPTION (Lathe) 791 SPARE 1 (Vert & Lathe) PALLET CW (Horiz) 792 SPARE 2 (Vert & Lathe) PALLET CCW (Horiz)

793 COMMON 794 SHIELD DRAIN

800 10VAC TO PALLET READY LAMP (Horiz) 801 UNSWITCHED LEG 1 802 SWITCHED LEG 2

803 SHIELD DRAIN

800A LAMP SWITCH JUMPER (Horiz) 801A JUMPER TO 802A

802A JUMPER TO 801A

810 TOOL CHANGER MOTORS 811 TURRET MOTOR + (IO P30-2 TO P6-J) 812 TURRET MOTOR - (IO P30-1 TO P6-I)

813 SHIELD DRAIN

810A TOOL CHANGER MOTORS 811A SHUTTLE MOTOR + 812A SHUTTLE MOTOR -

813A SHIELD DRAIN

820 TOOL CHANGER STATUS 821 LOGIC RETURN (Vert) TOOL CHANGER IN (Horiz) TURRET UNCLAMPED (Lathe) 822 GENEVA MARK (INPUT 5 TO P6-G) (Vert) TOOL CHANGER OUT (Horiz) TURRET CLAMPED (Lathe) 823 TOOL #1 (INPUT 3 TO P6-E) (Vert) MAIN DRAWBAR UP (Horiz) UNUSED (Lathe) 824 SHUTTLE IN (INPUT 1 TO P6-C) (Vert) MAIN DRAWBAR DOWN (Horiz) PART LOAD (Lathe) 825 SHUTTLE OUT (INPUT 2 TO P6-D) (Vert) COMMON (Horiz & Lathe)

826 SHIELD DRAIN

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830 OVERHEAT THERMOSTAT 831 OVERHEAT SIGNAL (INPUT 14) 832 OVERHEAT RETURN (D GROUND) (65)

833 SHIELD DRAIN

840 CIRCUIT BREAKER FOR 160 VDC (Vert) 841 LEG 1 (TO 81) 842 LEG 2

843 SHIELD DRAIN

850 SERIAL PORT #1 TO SERIAL KEYBOARD INTERFACE CABLE

850A SERIAL PORT #2 INTERFACE CABLE - AUXILIARY PORT TO ROTARY CONTROLLER

860 +12V/+5V/Gnd POWER CABLES (Vert) +5V/+12V/-12V/Gnd FROM MAIN POWER SUPPLY (Horiz & Lathe)

861 +12 VOLTS (Vert) +5 VOLTS (Horiz & Lathe) 862 -12 VOLTS FROM LOW V SUPPLY TO 68020 PCB (Vert) LOGIC POWER RETURN (Horiz & Lathe) 863 +5 VOLTS (Vert) LOGIC POWER RETURN (Horiz & Lathe) 864 -5 VOLTS (Vert) +12 VOLTS (Horiz & Lathe) 865 LOGIC POWER RETURN (D GROUND) (Vert) -12 VOLTS (Horiz & Lathe)

866 POWER GOOD SIGNAL FROM SUPPLY (Vert)

860A 12 VOLT POWER TO IOPCB (Vert & Lathe) 12 VDC POWER TO M CODE RELAY BOARD (Horiz) 861A +12 VOLTS

862A LOGIC POWER RETURN (D GROUND) 863A SHIELD DRAIN

860B +5 POWER TO 3” FLOPPY DRIVE (Vert & Lathe)

860C +5,+12,-12 POWER TO 68030 (Vert & Lathe) 12 VDC POWER TO MONITOR FAN (Horiz)

861A +12 VOLTS

862A LOGIC POWER RETURN (D GROUND) 863A SHIELD DRAIN

870 115VAC TO OILER (Vert & Lathe)

871 115VAC LEG 1 872 115VAC LEG 2

873 SHIELD DRAIN

880A HIGH/LOW GEAR UNCLAMP/LOCK SOLENOID POWER (Vert)

115 VAC TO SPINDLE HEAD SOLENOIDS (Horiz & Lathe)

881A 115 VAC SOLENOID COMMON (IO P12-5) (Vert) WYE-DELTA SWITCH COMMAND (Horiz)

SPINDLE LOCK (Lathe 882A HIGH GEAR SOLENOID (IO P12-4) (Vert) TOOL UNCLAMP (Horiz & Lathe) 883A LOW GEAR SOLENOID (IO P12-3) 884A TOOL UNCLAMP SOLENOID (IO P12-2) (Vert) HIGH GEAR (Horiz & Lathe) 885A SPINDLE LOCK SOLENOID (IO P12-1) (Vert) 115 VAC COMMON (Horiz & Lathe) 886A PRE-CHARGE SOLENOID #18 (IO P12-7) (Vert) SHIELD DRAIN (Horiz & Lathe)

887A SHIELD DRAIN (Vert) PRECHARGE (Horiz & Lathe)

880B TRANSMISSION HIGH/LOW GEAR SOLENOIDS FOR LATHE (Vert & Lathe) 881B 115 VAC SOLENOID COMMON (IO P12-5) 882B HIGH GEAR SOLENOID (IO P12-4) 883B LOW GEAR SOLENOID (IO P12-3)

884B SHIELD DRAIN

890 SPINDLE STATUS SWITCHES 891 SIGNAL RETURN (D GROUND) (Vert) HIGH GEAR (Horiz & Lathe) 892 HIGH GEAR (Vert) LOW GEAR (Horiz & Lathe) 893 LOW GEAR (Vert) TOOL UNCLAMPED (Horiz & Lathe) 894 TOOL UNCLAMPED (Vert) TOOL CLAMPED (Horiz & Lathe) 895 TOOL CLAMPED (Vert) SPARE (Horiz) SPINDLE LOCKED (Lathe) 896 SPINDLE LOCKED (Vert) COMMON (Horiz & Lathe)

897 SHIELD DRAIN

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900 LOW COOLANT STATUS (Mill) SPARE (Lathe) 901 LOW COOLANT SIGNAL 902 LOW COOLANT RETURN (D GROUND)

903 SHIELD DRAIN

910 115 VAC CIRCUIT BREAKER TO SOLENOIDS 911 LEG 1 912 LEG 2

913 SHIELD DRAIN

910A 115VAC FROM CB4 ON MAIN POWER DIST. (Mill) SPARE 115 VAC (Lathe) 910B 115VAC TO SERVO FAN 910C 115VAC TO DELTA/WYE COIL (Vert & Lathe) 115VAC TO PURGE SOLENOID (Horiz)

910D 115VAC TO WORK LIGHT (Vert) 115 VAC TO PALLET ALARM (Horiz) 115 VAC TO PART CATCHER (Lathe)

920 REGENERATIVE LOAD RESISTOR FOR SERVO (Vert) 921 LEG 1 922 LEG 2

923 SHIELD DRAIN

930 FUSED 230 VAC FOR COOLANT PUMP 931 LEG 1 932 LEG 2

933 SHIELD DRAIN

940 230 VAC TO COOLANT PUMP 941 LEG 1 (P7-A) 942 LEG 2 (P7-F)

943 SHIELD DRAIN

940A 230 VAC SINGLE PHASE POWER TO THROUGH SPINDLE COOLANT PUMP (Horiz) 941A LEG 1

942A LEG 2 943A SHIELD DRAIN

950 LOW AIR PRESSURE/OIL LUBE SENSOR 951 LOW AIR SIGNAL (INPUT 12) 952 LOW AIR/OIL RETURN (D GROUND) (65) (Vert) LOW OIL LUBE SIGNAL (Horiz & Lathe) 953 LOW OIL PRESSURE SWITCH FOR VERTICAL TRANSMISSION (Vert) COMMON (Horiz & Lathe)

954 SHIELD DRAIN

950A LOW HYDRAULIC PRESSURE SWITCH FOR LATHE 952 LOW HYDRAULIC RETURN (D GROUND) 953 LOW HYD PRESSURE SWITCH FOR VERTICAL TRANSMISSION

954 SHIELD DRAIN

960 LOW LUB/DOOR OPEN SENSORS (Vert) LOW TRANSMISSION OIL LUBE (Horiz)

LOW HYD PRESSURE (Lathe) 961 LOW LUB SIGNAL (Vert) LOW TRANSMISSION OIL LUBE SIGNAL (Horiz) LOW HYD PRESSURE (Lathe) 962 LOW LUB RETURN (D GROUND) (65)

963 SHIELD DRAIN

970 LOW VOLTAGE SENSOR (Vert) VECTOR DRIVE OVER-VOLT SENSOR (Horiz & Lathe) 971 LOW VOL SIGNAL (Vert) OVERVOLTAGE SIGNAL (Horiz & Lathe) 972 LOW VOL RETURN (D GROUND) (Vert) OVERVOLTAGE RETURN (Horiz & Lathe)

973 SHIELD DRAIN

980 VOLTAGE MONITOR 981 VOLTAGE MONITOR 0 TO 982 VOLTAGE MON RET

983 SHIELD DRAIN

96-0284 rev H © Haas Automation January 2010

Cable List

Page 50

990 HOME SENSORS 991 X HOME SWITCH (Vert) COMMON (DATA GROUND) Horiz & Lathe) 992 Y HOME SWITCH (LATHE TAIL STOCK) (Vert) X-AXIS HOME SWITCH (Horiz & Lathe) 993 Z HOME SWITCH (Vert) Y-AXIS HOME SWITCH (Horiz & Lathe) 994 HOME SWITCH RETURN (Vert) Z-AXIS HOME SWITCH (Horiz & Lathe)

995 SHIELD DRAIN

1000 SPINDLE ENCODER CABLE (LATHE TAIL STOCK)(BRUSH SYSTEMS) (Vert) 1001 LOGIC RETURN (D GROUND) 1002 ENCODER A CHANNEL 1003 ENCODER B CHANNEL 1004 +5 VDC 1005 ENCODER Z CHANNEL

1006 SHIELD DRAIN

1000 SPINDLE ENCODER CABLE (MOCON SIDE CONNECTION) (Horiz & Lathe) 1000-1 LOGIC RETURN (D GROUND) 1000-2 ENCODER A CHANNEL 1000-3 ENCODER B CHANNEL 1000-4 +5 VDC 1000-5 ENCODER Z CHANNEL 1000-6 NOT USED 1000-7 NOT USED 1000-8 ENCODER A* CHANNEL 1000-9 ENCODER B* CHANNEL 1000-10 ENCODER Z* CHANNEL 1000-11 NOT USED 1000-12 NOT USED 1000-13 NOT USED 1000-14 NOT USED 1000-15 SHIELD DRAIN

1000-16 NOT USED

1010 AUX FRONT PANEL CABLE (HS-1R/RP) 1011 COMMON FOR CYCLE START AND FEED HOLD RETURN 1012 CYCLE START 1013 PART READY 1014 COMMON FOR PALLET ROTATE AND PART READY 1015 PALLET ROTATE 1016 FEED HOLD

1017 SHIELD DRAIN

1020 SPINDLE TEMPERATURE SENSOR CABLE 1021 SIGNAL 1022 ANALOG RETURN 1023 +5 VOLTS TO SENSOR

1024 SHIELD GROUND

1030 SPINDLE LOAD RESISTOR 1031 REGEN LOAD RESISTOR FOR SPINDLE DRIVE (B1) 1032 REGEN LOAD RESISTOR FOR SPINDLE DRIVE (B2)

1033 SHIELD DRAIN

1040 115 VAC TO MIKRON DOOR INTERLOCK SWITCH (OR HORIZONTAL PART READY LAMP (Vert))

1041 LEG 1

1042 LEG 2 1043 SHIELD DRAIN

1050 DOOR SWITCH WIRING THRU SUPPORT ARM

1051 DOOR OPEN SIGNAL (INPUT 9) 1052 DOOR OPEN RETURN (D GROUND) (65)

1053 SHIELD DRAIN

Cable List

96-0284 rev H

Page 51

1060 GROUND FAULT DETECTION SENSE INPUT 1061 + INPUT FROM SENSE RESISTOR

1062 - INPUT FROM SENSE RESISTOR 1063 SHIELD DRAIN

1070 SKIP INPUT FROM SENSOR (Vert & Lathe) PROBE INPUT OPTION (Horiz) 1071 LOGIC COMMON (Vert & Lathe) PROBE SIGNAL (Horiz) 1072 SKIP SIGNAL (Vert & Lathe) LOGIC COMMON (Horiz)

1073 SHIELD DRAIN

1070A PROBE OUTPUT (MCD RELAY BOARD M22) (OPTION) (Horiz) 1071A UNSWITCHED LEG 1 1072A SWITCHED LEG 2

1073A SHIELD DRAIN

96-0284 rev H © Haas Automation January 2010

Cable List

Page 52

PCBS, CABLE LOCATIONS, AND DIAGRAMS

Friction Lock

Red Wire

Ribbon Cables

Mini Fit

Shown below are three types of commonly used cable connectors. They are shown as seen when plugged into the pc board. These diagrams are to aid in locating the pins for troubleshooting.

4 6

Red Wire

4 6

NOTE: The numbering sequence is the same regardless of the number of pins.

Connection Example

Electrical Service

Pin 1

Pin 5

96-0284 rev H

Page 53

MICROPROCESSOR PCB

1MB 16MB

U1 U2 U3

Plug numbers and descriptions are on the next page

R52

R53

U11

9.6K

BAUD

38.4K

512K

128K

RUN

BT1

U24

U15

850850A

U2 U3

FLASH MEMORY

J5 J4

C39C38C37

C40

BT1 BT2

9.6K

38.4K RUN

BAUD

RUN

PGM

CRT

MSG

SIO

POR

HALT

+5V

850

U22

850A

C46C45C43

C47

U38

U37

C76

ADDRESS BUS

3.3V DC

BATTERY

U16

DRAM

U17

COLDFIRE

PROCESSOR

C82

U39

DATA BUS

U41

BATTERY BACKED UP

RAM 1MB OR 16MB

FLASH

RAM

C74

STATUS

LEDS

C75

850A

LINE 1:

850

LINE 3:

LINE 2:

SUB ASSY

D1 D2 D3 D4 D5 D6 D7 D8

U53

U58

C92

3.3V DC

BATTERY

U35

U59

J2J1

DATA BUSADDRESS BUS

STATUS

FLASH

RAM

LEDS

U43

U60

PAL4.9X

C91

C94

LINE 3:

LINE 2:

LINE 1:

RUN

PGM

VIDEO

MSG

SIO

POR

STAT

+5V

850

U34

DRAM

850A

BATTERY BACKED UP

RAM 1MB OR 16MB

J10

COLDFIRE

PROCESSOR

J14

USB

J13

J1 J2

DATA BUSADDRESS BUS

ADDRESS BUS DATA BUS

   Coldre    Coldre2(CF2)

96-0284 rev H © Haas Automation January 2010

Electrical Service

Page 54

PLUG # CABLE # SIGNAL NAME  TO  LOCATION PLUG #

J1 ADDRESS ADDRESS BUSS MOCON-MOTIF ____ J2 DATA DATA BUSS MOCON-MOTIF ____ J3 (CF2) SERIAL DATA J3, J6 (CF2) 860 LOW VOLTAGE <FROM>PSUP PCB ____ J4 850 KEYBOARD DATA KEYBOARD INT. ____ J5 PORT 2 850A SERIAL PORT #2 AUX PORT AUX SERIAL PORT ____ J6 AUX BATTERY INPUT

J10 VIDEO SIGNAL LCD J13 USB DATA J14 NOT USED

SERVO SYSTEM BLOCK DIAGRAM

LOW VOLTAGE POWER SUPPLY & PENDANT

CURRENT COMMAND

ENCODER

CURRENT COMMAND

ENCODER

VECTOR DRIVE/ HIGH VOLTAGE POWER SUPPLY

320V DC

BRUSHLESS SERVO AMP

MTR PWR

ALTERNATE

MINI MILL/ OFFICEMILL HIGH VOLTAGE POWER SUPPLY MEDIUM/LARGE AMPLIFIER

BRUSH

CONVERTER

BOX

AXIS

CABLE

MTR PWR

ENCODER

BRUSHLESS AXIS MOTOR/ ENCODER

TYPICAL

BRUSH AXIS MOTOR/ ENCODER (Opt)

TYPICAL

MOCON BOARD

C-AXIS COMMAND

C-AXIS ENCODER

SPINDLE ENCODER

VECTOR DRIVE OR LARGE AMP

Electrical Service

DELTA-

WYE (Opt)

SPINDLE MOTOR

MOTOR/ ENCODER (Opt)

SPINDLE ENCODER

96-0284 rev H

Page 55

BRUSHLESS SERVO AMPLIFIER (P/N 32-5550F)

SERVO DRIVE

CURRENT COMMAND

( FROM MOCON)

FAULT PWR ON

HAAS

Servo Amplifier

30A

CAUTION

HIGH VOLTAGE

-H.V.

+H.V.

PLUG # CABLE # SIGNAL NAME  TO  LOCATION PLUG #

POWER TO

SERVO MOTOR

335VDC (FROM HAAS VECTOR DRIVE, MINI MILL POWER SUPPLYOR OFFICE MACHINE POWER SUPPLY)

X AXIS AMP

TB A, B, C ——- MOTOR DRIVE X SERVO MOTOR ——SERVO PLUG 610 X DRIVE SIGNAL MOCON PCB P2 TB -HV +HV ——- 335VDC SPINDLE DRIVE ——-

Y AXIS AMP

TB A, B, C ——- MOTOR DRIVE Y SERVO MOTOR ——SERVO PLUG 620 Y DRIVE SIGNAL MOCON PCB P3 TB -HV +HV ——- 335VDC SPINDLE DRIVE ——-

Z AXIS AMP

TB A, B, C ——- MOTOR DRIVE Z SERVO MOTOR ——SERVO PLUG 630 Z DRIVE SIGNAL MOCON PCB P4 TB -HV +HV ——- 335VDC SPINDLE DRIVE ——-

A AXIS AMP

TB A, B, C ——- MOTOR DRIVE A SERVO MOTOR ——SERVO PLUG 640 A DRIVE SIGNAL MOCON PCB P5 TB -HV +HV ——- 335VDC SPINDLE DRIVE ——-

96-0284 rev H © Haas Automation January 2010

Electrical Service

Page 56

SMART AMPLIFIER (P/N 93-5550J (30A) 93-3551J (45A))

LEDs

A B C

H-

H+

PLUG # CABLE # SIGNAL NAME  TO  LOCATION PLUG # X AXIS AMP

TB A, B, C ——- MOTOR DRIVE X SERVO MOTOR ——SERVO PLUG 610 X DRIVE SIGNAL MOCON PCB P2 TB -HV +HV ——- 335VDC SPINDLE DRIVE ——-

Y AXIS AMP

TB A, B, C ——- MOTOR DRIVE Y SERVO MOTOR ——SERVO PLUG 620 Y DRIVE SIGNAL MOCON PCB P3 TB -HV +HV ——- 335VDC SPINDLE DRIVE ——-

Z AXIS AMP

TB A, B, C ——- MOTOR DRIVE Z SERVO MOTOR ——SERVO PLUG 630 Z DRIVE SIGNAL MOCON PCB P4 TB -HV +HV ——- 335VDC SPINDLE DRIVE ——-

A AXIS AMP

TB A, B, C ——- MOTOR DRIVE A SERVO MOTOR ——SERVO PLUG 640 A DRIVE SIGNAL MOCON PCB P5 TB -HV +HV ——- 335VDC SPINDLE DRIVE ——-

Electrical Service

96-0284 rev H

Page 57

SYSTEM BLOCK DIAGRAM - HIGH/LOW VOLTAGE

INPUTVOLTAGE

195-260V AC

(353-480V AC)

230V AC

115V AC

MAIN POWER DISTRIBUTION

12V DC

M CODE RELAY BOARD (Opt)

MICRO PROCESSOR (CNC UNIT)

DC MTR DRV BOARD (Opt)

LOW VOLTAGE

12V DC

195-260V AC

(353-480V AC)

INPUT

115V AC

230V AC

CMDS

FAULTS

MAIN TRANSFORMER

VIDEO, KEYBOARD, AND JOG

BRUSHLESS SERVO AMPLIFIERS (X, Y, Z, A, 5TH TC (SS) OPTION (Vert)

PWR

SPINDLE COMMANDS

SPINDLE ENCODER

12V DC

(FLOPPY DRIVE&RJH)

335V DC

(325V DC

Horiz)

EXCESS PWR

OPERATOR PENDANT

HAAS VECTOR DRIVE

FAULTS

230V AC

SP PWR

CHIP CNVYR BOARD

(Opt)

CHIP CNVYR MTRS

(Opt)

PWR

WYE-DELTA CONTACTORS

(Opt)

230V AC

TSC OPTION (Vert)

CMDS

STATUS

DISCRETE INPUTS AND OUTPUTS

COOLANT PUMP & CHIP CONVEYOR

POSITIONDATA

HOME SWITCH (Vert & Lathe)

230V AC

SENSORS

CMDS

SERVO MOTORS

REGEN

SPINDLE MOTOR

ASSY

LIMIT SWITCHES GEAR BOX SWITCHES TOOL CHANGER/OVERHEAT SENSORS/ LOW LUBE/LOW COOLANT/SOLENOIDS

WYE/DELTA CONTACTORS

*CONTACTOR COILS FOR WYE/DELTA CONTACTORS

ARE DRIVEN THROUGH I/O WITH 120V AC.

96-0284 rev H © Haas Automation January 2010

Electrical Service

Page 58

POWER PCB VERSION K/L

P35 P34 P8 P33 P28

P27

P25

P24 P4

P13

P14

P15 P16

P17

P19

P36

P20

P21

BRACKET

PHASE DETECT

(FOR3PHASE ONLY)

P11

P12

SW DOORF

90A

MONITOR

PROBE PS

DELTA-WYE

SERVO FAN

T PS

LOW VOL

AC GROUND

90C

MCD2

MCD1

GND

+12V

90A

LE2

+12V

90A

90C

94/N

90C

115V INPUT

115V SPARES

90C 90C 90C 90C

LVINPUT

-12V

GND

LE3

-12V

TS1

MAIN115V XFRMR

XFRMR

LE1

GND

+12V

-12V

IOPCB

+5V

GND

P30

GND

+12V

COOLANT PUMP

92A

MOCON2

+5V

-12V

+12V

MOTIF

+5V

GND

+12V

+5V

P18

AMPS

-12V

GND

+12V

GFI COOLANT PUMP TSC COOLANT PUMP CHIP CONVEYOR

ONON

7A 115V

GFIMAIN

CB6CB2

3PH 115VTO IOPCB

GND

+12V

+5V

10A 230V10A 115V

CB3

GFI/

PASS FAIL

+5V

NE6 NE5

WORKLIGHT

71 73

NE1 NE3

10A 230V

TSC COOLANT PUMP

CB5

POWER SUPPLY ASSY

930

COOLANT/TSC

1A 250V

PSUP-K

PRI SEC

TO T5

230V IN

170

740

P10

ONON

5A 230V

CHIP CONVEYOR

CB4

160

CHIPC 230V

ACTOR

P23

AUTO OFF/CONT

P22

ON/OFF

PLUG # CABLE # SIGNAL NAME  TO  LOCATION PLUG#

P1 94-96 3-PHASE Transformer P2 90C 115VAC LVPS P3 90A 115VAC Spare P4 Jumper Jumper P5 90B 115VAC Switch Door Fan P6 90A 115VAC Servo Fan P7 90A 115VAC Delta-Wye P8 Jumper +12/-12/+5 VDC In From LVPS P9 Jumper Jumper P10 77/79 230VAC 3/PHASE Transformer P11 90A 115VAC Front Pnl P.S. (spare) P12 90C 115VAC spare P13 90C 115VAC spare P14 90C 115VAC spare P15 90C 115VAC spare P16 90C 115VAC spare P17 90C 115VAC spare P18 860 115VAC Ampliers P19 90 3PH 115VAC I/O PCB P56 P20 930 230V CLNT PUMP/TSC I/O PCB P44 P21 160 Chip Conv. 230V 3PH I/O PCB P39 P23 170 Auto Off/Contactor Contactor K1/ I/O PCB P42 P22 740 On/Off Front Panel (SKBIF) J20 P24 T5 Main Cont Frmr To T5 P25 71, 72, 73 230VAC IN From Contactor K1 P27 860 +12/+5 VDC I/O PCB P60 P28 860 +12/+5 VDC Motif PCB P15 P30 860 +12/-12/+5 VDC spare P33 860 +12/-12/+5 VDC Mocon 2 PCB P15 P34 860A +12 VDC SMTC PCB P2 P35 860 +12 VDC MCD Relay PCB P2 P36 92A Worklight

BRACKET REV "L" HAS NO

Electrical Service

96-0284 rev H

Page 59

OFFICE MILL POWER SUPPLY

230VAC

C14

C12

CR4

DZ4

CR6

860A

TP3

+12V

12VRTN

C10

DZ1

LE1

HIGH

VOLTAGE

PRESENT

R23

DZ2

320VDC

CR1

REGEN

BL 320V PS

R21

R14

CR18

C28

C31

C13

DZ3

VOLTMON

CR2

CR3

CR9

VR1

JP1

970

FAULT

CR7

CR12

CR10

TP1

320VRTN

C19

TP2

LE2

FAULT

ISP

C11

CR5

PLUG # CABLE # LOCATION PLUG#

P1 32-5827A Ofce machine main transformer LV 1PH Main transformer P2 N/A

P3 33-0982 Cable 860A +5/+12 GND I/O PCB I/O PCB P60 P4 33-4150 Cable 970 Vector Drive Over Volt I/O PCB P11 P5 32-7044 40 Ohm Regen Resister P6 33-9861 Cable Volt Monitor MOCON P17 P7 33-0167A Cable 230V in to BL320VP PSUP (34-4075K) P10 P8 33-0492 Cable 320VDC to amp 320VDC AMP TB

96-0284 rev H © Haas Automation January 2010

Electrical Service

Page 60

I/O PCB VERSION W, Z, AA, AB

TB1

K33K34 K35K36 K37

P2A

CR12 CR13 CR14 CR15 CR9

P72

P81

P10

P11

P12

P13

P14

P15

P16

P17

P18

P19

P20

P21

P22

P23

P24

P25

P26

P82

P70

P27

C31

P28

P71

Q22

P29

P30

P31

P62

P61

Q33

Q32

P63

C86

U73

P74

P66

P67

P68

P69

P76

PCOOL SOLID STATE RELAY DTRPCB

Q21

Q23

Q20

P33

P32

R4 R52

Q19

Q13

Q14

Q15

Q16

Q41

Q42

Q10

D10

R145

Q26

CR8

R66

R146

R42

D17

D18

D20

D21

P54

P53

P53A

P47

Q11

Q45

Q36

Q43

Q12

D19

D22

P56

P55

P52

P51

P49

P46

P73

P50

P48

P42

P45

P44

P43

P41

P40

TB2

Z10

CR1

CR33

Q44

Q30

Q31

Q28

Q29

Q27

Q46

P83

P36A

P36

TP8

P75

P79

Q35

COMPONENT

MARK

*T1

COMPONENT

MARK

C59

Q37

P34

P60

C52

C42

P77

CR30

P80

TP2

CR34

C78

C69

CR5

C75C85

LINE 1 LINE 2 LINE 3

CR10 CR11

P37A

P37

P35 200

P57

P78

K9 K10K11 K12

C87

C70

CR35

TP42

R122

TP6

TP7

R51

R127

CR25

P58

CR7

K38

P59

Q39

P64

P65

CR16

K32

P38

Q40

C46

R311

R44

TP3

MILL LATHE

C15

C14

P39

PLUG # CABLE #  TO  LOCATION PLUG #

P1 140B Chip Conveyor Ckt Bd (32-3072) P3 P2 820B TC in/SMTC Pkt down P2 (Lathe) 820 TT Unlock/Lock P2A 820B Shuttle In/Out P3 820 TC out/SMTC pkt up/Tool #1/TC mark P3 (Lathe) 820 C-axis Engage/Disengage P4 900 Low TSC press P4 (Lathe) 900 Spare P5 770 E-Stop Sw A P6 770A E-Stop Sw B P7 770B E-Stop Sw C P8 1050 Door Open A P9 1050A Door Open B

Electrical Service

96-0284 rev H

Page 61

PLUG # CABLE #  TO  LOCATION PLUG #

P10 100 M-Fin P11 970 VD Over Volt VD J1 P12 950 Low Air/Low Oil/VB low chill pressure P12 (Lathe) 950 Low Air/Hyd. pressure P13 960 Low Lube P14 830 Regen Overheat P15 890 SPDB Open/Closed P15 (Lathe) 890 Spare/Gearbox P16 780 2nd VD OV/contactor On/counterbalance P16 (Lathe) 780 Spare P17 410 APC Door Open , VB Clamshell P17 (Lathe) 410 TS Foot Sw/Sub Spndl Chuck Foot Switch P18 790 APC Pin Clear - door open/closed P18 (Lathe) 790 Probe Home P19 190 Remote Unclamp Sw P19 (Lathe) 190 Chuck Unclamp Foot Sw P20 190A Remote Unclamp B P20 (Lathe) 190A Not Used P21 240 Spare 3, APC Pallet Home / Grnd fault/ pal up,dwn P21 (Lathe) 240 BF Load Bar/Q/RPL P22 1070 Skip M22 P23 420 Spare 4, APC #2 pin clr / pal home P23 (Lathe) 420 Spare (VTC: Pocket up/down/tool one/TC Mark) P24 440 Spare 6, Auto Door Open / Spare P24 (Lathe) 440 Auto Door Open P25 450 Spare 7, APC #2 door open P25 (Lathe) 450 Steady Rest Foot Switch P26 460 Spare 8, APC #2 door closed P26 (Lathe) 460 Apl Rotator Mark, Home (VTC: Low Way/SS Lube) P27 470 Spare 9, SMTC mtr stop / SMTC origin/ /smtc cl uncl P27 (Lathe) 470 Spare (VTC: Motor Stop/Origin/Cl/Uncl) P28 480 Spare 10, APC door closed/Open / APC pal clamped P28 (Lathe) 480 Spare 10 (VTC: Rem Uncl/SS DB Open/Closed) P29 1040A CE Door LK P29 (Lathe) 1040A Not Used P30 1040 CE Door LK P31 230 5th Axis Brake P31 (Lathe) 230 T/S Fwd P32 250 HTC shut, APC Door open, VR Shut In P32 (Lathe) 250 T/S Rev P33 260 TSC Purge P33 (Lathe) 260 T/S Rapid (VTC: Purge) P34 270 APC Pal Ready Lt P34 (Lathe) 270 Spare (12V Output) P35 (35A) 200 Spigot CW/CCW P35 (Lathe) 200 Spare (VTC: Spigot CW/CCW) P36 280 Spindle Lube P36A 280 Worklight

96-0284 rev H © Haas Automation January 2010

Electrical Service

Page 62

PLUG # CABLE #  TO  LOCATION PLUG #

P37 140A Chip Conv Enable P37 (Lathe) 140A Not Used P38 140 Chip Conveyor P39 160 230V Coolant, Chip Conv Power PSUP P21 P39 (Lathe) 160 250V for Chip Conv. P40 300 250V Oil Pump/Luber P40 (Lathe) 300 SP Fan/Oil Pump/Luber P41 300A SP Fan/Oil Pump P41 (Lathe) 300A Gear Box Oil Pump P42 170 Auto Off PSUP P23 P43 940 Coolant Output P44 930 250V TSC/Cool Input Power PSUP P20 P44 (Lathe) 930 230V for Coolant P45 940A TSC Coolant TSC Cool. Out. P45 (Lathe) 940A hp Coolant PSUP P20 P46 390 4th Axis Brake P46 (Lathe) 390 Spin Brake (Live Tooling Hyd Brake) P47 350 Servo Brake Trans P6 P47 (Lathe) 350 Hyd Pump En P48 120 Coolant Over Temp P48 (Lathe) 120 Not Used (Jumper) P49 350A Servo Brake, Hyd En Trans P4 P49 (Lathe) 350A Brake Release P50 130 TSC Over Temp P50 (Lathe) 130 Not Used (Jumper) P51 430 Pallet up P51 (Lathe) 430 APL Light/BF Extend Push P52 710 Spare, APC #1 pal ready #1,2 P52 (Lathe) 710 APL Gripper Grip 1, Grip 2 P53 (P53A) 880C (880D) Wye-Delta Switch P54 880B Gearbox, High/Low Gear P55 880A Tool unclamp precharge (spindle head solenoids) P55 (Lathe) 880A Chuck Unclamp/TT Out/MLB Fast Push P56 90 115V 3ph power PSUP P19 P57 Haas P/N 33-0815B TC Jumper or SMTC brake resistor P57 (Lathe) External TC Motor Resistor (Jumper) P58 810A T.C. in/smtc ATC fwd / APC chn drv en/rev P58 (Lathe) 810A Spare P59 810 T.C. CW/ SMTC CRSL CW P59 (Lathe) 810 Auto Dr, BF Id Bar/Q, APL Rtr (VTC: Car CW/CCW) P60 860A +5/+12V Logic Pwr (LVPS) (I/O PCB) PSUP P27 P61 540 Outputs Cable 24-55 (I/0PCB) MOCON P14 P62 540A To 2nd M-code PCB MCD Relay P1 P63 550 Inputs Cable MOCON P10 P64 520 Outputs Cable 8-15 MOCON P12 P65 510 Outputs Cable 0-7 MOCON P11 P66 1100 (M27) Air Blast P67 1110 (M28) Beeper P67 (Lathe) M28 Sub Spin Chuck Sol

Electrical Service

96-0284 rev H

Page 63

PLUG # CABLE #  TO  LOCATION PLUG #

P68 310 Pallet CW/CCW, Auto Door open P68 (Lathe) 310 APC Door open P69 220 Air Door, Pckt Up/Down,VR Shtle Out, VB Clamshell P69 (Lathe) 220 C-axis Engage P70 530 Outputs Cable 16-23 MOCON P13 P71 500 N/A P72 770C E Stop D/E P73 Haas P/N 33-1966 TSC Enable P74 M26 Spare P75 710A NSK Spindle P76 1160 Oil Squirt (MOM) P77 1070 Probe P78 350A Axis Brake P79 350A Axis Brake P80 N/A P81 770C E-Stop P82 1130 Oil Squirt (MOM) Low Oil P83 From GFI for Worklight TB1 TB 12 x 200 (M21-24) M-Code Outputs (Probe, M-Fin, User Spare) TB2 TB 3 x 200 (M25) M-Code Outputs TB2 (Lathe) TB 3 x 200 (M25) User Spare

ISCRETE INPUTS

+12V

Typical Discrete Input Circuit

MACRO CABLE HORIZONTAL VERTICAL LATHE

1000 820 P2/3 TC In (C) TC In (C) TT Unlock

SMTC Arm Mark (O) SMTC Pkt Dwn TL TC Home EC-400 (O) SMTC Pkt Dwn

1001 820 P2/3 TC Out (C) TC Out (C) TT Lock

SMTC Shuttle Out (O) SMTC Pkt Up TL TC Mark EC-400 (O) SMTC Pkt Up

1002 820 P3 PC DB Down (C) Tool #1 *C-axis Disengage

EC-400 (O) SMTC Tool #1 (O) SMTC Tool #1

1003 900 P4 Lo TSC Press Lo TSC Press Spare

EC-400 Lo TSC Press

1004 820 P3 PC Collet Down (C) TC Mark *C-axis Engage

EC-400 SMTC TC Mark (C) SMTC TC Mark

1005 890 P15 (O) High Gear (O) High Gear High Gear

1006 890 P15 (C) Low Gear (C) Low Gear Low Gear

96-0284 rev H © Haas Automation January 2010

Electrical Service

Page 64

MACRO CABLE HORIZONTAL VERTICAL LATHE

1007 770 P5/6/7 E-Stop E-Stop E-Stop

1008 1050 P8/9 (O) Door Open (O) Door Open Door Open

1009 100 P10 M-FIN M-FIN M-FIN

GR Plasma Conrm

1010 970 P11 Over Volt Over Volt Over Volt (not used)

1011 950 P12 Low Air Low Air Low Air

1012 960 P13 Low Way Lube Low Way Lube Low Way Lube

1013 830 P14 Overheat Overheat Overheat

1014 890 P15 (C) SP DB Open (C) SP DB Open Gearbox Low Oil

1015 890 P15 (C) SP DB Closed (C) SP DB Closed Spare

1016 890 P15 Spare 3rd DB Pos Sw Spare

EC-400 3rd DB Pos Sw

1017 780 P16 2nd VD OV 2nd VD OV Spare

1018 780 P16 Contactor On Contactor On Spare

1019 780 P16 Cntr Balance Cntr Balance Spare

1020 950 P12 Gearbox Low Oil Gearbox Low Oil Low Hydraulic

1021 410 P17 Air Door Sw GR Air Curtain APC (O) *TS Foot Sw

EC-400 TC Door Open CE Door Open (O) *Sub Spin Chck Ftsw Old EC-300 Tool Door Open

1022 790 P18 PC Pallet CW (C) APC Pin Clr #1 (O) *Probe Home

EC-400 PP Pallet Lift (O) MD Op Door Open

1023 790 P18 PC Pallet CCW (C) APC Pin Clr #2

EC-400 PP Pallet Lower (O) MD Op Door Closed

1024 190 P19/20 PC Op Station Locked/ Rem Uncl (O) Chuck Uncl Foot Sw

Frnt Door BF End of Bar

1025 500 P71 LO Phase/Low Grease LO Phase/Low Grease LO Phase/Low Grease

1026 240 P21 PC Pallet Up (C) APC Pal #2 Home (C) BF Load Bar

BF Load Bar (C) Old MD Pal Up

1027 240 P21 PC Pallet Down (C) APC Pal #1 Home BF Load Q

BF Load Q (C) Old MD Pal Down EC-1600 Clamp Press

1028 Grnd Fault Grnd Fault Grnd Fault

1029 1070 P22/77 Skip Skip Skip

1030 200 P35 Possible P-Cool Spigot (C) BF End of Bar

EC-400 Spigot

1031 140B P1 Chip Conveyor Chip Conveyor Chip Conveyor

1032 420 P23 Mori Notch Pin In/ (C) APC #2 Pin Clr #1 Pocket Down

SMTC Arm In EC-400 Pallet Clamped

Electrical Service

96-0284 rev H

Page 65

MACRO CABLE HORIZONTAL VERTICAL LATHE

1033 420 P23 Mori Man Tool Rls In/ (C) APC #2 Pin Clr #2 Pocket Up

SMTC Arm Out

EC-400 Pallet Unclamped

1034 420 P23 Mori Tool 1/SMTC Arm CCW (C) APC #2 Pal #2 Home Tool One

EC-400 Pallet Clamp Error

1035 420 P23 Mori TC Mark/SMTC Arm CW (C) APC #2 Pal #1 Home TC Mark

1036 440 P24 Mori Arm In/SMTC Cage (O) Auto Door Open (O) Auto Door Open

Door Open EC-400 SMTC Cage Door Open

1037 440 P24 Mori Arm Out APL Load Station Door Open

1038 450 P25 Mori Arm CCW APC #2 CE Door Open *Steady Rest Ftsw

1039 450 P25 Mori Arm CW Spare for Foot Sw

1040 460 P26 Mori Slide 1/2 Way APC #2 Door Closed (O) APL Rotator Mark

1041 460 P26 Mori Slide Left APC #2 Door Open (O) APL Rotator Home

1042 470 P27 Mori Swing Spin/SMTC SMTC Motor Stop Motor Stop

Shuttle Mark EC-400 SMTC Motor Stop

1043 470 P27 Mori Swing Mag/SMTC SMTC Origin Origin

Slide at Chain EC-400 SMTC Origin

1044 470 P27 Mori Cage Door Open/ SMTC Cl/Uncl Cl/Uncl

SMTC Slide at Standby EC-400 SMTC Cl/Uncl

1045 470 P27 Mori Slide Right/SMTC

Slide at Spindle EC-400 Tool Transer

1046 480 P28 EC-400 8-pos TC Unlock APC Door Closed APL Door Closed

1047 480 P28 EC-400 8-pos TC Lock APC Door Open APL Door Open

1048 480 P28 EC-400 8-pos TC Mark APC Pal Clamped SS DB Open

1049 480 P28 EC-400 8-pos TC Home APC Pal In Position SS DB Closed

1050 1130 P82 EC-400 Oil Squirt Low Oil Oil Squirt Low Oil Oil Squirt Low Oil

96-0284 rev H © Haas Automation January 2010

Electrical Service

Page 66

DISCRETE OUTPUTS

MOCON PCB

I/O PCB

0VDC

+12VDC

Typical 115/230V Output Circuit (Kxx)

115/230V

SOLENOID/PUMP

LE 1

Note that voltages other than 115/230V are provided by specialty output circuits. These are identified with an asterisk.

MACRO RELAY CABLE HORIZONTAL VERTICAL LATHE (SL) VOLTAGE

1100 K1 350 P47/49 Servo Pwr/Brk (EC) Servo Pwr/Brk Hyd Pump En 115V

Servo Brake (HS)

1101 K2 430 P51/75 TC Door Open (EC) APC Pal Clamp APL Light 115V

PC Pallet Up (HS) Old MD Pal Up BF Extd Push

New MD Pal Unclamp GR Air Curtain NSK Spin Fwd

1102 K3 710 P52/75 PC Pallet Up (EC) APC#1 Pallet Ready 1 APL Grip 1 115V

P-Cool (HS) NSK Spin Rev BF Collet Open (HS)

1103 K4 710 P52 PC Pallet Down (EC) APC#1 Pallet Ready 2 APL Grip 2 115V

BF Collet Close (HS) Robot Fix Uncl

1104 K5 390 P46 4th Axis Platter Up (EC) 4th Axis Brake Spin Brk 115V

4th Axis Brake (HS)

1105 K6 940 P43 Coolant Coolant Coolant 230V

1106 K7 170 P42 Auto Off Auto Off Auto Off 24VAC*

1107 K8 300 P40/41 Sp Fan Sp Fan Sp Fan 115V

Oil pump Oil pump Oil pump Luber Luber Luber

1108 K9 810 P58/59 SMTC ATC Fwd (EC) TC In APL Rotator CW 170VDC*

Tool Xfer Fwd (EC) SMTC ATC Fwd BF load Q paired w/ PC Main DB Fwd (HS) APC Chn Drv Fwd 8-pos TC Rotate K10 BF Load Q (HS)

1109 K10 810 P58/59 SMTC ATC Rev (EC) TC Out APL Rotator CCW 170VDC*

Tool Xfer Rev (EC) SMTC ATC Rev BF Load Bar paired w/ PC Main DB Rev (HS) APC Chn Drv Rev 8-pos TC Rotate K9 BF Load Bar (HS)

Electrical Service

96-0284 rev H

Page 67

MACRO RELAY CABLE HORIZONTAL VERTICAL LATHE (SL) VOLTAGE

1110 K11 810 P59 SMTC Crsl CW (EC) TC CW Auto Door Mtr Open 170VDC*

TC In (HS) SMTC Crsl CW paired w/

K12

1111 K12 810 P59 SMTC Crsl CCW (EC) TC CCW Auto Door Mtr Close 170VDC*

TC Out (HS) SMTC Crsl CCW paired w/

K11

1112 K13 880A P54/55 High Gear (EC) High Gear High Gear 115V

4 High Gear (HS)

1113 K14 880A P54/55 Low Gear (EC) Low Gear Low Gear 115V

4 Low Gear (HS)

1114 K15 880A P55 Tool Unclamp Tool Unclamp Chuck Unclamp 115V

1115 K16 880A P53 Delta-Wye Switch Delta-Wye Switch Delta-Wye Switch 115V

P53A/P55 Laser Hi Press Assist

1116 K17 200 P35 Spigot CW (EC) Spigot CW TL TC CW +12VDC*

P-Cool (HS)

1117 K18 200 P35 Spigot CCW (EC) Spigot CCW TL TC CCW +12VDC*

P-Cool (HS)

1118 K19 260 P34 Pallet Ready Light APC Pal Ready +12VDC*

1119 K20 270 P33 TSC Purge TSC Purge T/S rapid 115V

OM live tool #2

1120 K21 880A P55 Precharge Precharge TT Out 115V

Laser Low Press Assist TL TC up

1121 K22 250 P32 PP Pallet Lift (EC) VR Shut In T/S Rev 115V

HTC Shuttle (HS) APC Door Open OM live tool #3 Mori Manual Tool Rls (HS) Old MD Niagra Clnt On

1122 K23 230 P31 5th Axis Brake 5th Axis Brake T/S Fwd 115V

OM live tool #1

1123 K24 1040 P29/30 Door Interlock CE Door Lock CE Door Lock 115V

1124 K25 310 P68 PC Pallet Clamp (EC) APC#2 Door Open Auto Door Clutch 115V

PC Pallet CW (HS)

1125 K26 310 P68 PC Air Blast DES Vac Enable Parts Catcher 115V

Proto Flood Coolant GR Plasma Head Down PC Pallet CCW (HS)

1126 K27 220 P69 SMTC Pkt U/D Sol (EC) VR shut out C-Axis Engage 115V

Air Door (HS) VB clamshell

SMTC Pkt U/D Sol Laser Vac Enable

1127 K28 940A P45 TSC Clnt TSC Clnt P73 HP coolant 230V

1128 K29 280 P36 Spindle Lube Spindle Lube Spindle Lube 115V

1129 K30 280 P36 Worklight Worklight Worklight 115V

1130 K31 140 P37/38 ChipC En ChipC En ChipC En 230V*

paired w/ K32

96-0284 rev H © Haas Automation January 2010

Electrical Service

Page 68

MACRO RELAY CABLE HORIZONTAL VERTICAL LATHE (SL) VOLTAGE

1131 K32 140 P37/38 ChipC Rev ChipC Rev ChipC Rev 230V*

paired w/ K31

1132 K33 M21 TB1 M-Fin M-Fin M-Fin Relay

Shower Coolant (EC) GR Plasma Start Contact* Mori Notch Pin Out (HS) HIT Index

1133 K34 M22 TB1/P77 Probe Probe Probe Relay

Laser Aim Beam On Contact*

1134 K35 M23 TB1/P77 Probe (EC) Laser Shut Open Spin Probe Enable Relay

Mori Mag CW (HS) Spin Probe Enable` Contact*

1135 K36 M24 TB1 Flood Coolant (EC) HIT Go Home Probe Arm Up Relay

Mori Mag CCW (HS) Contact*

1136 K37 M25 TB2/P76 Oil Squirter (MOM) Oil Squirter (MOM) Probe Arm Down Relay

Oil Squirter (MOM) Contact*

1137 K38 810A P58/74 PC Main DB En (HS) APC Chn Drv Pwr En 8-pos TC Rotate 160VDC*

1138 K39 M27 P66 Air Jet Blast (EC) Gantry Oil Air Blast 115V

PC Air Blast (HS) Air Blast ML BF push

Air Closer Enable Chuck Clamp

1139 K40 M28 P67 PC Beeper APC Beeper, Airblast Sub Spin Chuck 115V

Old EC300 Tool Door New MD Airblast

Electrical Service

96-0284 rev H

Page 69

SERIAL KEYBOARD INTERFACE PCB WITH HANDLE JOG (34-4241D)

J21

SPEAKER

SUPPLY

J12

TP11

GND

WORK LIGHT

JOG HOOK

USB IN

+15V/+12V

GND

+15V/+12V

CR1

C32

J23

USB OUT

C60

C36

P6A

AUX FRONT PANEL

+3.3V

TP18

+12V

TP16

C49

TP12

+5V

SW1

BEEP

SPKR

OFF

BACKLIGHT

J13

P10

BEACON

J15

LINE 1: LINE 2: LINE 3:

RP22RP21 CP11

MCU PROGRAM

RP26RP25

CP13

CP12 CP10

PAL1

PAL2

PAL PROGRAM

J14

C12

TP15

J10

OPT SW

C59

C10

TP2

RP24 RP20

RP23 RP19

U12

ADJUST

J16

TO LCD PANEL

COLOR

J11

PALLET RDY

TOOL CHANGER

JOGENCODER

TP13

TP9

TP14 TP6

R18

SW2

OFF

TP8

TP7

TP5

U18

U19

STROBE

CP1 RP1 RP2

TP3

METER

TO RJOG

RP7

TP1

TP13

U11

U13

J17

TO ESTOP

RP8

D1D6D5D4D3

RS232 TO CPU

J19

DIsRJH E/S

TO RJH

JOG 750C

TP10

GND

U14U15U10U16U17

RS232

TP4

START/HOLD

J20

CP8

CP9

CP4

CP5

J18

J22

C14

VIDEO DATA

MAIN CAB

PWR ON/OFF

RP15RP17

RP16RP18

RP3RP5

RP5RP6

KEYPAD

FRONT PANEL HARNESS

The Serial Keyboard Interface PCB (SKBIF) provides:

• connection between the operator keypad and the main processor

• differential receiver for video data

• power for the backlight of the LCD

• connection between the jog handle (remote jog handle) and the main processor

• various machine-dependent functions.

The SKBIF is backward-compatible for all previous mill, lathe and simulator hardware and software versions.

NOTE: The video data connectors are only used by machines with a 15” monitor. Machines

Connector Descriptions

P1 This connector supports an RS-232 ribbon cable that sends and receives data from the Main Processor. P2 This connector is used for the operator keypad interface. It receives keyboard data, which it sends to

the SKBIF micro-controller (U8), where the data is processed and sent out over the RS-232 line to the Main Processor.

96-0284 rev H © Haas Automation January 2010

with a 10” monitor have a separate differential card in the LCD panel connected

directly to the main processor.

Electrical Service

Page 70

P3 This connector is wired directly to the Cycle Start and Feed Hold buttons on the operator pendant front

panel. The signals are sent to the SKBIF micro-controller (U8), where the data is processed and sent out over the RS-232 line to the Main Processor.

P4 This connector is used on machines with an an analog Load Meter and is wired directly to the Load

Meter on the operator pendant front panel. The signals are sent to the SKBIF micro-controller (U8),

where the data is processed and sent out over the RS-232 line to the Main Processor.

P5 This connector is wired directly to the Beeper on the operator pendant front panel. The Main Processor

sends On/Off commands to the Beeper, while the ‘beeps’ associated with each key stroke are controlled by wiring between P5 and the SKBIF micro-controller (U8).

P6 This connector is wired directly to the Cycle Start and Feed Hold buttons on a Remote Jog Handle or

an auxiliary front panel. It handles Part Ready and Pallet Rotate signals as well as mill Pallet 6 scheduling. The signals are sent to the SKBIF micro-controller (U8), where the data is processed and sent outover the RS-232 line to the Main Processor.

P6A This connector is wired directly to an auxiliary front panel (such as a Tool Changer panel). It handles

Cycle Start, Feed Hold, Part Ready and Pallet Rotate signals as well as mill Pallet 6 scheduling. The signals are sent to the SKBIF micro-controller (U8), where the data is processed and sent out over the RS-232 line to the Main Processor.

P7 This connector is used by mills utilizing a pallet changer. Pallet 1 and 2 scheduling signals are sent to

the SKBIF micro-controller (U8), where the data is processed and sent out over the RS-232 line to the Main Processor.

P8 This connector is used by mills utilizing a pallet changer. Pallet 3 and 4 scheduling and vertical mill MD

Load Table Rotation signals are sent to the SKBIF micro-controller (U8), where the data is processed and sent out over the RS-232 line to the Main Processor.

P9 This connector is wired to the Enhanced Remote Jog Handle. RJH(E) signals are sent to the SKBIF

micro-controller (U8), where the data is processed and sent out over the RS-232 line to the Main Processor.

P10 This connector is wired to the beacon on the operator pendant. Thin pendant signals are sent in over

the RS-232 line from the Main Processor to the SKBIF micro-controller (U8), which turns the beacon on and off. A regular operator pendant has the beacon connected directly to the I/O Board, which turns the

beacon on and off.

P11 This connector is not currently used. P12 This connector is not currently used. J1 This connector is wired to the Jog Handle on the operator pendant front panel. Jog Handle signals are

sent to the SKBIF micro-controller (U8), where the data is processed and sent out over the RS-232 line to the Main Processor. If a cable is present on J3, jog handle signals are sent to the MOCON from J3.

J2 This connector is wired to the Remote Jog Handle. RJH signals may be sent to the SKBIF

microcontroller (U8), where the data is processed and sent out over the RS-232 line to the Main Processor. Alternatively, the RJH signals may be connected to J3, from where the data is sent directly to the MOCON.

J3 This connector is wired to the Remote Jog Handle connector J2. RJH data is sent from J3 directly to the

MOCON.

J4 This connector is wired to the pendant’s Worklight Switch on a vertical mill thin pendant. Worklight

Switch signals are sent to the SKBIF micro-controller (U8), where the data is processed and sent out over the RS-232 line to the Main Processor.

Electrical Service

96-0284 rev H

Page 71

J5 Combines E-Stop, On/Off, Jog Handle, Cycle Start/Feed Hold, Beeper and Work Light signals. J6 This connector receives video data from the Main Processor. The video data exits the SKBIF from J16

and is sent directly to the LCD panel.

J7 This connector is not currently used. J8 This connector is wired to the Enhanced Remote Jog Handle Switch on vertical mills. When the RJH(E)

is placed in its receiver cradle, a HOOK signal is received over J8 and sent to the SKBIF microcontroller (U8), where the data is processed and sent out over the RS-232 line to the Main Processor.

J9 This connector is used by horizontal mills utilizing a tool changer. Tool Changer Magazine CW/CCW,

Manual, and Tool Release Pedal signals are sent from the Tool Changer box, received over J9 and sent to the SKBIF micro-controller (U8), where the data is processed and sent out over the RS-232 line to the Main Processor.

J10 This connector is used by machines utilizing CE Push Button, Edit Lock Key Switch, 2nd Home Push

Button, and Auto Door Push Button signals. Signals are sent from the Push Button or Switch, received over J9 and sent to the SKBIF micro-controller (U8), where the data is processed and sent out over the RS-232 line to the Main Processor.

J11 This connector is used by machines utilizing a pallet changer. Part Ready, Pallet Rotate, and Autodoor

signals are sent by all machines. Pallet scheduling signals are sent by mills. The signals are sent to the SKBIF micro-controller (U8), where the data is processed and sent out over the RS-232 line to the Main Processor.

J12 This connector provides +12V DC power to the SKBIF from a power supply built into the LCD

assemblies. This connector is not used for thin pendants, or if cabling is present on J20 and J22.

J13 This connector provides power to a high voltage power supply in the LCD panel to supply backlighting

to the LCD.

J14 This connector is used to program the SKBIF micro-controller. J15 This connector is used to program PAL chip U12. J16 This connector receives video data from the Main Processor by way of J6. The video data exits the

SKBIF from J16 and is sent directly to the LCD panel.

J17 This connector is wired to the E-Stop button on the operator pendant front panel and to J20. The E-

STOP signal enters at J17 and exits at J20, where it is sent to the I/O Board and Power Supply card.

J18 This connector supports an RS-232 RJ-11 style phone cable that sends and receives data from the

Main Processor.

J19 This connector is not used at this time. A jumper is in place across the two pins. J20 This connector receives +12V DC to power the SKBIF, Power On, Power Off and E-Stop signals. J22 This connector is wired to the Power On and Power Off buttons on the operator pendant front panel and

to J20. The Power On and Off signals are received by J22 and sent to J20.

SW1 This switch determines how the beeper is being driven. The switch is set to ‘BEEP’ for a front panel

that contains a buzzer. The switch is set to ‘SPKR’ for a front panel that contains a speaker.

SW2 The COLOR switch is set based upon what LCD assembly is used. SHARP LCD assemblies require

the switch to be placed to the left (toward COLOR). LG LCD assemblies require the switch to be placed to the right (away from COLOR). The STROBE switch should always be placed to the left (toward STROBE).

96-0284 rev H © Haas Automation January 2010

Electrical Service

Page 72

VIDEO & KEYBOARD PCB W/ETHERNET & USB DRIVE

USB Cable to Pendant

U66

BT1

C106

C148

MON

15" 10"

C109

C24

RUN

U66A

U57

U60

C34

C102

C47

RS-232 PORT1

RS-232 PORT2

C206

C113

C30

U37

U35

C78

U36

U34

C76

C77

U21

J14

C138

C41C39

ADDRESS BUS

E-NET (RJ-45 Jack)

U46

CF2

C44

C45

C282

U10

U11

U12

U13

U14

U15

U16

U17

DATA BUS

U51

C27

C281

C283

U74

C48

U80

C25

J10

D6 D5 D1 D2 D3 D4 D7 D9

U29

J13

RUN PGM VIDEO MSG SIO POR STAT +5V

850-to SKBIF

To 15" LCD Video Monitor

Power

J12

RP1

(1)

(DOC

(BATTERY)

USB

(33-0211B)

J13

PC 104 CCA

HARD

J10

J11

(ICOP CCA)

U18

U23

ADDRESS

U19

U29

RP4

B10

U24

DRIVE

J14

KYBRD

U21

PC 104

(34-3406)

U25

DATA

C34

C35

U30

U31

U32

Video/Floppy CCA

Left side end view of

LCD ENET/HD OPT (32-3406/7)

Power

PLUG # CABLE # SIGNAL NAME TO  LOCATION PLUG #

P1 860 LOW VOLTAGE POWER SUPPLY PCB — —

J2 ____ VIDEO SIGNAL N/A ____ J4 ____ ADDRESS BUSS MICRO PROC.PCB ____ J5 ____ DATA BUSS MOTIF PCB ____ J13 850 SERIAL DATA N/A J1 J14 ____ SERIAL DATA KYBD ____

Electrical Service

96-0284 rev H

Page 73

MOCON PCB

P26

P27 P28

P18

P20

P24

P10

P34

P21P17 P22

P11

P12

P13

P14

P16

P33

P32

P30

P31

P19

JU2

U43

INSTALL JUMPER FOR MOCON 2

P35

P15

PLUG # CABLE # SIGNAL NAME  TO  LOCATION PLUG #

P1 ——- DATA BUSS VIDEO PCB ——-

MICRO PROC. PCB ——P2 610 X DRIVE SIGNAL X SERVO DRIVE AMP. P P3 620 Y DRIVE SIGNAL Y SERVO DRIVE AMP. P P4 630 Z DRIVE SIGNAL Z SERVO DRIVE AMP. P P5 640 A DRIVE SIGNAL A SERVO DRIVE AMP. P P32 640B B DRIVE SIGNAL B SERVO DRIVE AMP. P P6 660 X ENCODER INPUT X ENCODER ——-

96-0284 rev H © Haas Automation January 2010

Electrical Service

Page 74

PLUG # CABLE # SIGNAL NAME  TO  LOCATION PLUG #

P7 670 Y ENCODER INPUT Y ENCODER ——P8 680 Z ENCODER INPUT Z ENCODER ——P9 690 A ENCODER INPUT A ENCODER ——-

P30 690B B ENCODER INPUT B ENCODER ——-

P10 550 MOTIF INPUTS/I/O OUTPUTS I/O PCB P4 P11 510 I/O RELAYS 1-8 I/O I/O PCB P1 P12 520 I/O RELAYS 9-16 I/O PCB P2 P13 530 I/O RELAYS 17-24 I/O PCB P51 P14 540 I/O RELAYS 25-32 I/O PCB P3 P15 860 LOW VOLTAGE POWER SUPPLY PCB ——P16 720 SP. LOAD METER LOAD METER ——P17 640C VOLTAGE MONITOR VECTOR DRIVE J3 P18 750 JOG ENCODER INPUT JOG HANDLE ——P19 ADDRESS BUSS VIDEO PCB ——-

MICRO PROC. PCB ——P20 1000 SP. ENCODER INPUT SPINDLE ENCODER ——P21 X-AXIS TEMP SENSOR P22 730B SP. DRIVE LOAD SPINDLE DRIVE ——-

P24 990 HOME SENSORS X, Y & Z LIMIT ——-

P26 Y-AXIS TEMP SENSOR P27 Z-AXIS TEMP SENSOR P28 SPARE

P31 690C C ENCODER INPUT SPINDLE MOTOR

(lathe- 2nd spindle encoder) P33 640C VCTR DR CUR. CMD. VECTOR DRIVE J3 P34 SPARE P35 PWM OUTPUT (LASER)

RS-232 P

ORT #1 PCB

GND

PIN 1

34-4090

PLUG # CABLE #  TO  LOCATION PLUG #

P1 850 CABINET CONNECTION P2 850A VIDEO & KEYBOARD J13 P3 850A PC104 OPTION J9

Electrical Service

96-0284 rev H

Page 75

WYE-DELTA SWITCH ASSEMBLIES

Vector Drive

Black

SPINDLE

MOTOR

650A

CA7

-37

White

Red

3L1

CA7

DELTA WYE

To P53

I/O PCB

-37

650B

To Haas

M CODE RELAY BOARD

OUTPUT

M28

NO COM NC NO COM NC

12 11 10 987654321 12 11 10 987654321

LED8

U2 U4 U1

LED9

U6 U5

32-3085B

M CODE RELAY BOARD

U10

JP4 JP8 JP3 JP7 JP2 JP6 JP1 JP5

U11

12 VOLTDC

540/P6

OUTPUT

M21M25 M22M26 M23M27 M24

LED1

540/P1

INPUT

Addressing Jumpers

96-0284 rev H © Haas Automation January 2010

Electrical Service

Page 76

PLUG # CABLE # SIGNAL NAME  TO  LOCATION PLUG #

TB3 P4 P3

P1P2 P6

P1 540 MOCON INPUT I/O PCB P62 P2 860A 12V DC TO M-CODE PCBA PSUP P31 P3 540A I/O PCB OUTPUT P4 M21 M-FUNCTION

M22 PROBE OPTION M24 spare

P5 M25 spare

M26 spare M27 spare

P6 540B M CODE OUTPUT 2nd MCD P1

YDRAULIC PCB

OFF

K1K2

CB1

TB2

NE1

FU1

PLUG # CABLE #  TO  LOCATION PLUG #

P1 880B I/O PCB P12 P2 90 POWER PCB P8 P3 410 GEARBOX P4 350 I/O PCB (Hyd pump en) P54 P5 350A AXIS BRAKE Servo Motor P6 350 115V SERVO BRAKE P9 350A AXIS BRAKE Servo Motor TB2 340 HYDRAULIC MTR TB3 70 MAIN TRANSFORMER (VECTOR DRIVE UNIT)

Electrical Service

96-0284 rev H

Page 77

TSC MOTOR DRIVE/HIGH PRESSURE COOLANT PCB

P4 P1

TSC MTR DRV CCA

LINE 1:

230V AC IN

OFF

LINE 2:

LINE 3:

CB1

R4 Q3

HS2

HS3

HS1

230V AC

MTR OUTPUT

OVR TMP

R10

LE1

MOTOR EN

R11

PLUG # CABLE # LOCATION PLUG #

P1 33-0941E 3ph coolant pump socket Pump Socket P2 33-1944 Coolant Enable I/O PCB P73 P3 33-0941E OVR TMD Pump Socket P4 33-0987 230V IN Out transformer TB2

HAAS VECTOR DRIVE UNIT

TO I/O PCB

P58&P12

Power to

Servo Amps

DC Bus

230 VA C

TO MOCON

P17 C 640C

TO I/O PCB P18

Over Voltage

78 79

(Horiz)

Haas Vector Drive

12345678

R+-ABC

+- RSTGGUVW

PCBA

HOPT-A

AB C

Delta-Wye

Contactors

(Horiz &Vert)

UVWXYZ

REGEN

RESISTOR

SPINDLE

MOTOR

UVW

Electrical Service

Page 78

QUAD APC ( 32-3078A) PCB

P6A

as definedin user handbook

I/O Relay If

24V

Dual Probe

Lathe

C21

CR7

10A

AGND

TCL

TP2 TP1

C28

FU2

R25

R26

R27

Q3 Q4 Q5 Q6

P2 P1

FU1

P3A

PLUG # CABLE # LOCATION PLUG #

P1 33-1516 I/O PCB P62 P3 33-6038A Air Door P4 33-0191 From Power Card 6A 33-6038A Pallet Chain Motor

ENISHAW TOOL PRESETTER (LATHE)

N/CCN/ON/CCN/O

or M-Code

Board

Equipped

I/O Skip

OMI

WORK

PROBE

Note: To test probe use M53in MDI Verify that the yellow lead blinks and the green LED turns on

P22

BY R

Y W B Shield

WHT

M22M22

YEL

GREY

LTP

Shield

OMM 1

OMM 2

9START W

CONTROL O/P

POWER IN

Rtrn

N/CCN/O

1SIGNAL Y

2 SIGNALGY

3START W

40V GN

5 10V BN

60V GN

7 SIGNALY

8SIGNAL GY

ERROR

LOW BATT

SEE NOTE2

16 +24V

17 0V

18 GND/SCN

I/O or M-Code

M23

Relay Board If Equipped

Renishaw

Box

O/P

CONTROL

JUMPER

PowerCard P3

LTP and Work Probe-

M52LTP ON M62LTP OFF M53 PROBE ON M63 PROBEOFF

Note: To test probe use M53 in MDI Verify that the yellowlead blinks and the green LED turns on

This toggles the skip bit shownonthe Diagnostics page,when the probe is deflected

19 SIG. STRENGTH

20 AUDIO EXT.

21 +

M/CSTART 1ms-150 ms

22 -

23 +

SEE NOTE 2

24 -

Notes:

1. Set SW2 as shown

AUTOSTART

MC STARTIN21&22

2. Set SW3 as shown

BUZZER OFF

234

ABCD

BUZZER ON

3. Otherswitch configurations

234

ABCD

ERROR

O/P O/P

14&1523&24

STATUS STATUS

N/O N/O

ERROR

Electrical Service

96-0284 rev H

Page 79

OPERATOR PENDANT

LCD

USB DRIVE

REMOTE JOG HANDLE

CYCLE START FEED HOLD

ENHANCED

(OPTION)

HOOK

SWITCH

+5VDC 0 VDC A ENC B ENC

JOG HANDLE

HAAS

PENDANT SUPPORT ARM

CONTROL CABINET

BACKLIGHT

VIDEO DA

12V DC

RS-232 INTERFACE

VIDEO DATA

ESTOP, ON/OFF 12V PWR

BEEPER

LIGHT

SWITCH

12V DC

P9 J8

J16

SKBIF

J13

J18

J20

TOOL CHANGER

AUTO/MAN

CCW

AUX

FPANEL

J10

START/

FEED HOLD

J17

J22

CYCLE START

FEED HOLD

2ND HOME

(OPTION)

MEMORY KEY LOCK (OPTION)

24 PIN FLEX CABLE

EMERGENCY

STOP

POWER

OFF

USER'S AUX F-PANEL

PALLET ROTATE

PART READY

EMERGENCY

STOP

CE DOOR (EUROPE)

FRONT PANEL

KEYPAD

Electrical Service

Page 80

CIRCUIT BREAKERS

CB1

Minimill: CB2, 3,6=1PH, 3A

3PH, 40 AMP

240VAC

3PH, 30 AMP

600VAC

Line

115V 3PHS

230V 3PHS

P10

CB2

CB6

PSUP-L

3PH, 10 AMP

Neutral

1PH, 10 AMP

CB3

CB5

CB4

1PH, 10 AMP

1PH, 7 AMP

LV Power Supply

Servo Fan

Door Fan

I/O PCB-AB

P19 P56

170VDC

Power Supply

P36

GFI

P83 P36A

P20 P44

P21 P39 P38

Solenoids

Motor,Spindle Oil 1/20 HP 1.5A 114VAC

Spindle Motor Fan

Motor, APC (Option) 1/8 HP 90VDC 1.40A

Motor,Tool Chgr, Shuttle 1/8 HP 90VDC 1.40A

Motor,Tool Chgr, Carousel

HIL

Worklight

Motor, Coolant

P43

1/2 HP 230V 1PH 3.8A 50/60HZ (MM-1/8 HP)

P45

Motor, TSC (Option) 1/2 HP 230V 1PH 7.4A 60HZ

Motor, Chip Conveyor 1/6 HP 230V 3PH .7A 60HZ

1/8 HP 90VDC 1.40A

Vector Drive

P.S.

230V

Vector Drive

320VDC

Fan,

Spindle Motor 10 HP, 200V, 30A, 60HZ 20 HP, 200V, 58A, 60HZ

Servo Motor, XYZ Axes

1.1 HP, 850W, 7.6A

Amp

1.7 HP, 1300W, 13.7A

2.4 HP, 1800W, 18A

Electrical Service

96-0284 rev H

Page 81

HORIZONTAL MACHINE CONTROL CABINET WIRING DIAGRAM

CABLE 90A 90B 740 760 770 850 1050

CABLE 490B

690B

CABLE 490X 660

CABLE 490Z 680 350A

CABLE 490B 690B 230

NAME 115VAC to LCD LVPS 115VAC to Work Light Switch Power On/Off Video Data Emergency Stop SKBIF Door Switch Wiring

NAME Super Speed Tool Changer Motor Power Super Speed Tool Changer Encoder

NAME X-Axis Motor Power X Encoder,XHome Limit Switch

NAME Z-Axis Motor Power Z Encoder,ZHome Limit Switch 24VDC Servo Brake Release

NAME B-Axis Motor Power B Encoder,BHome Limit Switch 5'th Axis Brake

CONTROL

CABINET

FRONT

PANEL

SUPER SPEED

TOOL

CHANGER

AXIS

A2/

5TH AXIS

SPINDLE

HEAD

PALLET

CHANGER

AXIS

A1/

A-AXIS

TOOL

CHANGER

TSC

CABLE 190

200 300A

880A

890 950

CABLE 490X 660

CABLE 490Y 670

CABLE 490A 690 390

CABLE 810 810A 820

CABLE 940A 130

NAME Unclamp from Spindle Head to I/O PCB Coolant Spigot Motor 115VAC to Spindle Motor Fan/Oil Pump/Oiler High/Low Gear Unclamp/Lock Solenoid Power Spindle Status Switches Low Air Pressure Sensor

NAME X-Axis Motor Power X Encoder, Home Limit Switch

NAME Y-Axis Motor Power Y Encoder,Y-Home Limit Switch

NAME A-Axis Motor Power A Encoder, A-Home Limit Switch 4'th Axis Brake

NAME Tool Changer Turret Motor Tool Changer Shuttle Motor Tool Changer Status

NAME 230VAC 3PH to TSC Coolant Pump TSC Over Temp

CABLE 300 960

CABLE 140

NAME 115VAC to Oiler Low Lube

NAME 230VAC 3PH Power to Chip Conveyor Motor

CABLE 940

CABLE 420

NAME 230VAC to Coolant Pump

NAME APC #2 CLR #1/APC #2

PAL#2 Home 450 770B 810 880B

APC #2 CE Door Open

Emergency Stop Input

APC Motor

Transmission High/Low Gear

Solenoids

LUBE

PANEL

CONVEYOR

SPARE

FRONT PANEL/

PALLET CHANGER

TOOL CHANGER

REMOTE BOX/ FRONT PANEL

CHIP

SIGNAL

MFIN/

CLG

COOLANT

Electrical Service

CABLE 100 730B

CABLE 240

410 710

770B 790 810A M28

CABLE 250 310 430 460 480

NAME M-FIN SP Drive Load (Coolant Level Gauge Sensor)

NAME APC PAL Home/MD PAL UpAPC PAL1Home PAL Down APC CE Door Open APC #1 Pallet Ready 1/APC #1 Pallet Ready 2 Emergency Stop Input APC Pin CLR #1/APC Pin CLR #2 Tool Changer Motors

NAME APC Door Open APC #2 Door Open APC Pallet Clamp Left Door APC #2 Door Closed/Door Open APC Pallet Clamp Right Door

Page 82

VERTICAL MACHINE CONTROL CABINET WIRING DIAGRAM

Electrical Service

96-0284 rev H

Page 83

LATHE CONTROL CABINET WIRING DIAGRAM

Electrical Service

Page 84

CABLES

CABLE 71/72/73, POWER - K1 TO POWER SUPPLY (33-0952A)

12.0 IN

71-73 33-0952A OVR VLT PROTC

12345

PSUP P25

CABLE 77/78/79, 230V TRANSFORMER - POWER SUPPLY (33-0078B)

48.0 IN

73-L6 K1-3

72-L5 K1-2

71-L4 K1-1

77 XFMR TB2

78 XFMR TB2

79 XFMR TB2

2.0 IN

RED

WHT

BLK

77-79 33-0078A 230V OUT XFMR TB2

77-79 33-0078A 230V IN PSUP P10

RED

WHT

BLK

2.0 IN

Electrical Service

96-0284 rev H

Page 85

CABLE 90, 115V 3PH POWER SUPPLY - I/O PCB (33-0095A)

28.0 IN

1.5 IN 1.5 IN

2: RED

90, 33-0095A 115V 3PH I/O PCB P56

90, 33-0095A 115V 3PH PSUP P19

3: WHT

1: BLK

CABLE 90, 115V 1PH POWER SUPPLY - I/O PCB (33-0195A)

3: RED

2: WHT

1: BLK

Electrical Service

Page 86

CABLE 90A, 115V LCD LOW VOLTAGE POWER SUPPLY (33-8250)

LENGTH

2.00 IN

<LINE 1> 115V LCD LVPS LCD LVPS TB1

RED

BLK

3: GRN

213

2: BLK

1: RED

GRN

2.00 IN

ASSY.#

33-8250 33-8251 33-8252 33-8253 33-8254 33-8255 33-8256 33-8257 33-8258 33-8259 33-8248

MACHINE

VF 0-2, VB-1 MINI MILL ML SL-40 VF 6-11 VF 3-5, SL-20/30 HS (ALL) SL-40LB TRM VS-3 OM-1/OL-1

LENGTH

12.00 FT

9.50 FT

21.00 FT

18.17 FT

14.50 FT

7.85 FT

23.00 FT

10.00 FT

21.50 FT

6.00 FT

CABLE 90B, POWER TO LOW VOLTAGE POWER SUPPLY 5-PIN (33-0219A)

22.0 IN

90B, 33-0219A LVPS 115V PSUP P2

5: RED

90B, 33-0219A LVPS 115V LVPS PCB J1

90A, <ASSY#> 90C, <ASSY#> 90C, <ASSY#> 90A, <ASSY#> 90A, <ASSY#> 90A, <ASSY#> 90A, <ASSY#> 90A, <ASSY#> 90C, <ASSY#> 90A, <ASSY#> 90A, <ASSY#>

2: BLK

2.00 IN

PSUP P11 PSUP P16 PSUP P16 PSUP P11 PSUP P11 PSUP P11 PSUP P11 PSUP P11 PSUP P16 BASE CARRIER PSUP P11

1: RED

3: BLK

Electrical Service

96-0284 rev H

Page 87

CABLE 90B FAN CORD - VECTOR DRIVE 2HD (33-1024A)

UPPER

FANFAN

5.75 IN

CABLE 90B WORK LIGHT (33-2330)

90B, <ASSY.#>

3:WHT

WORK LIGHT LAMP PLUG

2:GRN

1:BLK

ASSY.# MACHINE

33-2331A 33-2330A 33-1330A 33-1331A 33-1337 33-1338

OL-1 OM-1 SL-20/30/40 SL-40LB GT-10 SL-30L/LB

LOWER

LENGTH

90B, <ASSY.#> WORK LIGHT FR PNL LAMP SW

LENGTH

7.0 FT

8.5 FT

10.4 FT

12.7 FT

20.0 FT

32.0 FT

90B, 33-1024 FAN CORD2HD PSUP P6

29.0 IN

SW P2 115V

WHT

SW P5 115V

BLK

5.00 IN

GRN

CABLE 90C, SPINDLE PURGE AIR SOLENOID (33-3550)

2: BLK

1: RED

90C, 33-3550 115SP PRG SOL SP PRG AIR SOL

TP/20AWG

4.0 FT

90C, 33-3550 115SP PRG SOL PSUP PCB P14

2: BLK

1: RED

Electrical Service

Page 88

CABLE 90C, 115V TRANSFORMER POWER SUPPLY - 8’ (33-6408)

8.0 FT

1: RED

90C, 33-6408 115V AC PSUP P17

2: BLK

CABLE 90C, SPINDLE FAN - TL-15/SL-20 (33-8310C)

LENGTH

3: RED

4: BLK

LENGTH

LABEL A

90C, <ASSY #> <LINE #2> <LINE #3>

LABEL A TEXT

ASSY#

90C, 33-6408 115V AC TRANS P2/P4

LABEL B

90C, <ASSY #> <LINE #2> <LINE #3>

RED

BLK

213

2: BLK

1: RED

LABEL B TEXT

33-8310C

33-8311C

33-8312

33-8315

8.00 FT

10.00 FT

8.00 FT

23.00 FT

SP FAN PWR

HPU FAN PWR

SP FAN PWR

Electrical Service

SP FAN

HPU FAN

SP FAN

SP FAN PWR

HPU FAN PWR

SP FAN PWR

PSUP P14

PSUP P16

PSUP P14

96-0284 rev H

Page 89

CABLE 94/95/96, 115V 3PH TO POWER SUPPLY (33-0905E)

50.0 IN

2.0 IN

RED

94 XFMR

WHT

2.0 IN

RED

BLK

WHT

95 XFMR

BLK

94-96 33-0905E 115V 3PH OUT XFMR TB1

96 XFMR

CABLE 100, M-FIN FUNCTION W/MCD (33-0101)

10.0 INCH

BLK <GND>

RED <SIG>

100, <ASSY #> M-FIN I/O PCB P10

ASSY.#

33-0100A 33-0301 33-0101

1: RED

2: BLK

L-1

17.0 INCH

69.0 INCH

LENGTH

2.25 FT

6.60 FT

94-96 33-0905E 115V 3PH IN PSUP P1

22.0 IN

LENGTH

4: RED

3: BLK

I/O PCB TB1-M21 MCD PCB M21 MCD PCB M21

GRN/YEL

L-1

100, <ASSY #> M-FIN <LINE 3>

BLK

RED

N/O P4-3

COM P4-2

RED BLK

Electrical Service

Page 90

CABLE 140A, CHIP CONVEYOR ENABLE/REVERSE (33-0149)

140A 33-0149 CHIPC ENA/REV

BLK WHT YEL

CHIPC PCB P4

140A 33-0149 CHIP ENA/REV

YEL BLK

HOPT PCB P5

WHT<ENA>

CABLE 140A, LEFT CHIP CONVEYOR ENABLE/REVERSE (33-0164A)

RED

WHT

BLK

SHIELD

140A 33-0164A CHIPC EN/REV IOPCB P37/37A

CABLE 160, CHIP CONVEYOR 230V (33-0160D)

SHIELD

160, 33-0160D CHIPC 230V PSUP P21

2 1

BLK

RED

WHT

140A 33-0149 CHIP ENA/REV I/O PCB P37

140A 33-0164A CHIPC EN/REV CHIPC P2/3/4

160, 33-0160D CHIPC 230V IOPCB P39

SHIELD

RED

WHT

BLK

YEL

<COM>

WHT

<ENA>

BLK

<REV>

RED <+12V> WHT <EN.> BLK <REV.> SHIELD

CABLE 170, AUX/COIL 30HP CONTACTOR (33-0179A)

WIRE SIDE OF

CONNECTOR

RED BLK

RED

BLK

BLK RED

170 <ASSY#> AUTO/OFF PSUP P23

RED

BLK

RED

BLK

Electrical Service

170 <ASSY#> AUTO/OFF I/O PCB P42

2: RED

1: BLK

96-0284 rev H

Page 91

CABLE 190, TOOL RELEASE (33-0190C)

LENGTH

TOP VIEW

190, <ASSY #> REM UNCLAMP REM UNCL SW

RED

BLK

MACHINE

VF 0-2 VB-1 ML VR-11B VF 6-11 VF 3-5 VS-3 GR-510/512 GR-712 HS-3/3R OL-1

SIDE VIEW

ASSY.#

33-0190C 33-3190C 33-4190 33-5190A 33-6190C 33-7190C 33-8190A 33-8290A 33-8291 33-9190 33-9191

CABLE 190, TOOL RELEASE (33-1900)

P19 P19 P19 P19 P19 P19 P19 P19 P19 P19 P49

190, <ASSY #> REM UNCLAMP I/O PCB <LINE3>

LENGTH (IN)

176.00 IN

444.00 IN

60.00 IN

282.00 IN

264.00 IN

201.00 IN

372.00 IN

564.00 IN

588.00 IN

294.00 IN

126.00 IN

RED BLK

LENGTH (FT)

14.67 FT

37.00 FT

5.00 FT

23.50 FT

22.00 FT

16.75 FT

31.00 FT

47.00 FT

49.00 FT

24.50 FT

10.50 FT

SHIELD DRAIN

TOLERANCE

3.50 IN

1.5% OF LENGTH

2.00

1.5% OF LENGTH

3.50 IN

1.5% OF LENGTH

3.00 IN

TOP VIEW

SIDE VIEW

190, <ASSY #> REM UNCLAMP REM UNCL SW

RED

BLK

ASSY.#

33-1900 33-1901 33-1902 33-1903

MACHINE

VF 5/50T VF 6-11/50T VS-1/3 EC-1600

LENGTH

13.00 FT

19.70 FT

31.00 FT

23.00 FT

190, <ASSY #> REM UNCLAMP I/O PCB P19

TOLERANCE

3.00 IN±

3.50 IN

1.5% OF LENGTH

RED BLK

SHIELD DRAIN

Electrical Service

Page 92

190/240/260/710/770A FRONT ENCLOSURE SIGNAL RECEPTACLE (32-6660B)

SW P2 115V

95 SW P5

SHIELD

BLK

SHIELD

BLK

9: SHIELD

5: GRN

1: RED

8: BLK

4: WHT

RED

2 COND TP 22AWG

BLK

FRNT PNL WORK LITE FRNT PNL SW

190, 32-6660B FRONT DOOR I/O PCB P19

RED

260, 32-6660B PAL READY LITE I/O PCB P34

RED

AUX FP PAL RDY SW SKBIF J11

4 COND 24AWG

BACK SIDE OF CONNECTOR

STANDARD RECEPTACLE SOCKET CONTACTS (SIDE VIEW)

240, 32-6660B PAL UP/DWN SW I/O PCB P21

SHIELD

WHT BLK

A: RED <PAL DOWN>

B: WHT <PAL UP>

D: SHIELD E: RED <PAL ALARM> F: BLK <PAL ALRM RTN> H: SHIELD J: GRN <CW ROTATION> K: WHT <CCW ROTATION>

RED

M: RED <PAL RDY LITE>

P: BLK <LS DOOR RTN>

R: RED <LS DOOR CLOSE>

770A, 32-6660B 2ND E-STOP

I/O PCB P6

BAS

1: RED

2: BLK

M28, 32-6660B PALLET ALARM I/O PCB P67

RED

BLK

T: RED <2ND E-STOP> U: BLK <RETURN> V: BLK <GND> W: WHT <PAL UP> X: BLK <PAL RDY SW RTN> Y: RED <PAL RDY SW> Z: BLK <PAL RDY LITE RTN>

SHIELD

710, 32-6660B PAL UP/DWN SOL I/O PCB P52

GRN/YEL <CHASSIS GND>

BLK

RED

WHT

a: RED <WORKLITE> b: BLK <WORKLITE> d: RED <PAL DWN> e: BLK <PAL DOWN RTN>

CABLE 200, PROGRAMMABLE COOLANT (33-0202)

MACHINE

GR510/512 VF 0-5 VF 6-11 VB-3 VR-11B EC-300 EC-1600 VS-3

BLK

ORN

WHT

RED

ASSY.#

33-0201 33-0202 33-0203 33-0204 33-0205 33-0206 33-0208 33-8200

200 ,<ASSY.#> SPIGOT MTR/SW PROG COOL ASSY

LENGTH

50.00 FT

13.50 FT

20.50 FT

38.00 FT

22.00 FT

15.00 FT

24.00 FT

29.00 FT

TOLERANCE

1.5% OF LENGTH

3.50 IN

1.5% OF LENGTH

3.50 IN

1.5% OF LENGTH

200, <ASSY.#> SPIGOT MTR/SW I/O PCB P35

RED BLK

ORN

WHT SHIELD

Electrical Service

96-0284 rev H

Page 93

CABLE 210, FLOPPY DRIVE DTA VF0-2/VB-1 (33-0210A)

SHLD DRN

6.0 IN 22AWG

3: BLK <DRAIN>

FRONT VIEW

OF SOCKET

CENTER

KEY

VIDEO J11

RED

STRIP

210, ASSY # FL DR DATA VIDEO PCB J12

2.0 IN 2.0 IN

210, ASSY # FL DR DATA FRNT PNL FLD

RED

STRIP

BACK VIEW

OF SOCKET

LENGTH

ASSY.#

33-0210A 33-1210B 33-6210A 33-7210A 33-8210A 33-6211

MACHINE

VF0-2, VB-1 CSM (ALL) VF/R6-11 VF3-5, SL (ALL) HS (ALL) TM-1/2 OFFICE MACHINES

CABLE 230, TAILSTOCK CONTROL - FORWARD (33-1988)

15.0 FT.

230 33-1988 FORWARD (TS) SOLENIOD

Back view

LENGTH

12.00 FT

1.50 FT

19.00 FT

15.00 FT

6.00 FT

9.00 FT

TOLERANCE

3.00 IN .50 IN

0±±

3.50 IN

2.00 IN

230 33-1988 FORWARD (TS) I/O PCB P31

1 BRN 2 BLU

231

3 GRN

Electrical Service

Page 94

CABLE 240, PALLET UP/DOWN SWITCH (33-0113)

11.50 FT

PALUP

3: BLK

240, 33-0113 PAL UP/DWN SW PAL CHNGR

1: RED

PAL DWN

PALUP

PAL DWN

GND

SHLD

2: RED 3: WHT 4: BLK

240, 33-0113 PAL UP/DWN SW I/O PCB P21

2: WHT

CABLE 240/260/430/770A/790 AUX. FRONT PANEL SIGNAL RECEPTACLE (32-6670)

GRN

SW P2 115V

95 SW P5

BLK [LS DOOR RTN]

RED

BLK

SHLD

RED [LS DOOR CLOS]

BLK [PAL RDY LITE RTN]

SHLD

RED [PAL RDY LITE]

260 32-6670 PAL READY LITE I/O PCB P34

BACK SIDE OF CONNECTOR

9: SHIELD

5: GRN

1: RED

8: BLK

4: WHT

32-6670 WORK LITE FRNT PNL SW

790, 32-6670 FRONT DOOR I/O PCB P18

AUX FRNT PNL PAL RDY SW SKBIF J11

Standard Receptacle Socket Contacts Side View

32-6670 LIFT PROTECT SOL PSUP P15

430, 32-6670 PAL UNCLMP SOL I/O PCB P51

770A 32-6670 2ND E-STOP I/O PCB P6

240, 32-6670 PAL UNCLMP SW I/O PCB P21

SHIELD

RED [PAL UNCLMP SOL]

G: GRN/YEL [GND]

M28 32-6670 AIRBLAST SOL I/O PCB P67

RED [LIFT PROTECT SOL]

BLK [RTN]

BLK [PAL UNCLMP SOL RTN]

RED [2ND E-STOP]

BLK [RTN]

RED [+12V]

SHIELD

RED [AIR BLAST SOL]

SHIELD

BLK [SOL RTN]

WHT [PAL UNCLMP SW] BLK [RTN]

JUMPER

3IN

A: GRN [WORKLITE GND] B: SHIELD

D: RED [2ND E-STOP] E: BLK [RTN] K: GRN [CW ROTATION] L: WHT [CCW ROTATION] M: RED [PAL RDY LITE]

N: BLK [PAL RDY LITE RTN]

P: BLK [LS DOOR RTN] R: RED [LS DOOR CLOSE] T: BLK [LIFT PROTECT RTN] Y: BLK [PAL RDY SW RTN] W: SHIELD

X: SHLD

Z: RED [PAL RDY SW]

a: RED [WORKLITE] b: BLK [WORKLITE] d: SHIELD

e: RED [LIFT PROTECT SOL]

3" BLK

4: BLK

Electrical Service

96-0284 rev H

Page 95

CABLE 240/260/430/770A/790 AUX. FRONT PANEL SIGNAL CABLE (32-6665A)

F: BLK [PAL UNCLMP SW]

c: WHT/BLK [PAL UNCLMP SW RTN]

A: BRN [WRK LITE GND]

R: RED [FRNT DR SW]

b: BLK [WRK LITE RTN]

P: WHT/RED [FRNT DR SW RTN]

e: WHT/BRN [LIFT PROTECT SOL]

a: RED [WORK LITE]

W: SHIELD

1TP #18 AWG

DETAIL B

AUX FRONT PANEL SIGNAL CABLE

8.0IN

U: BLU [PAL UNCLMP SOL RTN]

C: ORG [PAL UNCLMP SOL]

T: BRN [LIFT PROTECT SOL RTN]

H: WHT [AIR BLAST SOL]

N: BLK [PAL RDY LITE RTN]

M: RED [PAL RDY LITE]

J: GRN [AIR BLAST SOL RTN]

X: SHIELD

3TP #20 AWG

DETAIL A

2: BLK [WRK LITE RTN]

1: RED [WORK LITE]

1: RED 6" JUMPER

2: BLK 6" JUMPER

7 COND #24 AWG

DETAIL C

3: BLK [PAL UNCLMP SW]

1: WHT/BLK [PAL UNCLMP SW RTN]

2: RED [FRNT DR SW]

1: WHT/RED [FRNT DR SW RTN]

3: BRN [WRK LITE GND]

3: BRN 6" JUMPER

2: WHT/BRN [LIFT PROTECT SOL]

1: BRN [LIFT PROTECT SOL RTN]

2: WHT [AIR BLAST SOL]

1: GRN [AIR BLAST SOL RTN]

2: ORG [PAL UNCLMP SOL]

1: BLU [PAL UNCLMP RTN]

10: RED [PAL RDY LITE]

1 2

WORK

LITE

WORK

LITE

5: BLK [PAL RDY LITE RTN]

PAL UNCLMP

FRNT DR

2: WHT/BRN

[LIFT PROTECT

SOL]

LIFT PROTECT

SOL

AIR BLAST

SOL

PAL UNCLMP

SOL

E: WHT [2ND ESTOP RTN]

D: BLU [2ND ESTOP]

Z: RED [PAL RDY SW]

L: GRN [CCW ROT]

Y: BLK [PAL RDY SW RTN]

Y: BRN [ROT RTN]

K: ORG [CW ROT]

d: SHIELD

7 COND #24 AWG

DETAIL D

Electrical Service

9: BLU [2ND E-STOP]

8: GRN [CCW ROT]

7: ORG [CW ROT]

6: RED [PAL RDY SW]

1: BLK [PAL RDY SW RTN]

2: BRN [ROT RTN]

4: WHT [2ND ESTOP RTN]

AUX

FRNT PNL

Page 96

CABLE 240/260/430/770A/790 AUX. FRONT PANEL SIGNAL RECEPTACLE (32-6667B)

GRN

115V

95 SW P5

BLK [LS DOOR RTN]

SHLD

RED [LS DOOR CLOS]

BLK

RED

BLK

32-6667B WORK LITE FRNT PNL SW

790, 32-6667B FRONT DOOR I/O PCB P18

[PAL RDY LITE RTN]

SHLD

RED [PAL RDY LITE]

1 BACK SIDE OF CONNECTOR

9: SHIELD

5: GRN

1: RED

8: BLK

4: WHT

AUX FRNT PNL PAL RDY SW SKBIF J11

STANDARD RECEPTACLE SOCKET CONTACTS SIDE VIEW

260 32-6667B PAL READY LITE I/O PCB P34

A: GRN [WORKLITE GND]

32-6667B LIFT PROTECT SOL PSUP P15

430, 32-6667B PAL UNCLMP SOL I/O PCB P51

770A 32-6667B 2ND E-STOP I/O PCB P6

240, 32-6667B PAL UNCLMP SW I/O PCB P21

RED [LIFT PROTECT SOL]

BLK [RTN]

BLK [PAL UNCLMP SOL RTN]

SHIELD

RED [PAL UNCLMP SOL]

RED [2ND E-STOP]

BLK [RTN]

RED[+12V

SHIELD

]

WHT[PAL UNCLMP SW

BLK [RTN]

G: GRN/YEL [GND]

M28 32-6667B AIRBLAST SOL I/O PCB P67

RED [AIR BLAST SOL]

SHIELD

BLK [SOL RTN]

B: SHIELD C: RED D: RED [2ND E-STOP] E: BLK [RTN] K: GRN [CW ROTATION] L: WHT [CCW ROTATION] M: RED [PAL RDY LITE]

N: BLK [PAL RDY LITE RTN] P: BLK [LS DOOR RTN] R: RED [LS DOOR CLOSE] T: BLK[LIFT PROTECT RTN] W: SHIELD Y: BLK [PAL RDY SW RTN] Z: RED [PAL RDY SW]

]

a: RED [WORKLITE] b: BLK [WORKLITE] c: BLK d: SHIELD e: RED [LIFT PROTECT SOL]

CABLE 250, TAILSTOCK CONTROL - REVERSE (33-1989)

15.00 FT.

250 33-1989

REVERSE (TS) SOLENOID

Back view

250 33-1989

REVERSE (TS) I/O PCB P32

3 GRN

1 BRN 2 BLU

Electrical Service

96-0284 rev H

Page 97

CABLE 250 MORI T/C RECEPTACLE OUTPUTS (33-8155A)

BLK (PIN 4)

BLK (PIN 6)

BLK (PIN 7)

BLK (PIN 5)

GRN/YEL

BLK (PIN 14)

BLK

BLK (PIN 15)

BLK (PIN 8)

BLK (PIN 16)

BLK (PIN 9)

RED (PIN 13)

BLK (PIN 3)

BLK (PIN 1)

REAR VIEW

GRN

CABLE 260, READY LAMP - EC-300 (33-8105)

33-8155A

115V SOLENOIDS

SMTC PCB P3

54 IN

REAR VIEW OF CONNECTOR

250 TOOL RELEASE I/O PCB P32

CHASSIS GROUND

1516 14

REAR VIEW

GRN

BLK

PIN OUT OF CONNECTOR 1 MAG CW/Y01A 2 M22 (SPARE) 3 MAG NOTCH OUT/Y01C 4 SWING SP/Y017 5 CHANGE MAG/Y016 6 SLIDE RIGHT/Y015 7 CHANGE LEFT/Y014 8 ARM CCW/Y013 9 MAG CCW/Y01B 10 M25 (SPARE)

1213 1112910

11 115V SW LINE (SPARE) 12 CHASSIS GROUND (SPARE) 13 115V COMMON 14 ARM IN/Y010 15 ARM OUT/Y011 16 ARM CW/Y012

RDY LAMP

RED

RDY LAMP

BLK

260 33-8105 READY LAMP AUX F-PNL

CABLE 270, TAILSTOCK CONTROL - RAPID (33-1987)

13.5 FT.

270/880A 33-1987 RAPID(TS) TT / SOL

260 33-8105 READY LAMP I/O PCB P34

270/880A 33-1987 RAPID (TS) I/O P33/HPU SOL

123

1 3

RED BLK DRAIN

1 BRN 2 BLU 3 GRN

Electrical Service

Page 98

CABLE 280, HAAS BEACON (33-1035A)

RED

WHT

BLK

280, <ASSY.#> BEACON 115V BCON FRNT PNL

ASSY.# MACHINE

33-1035A 33-1036A 33-1037C 33-1039C 33-8160B

VF0-5, SL20/30 VF6-11 SL-40 VB1/3, HS-3 VS-3

CABLE 300, SPINDLE FAN/LUBE PUMP (33-1333)

300, <ASSY #> LUB OIL PUMP LUBE RACK

1:RED

2:BLK

300 LUBE PUMP

1: RED

2: BLK

280, <ASSY.#> BEACON 115V <LINE 3>

IOPCB P36 IOPCB P36 IOPCB P36 IOPCB P36 BASE CAPPER

ASSY.# MACHINE

33-1333 33-1343 33-1353 33-1363A

VF0-11 SL-10/30/40 SL-20 SL-40L

LENGTH

17.75 FT

21.75 FT

22.00 FT

13.50 FT

22.00 FT

SHLD

BLK

WHT

TOLERANCE

3.50 IN±

3.50 IN

300, <ASSY #> LUB OIL PUMP IOPCB P40

LENGTH

2.75 FT

10.50 FT

7.50 FT

13.50 FT

432 1

RED

SHIELD

BLK

RED

3 2

CABLE 300A, GEARBOX OIL PUMP - SL-30/40 (33-8168)

300A, <ASSY #> GBOX OIL PUMP

RED

BLK

OIL PUMP CON

ASSY.# CONTROL

33-8168 33-8169 33-8175A

BOTTOM TOP BOTTOM

LENGTH

7.00 FT

13.00 FT

16.00 FT

300A, <ASSY #> GBOX OIL PUMP I/O PCB P41

SHLD

312

BLK

RED

Electrical Service

96-0284 rev H

Page 99

CABLE 310, DOOR OPEN (33-2300)

ASSY.# MACHINE

32-2300 32-2301 32-2302 32-2303 32-2304 32-2305 32-2306 32-2307 32-2308 32-2309 32-2310 32-2313 32-2314 32-2316 32-2320

LATHES MM, SMM SL-10, ML SL-40 SL-20, TL-15 SL-30 APC, APCQ APC, APCQ APCQ APCQ MDC-1 EC-400 TL-1/2/3 EC-400/500/400PP EC-630

LENGTH

CABLE 350/350A, AXIS BRAKE (33-0904B)

LENGTH

18 IN 12 IN 39 IN 54 IN 75 IN

84 IN 150 IN 150 IN 186 IN 186 IN

21 IN

84 IN 150 IN 204 IN

2: BRN <SIG>

1: BLU <GND>

TABLE

RED

BLK

<LINE 1> <LINE 2> <LINE 3> <LINE 4> LENGTH 350 33-0904B 350A 33-0906A 350A 33-0908

AXIS BRAKE HYD PMP EN 1AXIS BRAKE

CABLE 350, Z-AXIS BRAKE (33-0907)

2: RED

3: BLK

350 33-0907 Z-AXIS BRK TRANS PCB P1

BRAKE PCB P6 TRANS PCB P4 BRAKE PCB P6

18.0 IN

I/O PCB P47

I/O PCB P49 I/O PCB P49

350 33-0907 Z-AXIS BRK I/O PCB P47

25.00"

23.00"

27.00"

2: BLK

1: RED

123

1 RED 2 BLK

Electrical Service

Page 100

CABLE 350A, HYDRAULIC PUMP CONTACTOR (33-0352B)

A1 COIL

BLK

350A33-0352B 115 HYD CNTCR CONTACTR COIL

A2 COIL

RED

CABLE 390, 115V 4TH AXIS BRAKE (33-8511)

3: BLK

1: SHLD

2: RED

390, <ASSY.#> <LINE 2> I/O PCB P46

ASSY.#

MACHINE

40"

LENGTH

350A33-0352B 115 HYD CNTCR I/O PCB P49

390, <ASSY.#> <LINE 2> BRAKE SOLENOID

LENGTH

BLK

2: BLK

1: RED

RED

33-8511 33-8512

HS-3R VTC

CABLE 410, TOOL CHANGER DOOR SWITCH (33-9825A)

410 <ASSY #>

RED

BLK

TC DOOR LS TC DOOR L/SWITCH

ASSY.#

33-9825A 33-9821A 33-9829 33-9830 33-9831

MACHINE

HS-1 (ALL) HS-2/3 EC-300 GR-408 GR-510/512/ 710/712

LENGTH

15.00 FT

5.50 FT

20.75 FT

28.00 FT

48.00 FT

9.50 FT

11.00 FT

115V 4TH BRAKE 115V SP BRAKE

410 <ASSY #> TC DOOR LS I/O PCB P17

TOLERANCE

3.00 IN 2±±

.00 IN

3.50 IN

4.00 IN

5.00 IN

RED

BLK

DRAIN

Electrical Service

96-0284 rev H