haas 96-0284A Service Manual

Haas Technical Publications

Manual_Archive_Cover_Page Rev A

any other party automatically voids the factory warranty.

June 6, 2013

HAAS SERVICE AND OPERATOR MANUAL ARCHIVE

Electrical Service Manual 96-0284A RevA English June 2006

• 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

SAFETY

MAIN POWER

ON

40

OFF

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

T o avoid possible shock, make sure circuit breakers are appropriately locked of f 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!WARNING!

WARNING!

WARNING!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 qualified electricians should have ac­cess to the panel. When the main circuit breaker is on, there is high
voltage throughout the electrical panel (including the circuit boards
and logic circuits) and some components operate at high tempera­tures. Therefore extreme caution is required.

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 and K1 contactor.

• Check I/O PCB.

• Check Power PCB.

96-0284 rev A June 2006

Electrical Service

1

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. Check for green Power LED at front of LCD/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.

ELECTRICAL ALARM TROUBLESHOOTING

Axis Drive Fault Alarm

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

amplifier.

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

normally for a while.
T o check an amplifier, switch the motor leads and control cables between the amplifier and the one next to it. If

the same problem occurs with the other axis, the amplifier must be replaced. If the problem stays on the same

axis, either the MOCON or control cable. The problem could also be the axis motor itself, with leads either

shorted to each other or to ground.

• Amplifier faulting out for valid reason, such as overtemp, overvoltage, or +/-12V undervoltage condition. This
usually results from running a servo intensive program, or unadjusted 12V power supply. Adjust voltage to

correct specifications 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.

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Electrical Service

96-0284 rev A June 2006

Axis Overload

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

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

Phasing Error

• The MOCON did not receive the proper phasing information from the motors. Do not reset the machine if this

alarm occurs. Power the machine down and back up. If the problem persists, it is probably a broken wire or
faulty MOCON connectors. This problem could also be related to the Low 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 amplifier 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 amplifier, it is probably due to a broken wire,
or a Phasing Error that was generated.

Axis Z Fault or Z Channel Missing

• During a self-test, the number of encoder counts was found to be incorrect. This is usually caused by a noisy
environment, and not a bad encoder. Check all shields and grounds on the encoder cables and the motor leads

that come into the amplifiers. An alarm for one axis can be caused by a bad grounding on the motor leads of
another axis.

Axis Cable Fault

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

Alarm 101, "MOCON Comm. Failure"

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

Alarm 157, MOCON Watchdog Fault

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

Alarm 222, C Phasing Error (Vert)

• If this alarm occurs on a VB-1, it is probably because Parameter 176 bit 3 (SP Axis Disabled) is set to 0. It

should be set to 1.

Alarm 261, Rotary CRC Error (Horiz & Vert)

• This alarm is normally the result of an incomplete software installation. To correct this error, Change Setting
30 to any selection but Off (note the original selection), then go to Parameter 43 and change one of the bits
from 1 to 0 or vice versa and press Write (the bit must be changed from its original value to its alternate value).
Simply changing the Setting and Parameter bit from one value to another and then back again corrects the
fault, and will clear any further occurrences of the alarm. Change the bit and Setting 30 back to their original
values. Press Reset to clear the alarms or cycle power to the machine.

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Electrical Service

3

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 appears below:

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 intermit-

tent 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 first, 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.

4

Electrical Service

96-0284 rev A June 2006

LINE VOLTAGE ADJUSTMENTS

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

T ools Required: Large flat 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.

Probe (Option)

Low Voltage Power Supply

T5 Transformer

MOCON-2

(if equipped)

LCD Video/Floppy

3-Phase Breaker

MOCON-1

Processor

K1 Contactor
Power PCB

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

Optional Servo
Tool Changer Amp

SERVODRIVE
ASSEMBLY

Haas Vector Drive
Wye-Delta Contactors

(underneath)

I/O Board

Single Axis Brake PCB

(if so equipped)

LOWVOLT -------------- 260-244V 243-227V 226-211V 210-195V

Transformer

Terminal block

Control Cabinet General Overview

ELECTRICAL CONNECTIONS

L2

L1

L3

High Volt Low Volt

Ground Line

75 76

488-458V 457-429V 428-403V 402-377V 376-354V

HIGH VOLT

74

LOW VOLT

----------------

260-244V 243-227V 226-211V 210-195V

74

75 76

T5 Transformer

Main Circuit Breaker

1. Hook up the three power lines to the terminals on top of the main switch at upper right of electrical panel
and the separate ground line to the ground bus to the left of the terminals.

NOTE: Make sure that the service wires actually go into the terminal-block clamps. (It

is easy to miss the clamp and tighten the screw. The connection looks fine but
the machine runs intermittently or has other problems, such as servo over-

loads.) To check, simply pull on the wires after the screws are tightened.

96-0284 rev A June 2006

Electrical Service

5

2. After the line voltage is connected to the machine, make sure that main circuit breaker (at top-right of rear
cabinet) is off (rotate the shaft that connects to the breaker counterclockwise until it snaps off). Turn on the

power at the source. Using an accurate digital voltmeter and appropriate safety procedures, measure the
voltage between all three pair phases at the main circuit breaker and write down the readings. The voltage

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

NOTE: Wide voltage fluctuations are common in many industrial areas; you need to

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

know the minimum and maximum voltage which will be supplied to the

machine while it is in operation. U.S. National Electrical Code specifies that
machines should operate with a variation of +5% to -5% around an average

supply voltage. If problems with the line voltage occur, or low line voltage is
suspected, an external transformer may be required. If you suspect voltage
problems, the voltage should be checked every hour or two during a typical day

to make sure that it does not fluctuate more than +5% or -5% from an average.

panel before you change 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

five 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 24V AC 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 about two inches from the transformer, which allow it to be connected to

either 240V or 200V. Users that have 220V-240V RMS input power should use the connector labeled 200V.

Users with the External High Voltage Option should use the 240V connector if they have 420V-510V 60Hz
power or the 200V connector if they have 50Hz power. Failure to use the correct input connector will result

in either overheating of the main contactor or failure to reliably engage the main contactor .

5. Set the main switch to ON (rotate the shaft that engages the handle on the panel door clockwise until it
snaps into the on position). Check for evidence of problems, such as the smell of overheating components
or smoke. If such problems are indicated, set the main switch to OFF immediately and call the factory

before proceeding.

T5 Transformer

K1

Contactor

WARNING!

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

6

Electrical Service

96-0284 rev A June 2006

6. After the power is on, measure the voltage across the upper terminals on the contactor K1 (located below
the main circuit breaker). It should be the same as the measurements where the input power connects to

the main breaker. If there are any 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 CRT. 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.

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
swapping L1 and L2 of the incoming power lines at the main circuit breaker.

PHASE

DETECT

PASS FAIL

6
E
N

5
E
N

WARNING!

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

9. Turn off the power (rotate the shaft that engages the handle on the panel door counterclockwise until it
snaps into the off position). Also, set the main switch handle on the panel door to OFF. (Both the handle
and the switch must be set to OFF before the door can be closed). Close the door, lock the latches, and

turn the power back on.

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

INSTALLATION PROCEDURE FOR EXTERNAL 480V TRANSFORMER

The external transformer adds to overall machine reliability and performance, however it does require extra

wiring and a place to locate it. The external transformer has a 45 KVA rating and provides electrostatically
shielded isolation. This type of transformer acts to isolate all common mode line transients and improve EMI

conducted emissions.

Installation

The transformer should be located as close to the machine as possible. The input and output wiring of the
transformer should conform to the local electrical codes and should be performed by a licensed electrician. The
following is for guidance only , and should not be construed to alter the requirements of local regulations.

The input wire should not be smaller than the 6 AWG for the 45KVA transformer. Cable runs longer than 100"
will require at least one size larger wire. The output wire size should be 4 AWG.

NOTE: Ensure the ground wire has been correctly installed.

The transformer is 480V to 240V isolation transformers with delta wound primary and secondary windings. The
primary windings offer 7 tap positions, 2 above and 4 below the nominal input voltage of 480V.

96-0284 rev A June 2006

Electrical Service

7

For domestic installations and all others using 60Hz power, the primary side should be wired as follows:

Input Voltage Range Tap

493-510 1 (504)

481-492 2 (492)

469-480 3 (480)
457-468 4 (468)
445-456 5 (456)
433-444 6 (444)
420-432 7 (432)

This should produce a voltage on the secondary side of 234-243V RMS L-L. Verify this and readjust the taps as
required. At the machine, connect the cables at the input of the internal 230V transformer to the 227-243V
taps. Apply power to the machine and verify that the DC voltage between pins 2 and 3 of the Vector Drive (2nd
and 3rd pins from the left) is 329-345V DC. If not, return to the 480V isolation transformer and readjust the taps
as required. Do not use the taps on the internal 230V transformer to adjust the voltage.

50Hz Installations

The external transformers are 60Hz rated, and cannot be used at 50Hz without derating the input voltage. For
these applications, the internal 230V transformer should be tapped on the lowest setting (195-210V RMS). The

external transformer should be tapped according to the table shown below . If these tap setting do not produce a

DC bus voltage between pins 2 and 3 on the Vector Drive between 320 and 345VDC, readjust the taps on the
external transformer as required. Do not move the taps on the internal transformer from the lowest position.

Input Voltage Range Tap

423-440 1 (504)

412-422 2 (492)

401-411 3 (480)
391-400 4 (468)
381-390 5 (456)
371-380 6 (444)
355-370 7 (432)

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Electrical Service

96-0284 rev A June 2006

FUSE REPLACEMENT

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

Some of the brushless amplifiers have one 15 amp fuse, F1. If this fuse is ever blown, the associated motor will
stop. A light on the amplifier will tell of a blown fuse. If necessary replace the fuse (Haas P/N 93-1089). If the

fuse blows again, the amplifier may be damaged, in which case the amplifier needs to be replaced.

The Power PCB contains three ½-amp fuses located at the top right (FU1, FU2, FU3). If the machine is subject
to a severe overvoltage or a lightning strike, these fuses will blow and turn off all of the power. Replace these
fuses only with the same type and ratings. FU 4, 5, and 5A protect the chip conveyor (FU6 is only used with 3
phase motors).

Size Fuse Name Type Rating (amps) Voltage Location

5mm FU1-FU3 Slo-Blo ½ 250V PSUP pcb, upper right
1/4 F1 Ultra fast 15 250V Amplifier (X, Y, Z, A, B)
5mm FU4, 5 Fast blow 5A 250V PSUP, bottom right corner

OVERVOLTAGE FUSES

WARNING!

The electrical panel will have residual voltage, even after power has
been shut off and/or disconnected . Never work inside this cabinet
until the small green Power On light on the servo amplifiers (servo
drive assembly on brush machines) goes out. The servo amplifiers/
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. Turn the main switch (upper right of electrical cabinet) to the off position.

MAINPOWER

ON

OFF

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 three overvoltage fuses are located in a row at the upper right of the Power Supply board. An orange
light will be on to indicate the blown fuse(s).

96-0284 rev A June 2006

Electrical Service

9

10A230V

P24

PHASE

DETECT

TB3

FU13

FU12

PASS FAIL

NE6

NE5

NE2

NE3

FU8

NE13

NE7

NE12

FU1

NE1

FU2 FU3

NE2

NE3

P1

P5

P7

32-4076GRev.A

P15

P14

10A115V

MAIN

P30P33P34P35

SPAREFUSES

10A115V

RTY/

USER POWER

P28

PASS FAIL

NE6 NE5

FU7

NE4

TB2

P25

PHASE

DETECT

FU1 FU2 FU3

NE1

C4 C3 C2 C7 C6 C5 C1

10A230V

COOLANT

TSC COOLANT

FU12 FU11 FU10 FU9

NE11 NE10 NE9 NE8

Power Supply Board; Fuse Locations

5. Using a flat tip screwdriver, turn the fuse(s) counterclockwise to remove and replace the blown fuse(s) with
ones having the same type and rating (½ amp, type AGC, 250V).

CAUTION! When the left fuse is blown, it is still possible to operate the machine,

thereby making an overvoltage situation possible. Verify absolute voltage
to the machine does not exceed 200V (max 260 leg to leg or leg to ground,
or 400V on high voltage machines - max 520V leg to leg or leg to ground).

SERVO DRIVER FUSES (VERT - BRUSH MACHINES ONLY)

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

2. Using a large flat tip screwdriver , loosen the three screws on the cabinet door and open the door enough to
safely work on the electrical panel. Wait until at the red charge light on the servo drive assembly goes out
before beginning any work inside the electrical cabinet.

3. On the Servo Drive Assembly, are three individual fuses on each of the Servo Drive boards as shown below.

4. On each of the Servo Driver boards, the fuses (F1, F2, F3) may be replaced by simply pulling them out by
hand and replacing with fuses of the same type and rating (F1, F2: 20 amp, type ABC, 250V; F3: 10 amp,
type ABC, 250V).

P8

F3

P8

LE1

R2 R15 R11

FUSE

FUSE

FU2

FU1

TB1

P11

P9

P12

P13

P10

P5

F1

FUSE

F2

FUSE

P3

F1

F2

P2

TB2 FU3

P1

P2

P3

F1 & F2

P4

P7

10

Servo Drive Assembly; Fuse Locations

Electrical Service

96-0284 rev A June 2006

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. There are two (2) screws on top of the pendant that need

removing so that the pendant door may pivot open.

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

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 panel on the back of the control panel. Take care to hold the cover

panel in place until all screws have been removed.

3. Disconnect the data cable from the receiver board on the LCD assembly (J3). Disconnect the power cable
and ground wire from the power supply board on the LCD assembly (TB1). Disconnect the cables to the
keyboard from the receiver assembly (P1) and power supply (TB2) on the LCD assembly.

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 fingerprints on the new LCD. Replace by sliding the new assembly onto the four
bolts (two each on top and bottom): eight bolts (four each on top and bottom) for Vertical machines. 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 .

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Electrical Service

11

Receiver Assembly

Keyboard Cables

Power Supply Board

Data Cable

Back of Operator’ s Pendant

Power Supply
Cable

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.

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 of the crank has no effect. When the axis being moved reaches its travel limits, the

handle inputs will be ignored in the direction that would exceed the travel limits. Parameter 57 can be used to

reverse the direction of operation of the handle.

Jog Handle Replacement

1. Turn the machine power off.

2. Remove the screws holding the cover panel on the back of the control panel. Take care to hold the cover

panel in place until all screws have been removed.

3. Unplug the cable leading to the jog handle encoder. Important! The blank pin side of the connector must
face as shown below when reconnecting; otherwise, damage may occur to the machine.

Blank pin goes to this

side of connector

+5V

BLK

Jog Handle Encoder Jog Handle Removal Jog Handle Wiring Diagram

A

RED

GND
WHT

+5V

RED

B

GRN

A

YEL

GND
WHT/
RED

B

BRN

WHT/

YEL

A

B
WHT/
BRN

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.

6. Replacement is reverse of removal. Keep in mind the important notice in Step 3.

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Electrical Service

96-0284 rev A June 2006

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 Parameter 57 contains a
status switch that if set, 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) should become jammed, the control will automatically come to an
alarm state. To correct this, push the Emergency Stop button and remove the cause of the jam. Push the
Reset key to clear any alarms. Push 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 auto-shutdown 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 that it wasn’t disconnected. If lamps don’t turn on, check the GFCI.

LAMP ON/OFF SWITCH

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

SWITCH REPLACEMENT

1. Turn the machine power off. Remove the screws holding the cover panel on the back of the control panel.

T ake care to hold the cover panel 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 switchcounterclock-

wise to loosen. Separate from the front portion and pull out.

4. For replacement, screw the front and rear portions together (reverse of removal) and tighten down the two

small set screws when the switch is properly positioned.

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.

96-0284 rev A June 2006

Electrical Service

13

SPINDLE LOAD METER

The load meter measures the load on the spindle motor as a percentage of the rated continuous power of the

motor. There is a slight delay between a load and the actual reflection of the meter. The eighth A-to-D input also

provides a measure of the spindle load for cutter wear detection. The second page of diagnostic data will

display % of spindle load. The meter should agree with this display within 5%. The spindle drive display #7
should also agree with the load meter within 5%. Note that there are different types of spindle drive that are

used in the control. They are all 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 control panel. 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.

KEYPAD REPLACEMENT

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

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

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

cable through the opening in the control to remove.

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

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.

14

Electrical Service

96-0284 rev A June 2006

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 la-

beled.

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

the screw and standoff loosely , then all other screws and st andoffs, until all are mounted. T ighten 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’.

96-0284 rev A June 2006

Electrical Service

15

SOLENOIDS

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. Turn power off.

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

3. Remove air supply from machine.

4. Disconnect all air lines from the air solenoid assembly. Do not remove fittings, remove lines from fittings.

5. Vert: Disconnect the two leads from the low air pressure sensor.

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

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

the solenoid assembly .

7. Vert: 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”.

8. Unscrew the air solenoid from the air solenoid assembly.

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

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

4. Vert: Reconnect the two leads to the low air preassure sensor.

5. Reconnect the wiring to the plugs on the solenoid bracket.

6. Ensure all air lines are reconnected to their proper fittings.

7. Reconnect air supply to the machine, and check for leaks.

8. Replace the sheet metal.

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96-0284 rev A June 2006

Air Solenoid

Disconnect

all air lines

Disconnect

all air lines

Air solenoid

assembly

Low air pressure

sensor

Assembly

EC

400

Motor Shroud

Air Solenoid

Assembly

EC

Sheet Metal

Tray

Check Valve Switch

Pre-

Charge

TRP Solenoid

To TSC

TSC Solenoid

Inlet

Pressure
Switch

Regulator

Check Valve Switch

TRP
Solenoid

Basic Air SolenoidAssembly

Check
Valve
Switch

Air Solenoid Assembly
With TSC Feature Added

Junction
Elbow

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

SPINDLE LUBE AIR SOLENOID

Removal

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

Pressure Gauge

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-fitting.

96-0284 rev A June 2006

Spindle
Lube
Solenoid

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

Lube Line

Main Air Line

Pressure Switch

Electrical Service

17

Installation

1. Reattach the solenoid assembly at the T-fitting.

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.

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.

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96-0284 rev A June 2006

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

WARNING!WARNING!

WARNING!

WARNING!WARNING!

The electrical panel will have residual voltage, even after power has
been shut off and/or disconnected . Never work inside this cabinet
until the small red Charge light on the servo amplifiers go out. The
servo amplifiers 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.

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

Steps for replacement will only differ in which board may need to be removed

before getting to the necessary board.

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 servo
commands and closing the servo loop around the servo motors.

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

MOCON Board Replacement

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

1. Turn machine power off.

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

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

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

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

all standoffs have been removed.

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

6. 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.

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

96-0284 rev A June 2006

Electrical Service

19

VIDEO/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

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

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, please 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 LED’s are used to diagnose internal processor problems. As the system completes power up testing,

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

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

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 doesn’t come on, there is a

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

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

there is a problem with serial I/O or interrupts. Disconnect anything on the external RS-232 and 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.

PO R 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.

20

Electrical Service

96-0284 rev A June 2006

HA LT 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

Memory Retention Battery

The memory retention battery (3.3V Lithium battery) is soldered into the Processor PCB. It maintains the
contents of CMOS RAM during power off periods. A minimum voltage of 2.5V DC is required for proper opera­tion. Prior to this battery being unusable, an alarm is generated indicating low battery. If the battery is replaced
within 30 days, no data is lost. The battery is not needed when the machine is powered on. Connector J6 on
the Processor PCB can be used to connect an external battery.

T o replace the battery, the 4-pin jumper, attached to a fresh battery , has to be temporarily att ached to J-6
before the old battery is removed. With the jumper in place, un-solder the old battery and remove. Install a new
battery and solder in place, then remove the temporary jumper.

NOTE: Do not attach the jumper after the old battery has been removed or remove the

jumper if a fresh battery has not been installed. This will result in complete

machine memory loss, which cannot be reversed.

Processor Board Replacement

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

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.

Servo Driver Board Replacement (Vertical Machines)

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

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

2. Disconnect all leads to the Servo Driver (Driver) board that you wish to replace. Ensure all cables are

properly labeled for reconnecting later.

NOTE: When replacing any Driver board, it will be necessary to disconnect all leads

on all Driver boards in order to remove or replace the board.

3. Remove the board by first removing the two screws that fasten it to the cabinet. Take care to hold the board

in place until both screws have been removed.

4. Replace the Driver board, attaching it to the cabinet with the two screws previously removed.

5. Reconnect all leads to all boards. Ensure the red and black leads go to the appropriate connections.

96-0284 rev A June 2006

Electrical Service

21

INPUT/OUTPUT ASSEMBLY

The I/O PCB contains a circuit for electronically turning drawbar motor power on and off to prevent any arcing of
the motor relays and increase their life. This includes an adjustable current limit to the tool changer. Potentiom­eter R45 adjusts the current limit to the drawbar motors, and R45 limits current to between 9 and 11 amps.

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 flowing through the grounding connection of the 160V DC buss, a ground fault alarm is

generated and the control will turn off servos and stop.

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

also plug-in types for controlling the drawbar motors.

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

I/O Board Replacement

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

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 first removing the twelve screws that fasten it to the cabinet. Take care to hold the

board in place until all screws have been removed.

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 ant 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. T wo 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 five input connections and will accept a range of voltages from 354V RMS to 488V RMS.

The 230V is used to power the spindle drive, which also develops the 325V DC power for the axis servo amplifi­ers. 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.

High Volt Low Volt

75

76

488-458V 457-429V 428-403V 402-377V 376-354V

HIGH VOLT

74

LOW VOLT

----------------

260-244V 243-227V 226-211V 210-195V

74

75

76

22

Polyphase Bank Transformer

Electrical Service

96-0284 rev A June 2006

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
first three terminals of TB10.

Circuit breaker CB1 is used to protect the spindle drive and to shut off all power to the control. The locking On/
Off handle on the outside of the control cabinet shuts this breaker off when it is unlocked. A trip of this breaker

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

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 of f 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.

Operator's Work Light

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

POWER SUPPLY ASSEMBLY

All power to the control passes through the power supply assembly . It is located on the upper right corner of
the control cabinet.

Power PCB (PSUP)

The low voltage power distribution and high voltage fuses and circuit breakers are mounted on a circuit board

called the Power PCB.

96-0284 rev A June 2006

Electrical Service

23

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 servo transformers and, if tripped, will

turn off the servo motors and air solenoids. CB2 could be blown by a severe servo overload.

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

motor or a short in the wiring to the motor.

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 output for the user.
GFCI Single-phase 115V 10A protected ground fault interrupt circuit.

Power PCB (PSUP) Replacement

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

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

2. Disconnect all leads to the Power PCB (PSUP) and move 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 you need to replace 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 the Power board at their proper location. Always refer to release notes for any

additional information.

LOW VOLTAGE POWER SUPPLY

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

For Lathes, a servo power supply is mounted on top of the Low Voltage Power Supply supply. It furnishes +12V
and -12V power to the servo amplifiers. This supply is powered from the 335V DC bus from the sub-spindle

vector drive.

Low Voltage Power Supply (LVPS) Replacement

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

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 have been disconnected, unscrew the two standoffs at the bottom of the board. Unscrew
the remaining two screws at the top of the LVPS board, taking care to hold the board in place until all

screws have been removed.

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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Electrical Service

96-0284 rev A June 2006

RS-232 SERIAL INTERFACE

There are two connectors used for the RS-232 interface. The RS-232 connector on the back of most PCs is a
male DB-25, 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 RS­232 connector on most PC's 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 first controller's
down line connector goes to the second controller's up line connector, etc.

The RS-232 interface sends and receives seven dat a bits, even p arity , and two stop bit s. 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 OR’ed 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 defined 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 eithe internal or external causes.

1. Unplug the cable from Port #1 of the Control Panel.

2. Plug the cable tester into Port #1 of the Control Panel.

3. Press Power Off if the machine is turned on.

4. Press Power On.

5. Press List Prog.

6. Press Param Dgnos twice.

7. Press Send RS232.

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25

8. If the internal serial port is OK, the lower left-hand part of the screen will display Serial Passed. (This
means that the system is OK to the output of the control panel. 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
you have a problem inside the control panel, or that the test connector is unplugged or missing.)

PLUG TESTER

BACK VIEW

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

Pins 2 & 3
Pins 14 & 16

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

RS-232 PCB Replacement

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

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

NOTE: It is suggested to make use of a step ladder high enough to allow you to work

from the top of the electrical cabinet. It is necessary, when replacing the RS­232 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 being the upper connection.

SERIAL
KEYBOARD
INTERFACE

P1

* Serial interface replaces cable 700 with cable 700B.

PCB

700B

VIDEO &
KEYBOARD
PCB

MICRO
PROCESSOR
PCB

RS-232 Wiring Diagram (with Serial Keyboar d )

P850A

J13

J3

P850

850

RS 232/ 32-4090 J1

PORT 1
Serial User’s Port

PORT 2
Aux Axis Port

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 discon-

nect the cable.

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96-0284 rev A June 2006

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

5. Replace the Serial Keyboard Interface (SKBIF) board, using the four screws previously removed, starting at

the top right. Att ach the screw and standof f loosely, then all other screws and standoffs, until all are
mounted. Tighten down completely .

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

96-0284 rev A June 2006

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27

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:

M21

M-FIN Discrete
Input 1009

CNC is:

Running Waiting

for M-fin

.05 ms
delay

Waiting for

end M-fin

Running

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

NOTE: See the 8M option section for more details.

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 specific machine Inputs and Outputs.

3

M-Code
Output Relay
Normally Open

4

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

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

terminal labeling.

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96-0284 rev A June 2006

WARNING!WARNING!

WARNING!

WARNING!WARNING!

Power circuits and inductive loads must have snubber protection.

I/O PCB Relays

CAUTION! If a screw terminal is already in use, do not connect anything else to it.

96-0284 rev A June 2006

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29

LIMIT SWITCHES

X, Y, Z Travel Limit Switches

The machine zero position is defined by a limit switch for each of the X, Y, and Z axes. After the search for

machine zero has been completed, these switches are used to limit travel in the positive direction. Travel in the
negative direction 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. All limit switches are wired through connector P5 on the side of the control cabinet. P5 also contains the

wiring to the lubrication pump and an alternate connection to the door open switches.

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.

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 Limit Switches?

If the machine is operated without connector P5, a Low Lube and Door Open alarm will be generated. In

addition, Home search will not stop at the limit switch and will instead run 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 only 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, you will not be able 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 that is 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

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

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

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96-0284 rev A June 2006

Tool Changer Geneva Wheel Position Mark

The turret rotation mechanism has a switch mounted so that it is activated for about 30o of travel of the Geneva

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

normally closed. The diagnostic display will show this status of this input switch as “TC MRK”. A “1” indicates
the Geneva wheel is in position.

Tool Changer Shuttle In/Out Switches

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.

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 extremely difficult to reach. Removal of this
assembly is necessary to replace these switches. See Mechanical Service,
for Spindle Motor and Transmission removal.

96-0284 rev A June 2006

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31

DIAGNOSTIC DATA

The Alarm Msgs display is the most important source of diagnostic data. At any time after the machine
completes its power-up sequence, it will either perform a requested function or stop with an alarm. Refer to the

alarms list 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 flag 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 will select the diagnostics
display page. The Page Up and Page Down keys are then used to select one of two different displays. These
are for diagnostic purposes only and the user will not normally need them. The diagnostic data consists of 32
discrete input signals, 32 discrete output relays and several internal control signals. Each can have the value of

0 or 1. In addition, there are up to three analog data displays and an optional spindle rpm display . Their number
and functions are:

DISCRETE 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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Electrical Service

96-0284 rev A June 2006

Discrete Outputs
# Name # Name

1100 Hyd Pump Enable 1116 Move Spigot CW
1101 Spare 1117 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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33

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

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

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Electrical Service

96-0284 rev A June 2006

# 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-fin
1113 Spindle Low Gear 1133 Probe

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

96-0284 rev A June 2006

Electrical Service

35

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.

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)

36

Electrical Service

96-0284 rev A June 2006

PCBS, CABLE LOCATIONS, AND DIAGRAMS

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 trouble shooting.

Red Wire

1
2
3

1
2
3

4
5

6

1
2
3
4

1
2
3

4
5

6

6
7

Friction Lock

2
4

6
8

10

12

14
16

1
3
5
7
9
11
13
15
17
19
21
23
25
27
29
31
33

1
2
3
4
5

1
2
3

4
5

6
7
8

Red Wire

1
3
5
7
9
11
13
15

Ribbon Cables

2
4

6
8

10

12

14
16
18
20
22
24
26
28
30
32
34

1
2
3

4
5
6

1
2
3

Mini Fit

1
2

3

3

4

4

5
6
7
8

1
2

1
2
3
4

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

Pin 5

Pin 1

Connection Example

96-0284 rev A June 2006

Electrical Service

37

MICROPROCESSOR PCB

U1 U2

U7

C6

1MB 16MB

U3

U11

J6

512K

R52

R53

S2

9.6K

BAUD

38.4K

U8

C5

128K

RUN

BT1

U24

Y1

850A 850

C9

D1
D2
D3
D4
D5
D6
D7
D8

U15

U7

J4J5

C39

C37

C38

C40

FLASHMEMORY

U1 U2 U3

J6

U8

BT1

S2

9.6K

38.4K
RUN

BT2

BAUD

C7

D1

RUN

D2

PGM

D3

CRT

D4

MSG

D5

SIO

D6

POR

D7

HALT

D8

+5V

Y1

J4

850

U22

J5

850A

C46

C43

C45

C47

C82

U38

U41

U37

C76

J1 J2

ADDRESS BUS DATABUS

64MB

DRAM

COLDFIRE 266 MHZ

PROCESSOR CHIP

(Co-processor built-in)

U39

3.3V DC

BATTERY

J7

U16

U17

LINE 1:

LINE 2:

LINE 3:

SUBASSY

U53

C75

C74

J3

U58

C92

J1 J2

BATTERY BACKED UP

RAM 1MB OR 16MB

ADDRESSBUS

U59

FLASH

RAM

J4

J5

D1
D2
D3
D4

STATUS

D5
D6
D7
D8

INTERFACE DATA

850

850A

DATABUS

LEDS

KEYBOARD

AUX PORT

U43

LINE 1:

LINE 2:

LINE 3:

U60

PAL4.9x

C91

C94

J3

38

J1 J2

Electrical Service

DATA BUSADDRESS BUS

J3

J3

LOW VOLTAGE

#860 CABLE

96-0284 rev A June 2006

ÖÖ

PLUG # CABLE # SIGNAL NAME

Ö TO

ÖÖ

Ö LOCATION PLUG #

ÖÖ

ÖÖ

J1 ADDRESS ADDRESS BUSS VIDEO-MOCON-MOTIF ____
J2 DATA DATA BUSS VIDEO-MOCON-MOTIF ____
J3 860 LOW VOLTAGE <FROM>PSUP PCB ____
J4 PORT 1 850 SERIAL PORT #1 KEYBOARD INT. ____
J5 PORT 2 850A SERIAL PORT #2 AUX PORT AUX SERIAL PORT ____
J6 AUX BATTERY INPUT

SERVO SYSTEM BLOCK DIAGRAM

LOW
VOLTAGE
POWER SUPPLY

LV HV

CURRENT
COMMAND

ENCODER

CURRENT
COMMAND

ENCODER

+/- 12V DC

VECTOR
DRIVE/HIGH
VOLTAGE
POWER SUPPLY

320V DC

BRUSHLESS
SERVOAMP

BRUSHLESS
SERVOAMP

MTR PWR

MTR
PWR

BRUSH

CONVERTER

BOX

AXIS

CABLE

MTR PWR

ENCODER

BRUSHLESS
AXIS
MOTOR/
ENCODER

TYPICAL

BRUSH
AXIS
MOTOR/
ENCODER
(Opt)

MOCON BOARD

96-0284 rev A June 2006

C-AXIS COMMAND

C-AXIS ENCODER

SPINDLE ENCODER

VECTOR DRIVE
OR
LARGE AMP

Electrical Service

DELTA-

WYE
(Opt)

TYPICAL

SPINDLE
MOTOR

MOTOR/
ENCODER
(Opt)

SPINDLE
ENCODER

39

BRUSHLESS SERVO AMPLIFIER (P/N 93-5550C)

CURRENT COMMAND

LOW VOLTAGE POWER

NOTE: Newer amplifiers do not have a blown fuse indicator.

SERVO DRIVE

( FROM MOCON)

(INPUT)

POWER TO

SERVO MOTOR

335VDC

(FROM HAAS

VECTOR DRIVE)

BLOWN FUSE

INDICATOR

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

LVPS PLUG 570 LOW VOLTAGE L. V. POWER SUPPLY ——­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

LVPS PLUG 580 LOW VOLTAGE L. V. POWER SUPPLY ——­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

LVPS PLUG 590 LOW VOLTAGE L. V. POWER SUPPLY ——­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

LVPS PLUG 600 LOW VOLTAGE L. V. POWER SUPPLY ——­TB A, B, C ——- MOTOR DRIVE A SERVO MOTOR ——­SERVO PLUG 640 A DRIVE SIGNAL MOCON PCB P5
TB -HV +HV ——- 335VDC SPINDLE DRIVE ——-

40

Electrical Service

96-0284 rev A June 2006

SYSTEM BLOCK DIAGRAM - HIGH/LOW VOLTAGE

INPUT VOLTAGE

195-260V AC

(353-480V AC)

230V AC

MAIN
POWER
DISTRIBUTION

12V DC

115VAC

195-260V AC

(353-480V AC)

INPUT

115VAC

230V AC

MAIN
TRANSFORMER

OPERATOR
PENDANT

115VAC

115VAC

230V AC

TSC
OPTION
(Vert)

M CODE
RELAY
BOARD
(Opt)

MICRO
PROCESSOR
(CNC UNIT)

DISCRETE
INPUTS
AND
OUTPUTS

DC
MTR DRV
BOARD
(Opt)

LOW VOLTAGE

CMDS

STATUS

230V AC

COOLANT PUMP &
CHIP CONVEYOR

CMDS

FAULTS

POSITION DATA

HOME
SWITCH
(Vert &
Lathe)

SENSORS

CMDS

VIDEO, KEYBOARD, AND JOG

(FLOPPY DRIVE & RJH)

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

PWR

SPINDLE COMMANDS

SPINDLE ENCODER

SERVO MOTORS

335V DC

(325V DC

Horiz)

HAAS
VECTOR DRIVE

EXCESS PWR

CONTACTORSCOIL

REGEN
ASSY

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

230V AC

SP

PWR

SPINDLE MOTOR

CHIP CNVYR
BOARD

(Opt)

CHIP CNVYR
MTRS

(Opt)

PWR

PWR

WYE-DELTA
CONTACTORS

(Opt)

96-0284 rev A June 2006

Electrical Service

41

POWER PCB

P5

P11

P3
P7
P6
P2

P12

P35 P34 P8 P33 P28

MCD 1

MCD 2

LVINPUT

GND

SW DOOR FAN

MONITOR

PROBE PS

DELTA-WYE

SERVO FAN

LOW VOLTPS

90A

90A

90A

90A

90A

90C

94/N

AC GROUND

90C

P13

GND

+12V

P1

96

95

+12V

LE2

+12V

115VINPUT

115VSPARES

P14

GND

GND

+5V

+5V

-12V

+12V

Z3

TS1

90C90C 90C

Z4

LE3

-12V

MAIN 115V XFRMR

ON ON ON ON ON

10A 115V

MAIN

XFRMR

CB2

90C 90C

P15 P16

P27

PHASE DETECT

(FOR 3 PHASE ONLY)

MOCON 2

-12V

P17

MOTIF

GND

GND

+5V

+12V

Z1

+5V

P18

AMPS

GND

+12V

-12V

GFI

7A 115V

GFI

CB6 CB3 CB5

3PH 115VTO IOPCB

P19

IOPCB

GND

GND

+5V

GND

+12V

92A

GND

+12V

GND

+5V

COOLANT PUMP

10A 230V

COOLANT PUMP

WORKLIGHT

GFI/

+5V

GND

+12V

P30

LE1

-12V

90

P36

FAILPASS

NE6

NE5

TSC COOLANT PUMP

930

P20

P25

71 73

F1

NE1

10A 230V

TSC COOLANT PUMP

POWER SUPPLY ASSY

COOLANT/TSC

1/2A 250V

NE3

PSUP-K

P24 P4

SEC

PRI

TO T5

F3

230V IN

P9

CHIP CONVEYOR

5A 230V

CHIP CONVEYOR

CB4

160

CHIPC 230V

P21

170

740

P10

P23

AUTO OFF/CONTACTOR

ON/OFF

P22

PLUG # CABLE # SIGNAL NAME Ö TO Ö LOCATION PLUG#

P1 94-96 115 INPUT CNC Unit Fan
P2 90C 115VAC LVPS
P3 90A 115VAC Probe PS
P4
P5 90B 115VAC Switch Door Fan
P6 90A 115VAC Servo Fan
P7 90A 115VAC Delta-Wye
P8 +12/-12/+5 VDC In From LVPS
P9 70 +12/-12/+5 VDC In
P10 90B 115VAC Door Fan
P11 90A 115VAC Monitor
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 Amps
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
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

42

Electrical Service

96-0284 rev A June 2006

OFFICE MILL POWER SUPPLY

P8

C10

DZ1

LE1

HIGH

VOLTAGE

PRESENT

BL 320V PS

R21

C8

C13

DZ3

CR3

Q2

U2

CR2

VR1

C7

C9

P7

230VAC

P1

CR7

R23

320VDC

P2

K1

CR12

U3

CR10

TP1

320VRTN

C19

TP2

LE2

FAULT

JP1

C11

CR5

CR4

T1

U4

C14

C12

DZ4

CR6

C31

R5

CR9

U9

C28

U8

U7

VOLTMON

P6

FAULT

P4

U6

U5

970

ISP

Q1

R14

R7

CR1

REGEN

CR18

DZ2

R1

P5

C3

P5

860A+12V

C1

Q3

U1

P3

TP3

12VRTN

PLUG # CABLE # LOCATION PLUG#

P1 32-5827A Ofice 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 A June 2006

Electrical Service

43

I/O PCB REV. U

P1
P2

P3
P4

P5
P6

P7
P8

P10
P11
P12
P13

P14
P15

P16
P17
P18
P19

P20
P21

P22

P23
P24

P25
P26

P27
P28

P71

P29
P30

TB2

NSK

P75

C59

*

M26

AIRBLAST

BEEPER

PALCW

PALCCW

AIRDOOR

OILEXTEND

260

PALRDY

860A

P77

K2

P79

P80

T1

CR10

K18

P35A

200

SPIGOT

P35P34P36

AXISBRAKE

P60

PROBE

P78

+25V

CR34

CR5

AGND

CR11

K17

CHIPCEN/REV

P57

K1

C69

TP4

Z9

R51

CR25

140A

P37

C9

Z6

CHIPC REV

M21

CR12

P63

P74
P66

P67

P69

P76

DOORLOK

Q21

230

5'THBRAKE

P31

M22

K33

M21

P61

540

FROMMOCON

Q33

Q32

550

M26

M27

P68

220

1160

HTCSHUT

PRE-CHG

5'THBRK

K34

M22

CR13

310

TSCPURGE

SPIGCCW

PALRDY

SPIGCW

Q20

250

HTCSHUT

P32

TB1

M23

K35

M23

CR14

P62

J9

(INPUTMUX

DISABLE)

SPARE

AIRBLAST

BEEPER

PALCW/CCW

AIRDOOR

OILSQUIRT

GREEN

RED

P33

Q23

C66

TSCPURGE

K36

M24

CR15

540A

TOMCD RLY

P70

530

Q18

270

NC COM

M24

CR33

NO

M25

K37

M25

CR9

Z10

CR1

U73

L1

Q44

Q30

Q31

Q28

Q29

Q27

Q46

Q7

Q17

280

BEACON

140B

CHIPCOC

820B

TCS TATSH IN/OUT

820

P2A

LOTSC

P72

900

ESTOP-D/E

770C/D

E-STOP-A/B/C

770

P81

770A

770B

P9

DOOR-A

1050

1050A

DOOR-B

M-FIN

100

970

LOAIR/OIL LO LUBOVERV

950

960

OVERH

830

SPHD STAT SPARE5 SPARE1

890

780

410

790

REMUNCL A/BSPARE2

190

190A

240

SKIPSPARE3

1070

420

SPARE6SPARE4

440

450

SPARE8SPARE7

460

P82

REM

470

SPARE9

SQUIRT

UNCL

LOOIL

190

A/B

SPARE10

480

PHLS

Q22

CEDOOR LOCK-A/B

1040/A

R3

CR24 CR23 CR21 CR22 CR20

K9

K10

CR2 CR3 CR4 CR6

C70

CR35

I/OPCB-U 3-AUGUST-05

IOPCB - U CCA

CHIPCOC ADJUST

R122

Z8

R127

140

CHIPCONVEYOR

P38

P58

CR7

K38

P64

P65

CHIPCEN

CR16

P59

APCMTR

TCMOTORS

810

Q39

R4

Q40

R145

D10

R66

CR8

R52

R146

R310

REMVTO ISOL 115

J2

CR19 CR17 CR18

K11

K12

R311

R7

R44

520

TCIN
TCOUT
TCCW
TCCCW
HIGHGEAR
LOWGEAR
UNCLAMP
DELTA-WYE

SERVOBRK
PALUP
SPARE1
SPARE2

510

4THBRK
COOLANT
AUTOOFF
SPINFAN

TSC COOL

MILL
LATHE

J1

C15

Q3

K32

C14

Q4

160

230VAC3PH

R42

R5

D1

D18

D17

D21

D20

C46

Q19

P54

880B

Q13

Q14

P53

Q15

P53A

Q16

Q5

Q41

P47

Q42

Q2

Q10

P50

Q11

P48

Q45

Q36

Q6

Q43

Q8
Q9

Q12

Q1

D19

115V3PH

P56

90

D22

GBI/F

SPHD SOLENOIDS

P55

880C

350

880A

DELTA-WYE

SPARE

P52

710

PALUP

430

P51

SERVOBRK-A/B

350A

P49

4'THBRAKE

P46

390

TSCENABLE

TSCO/T

130

120

P73

COOLO/T

170

P42

AUTOOFF

K7

TSCCOOL

940A

P45

COOL/TSC230 IN

930

P44

COOLANT

940

P43

SPINFAN

300A

P41

LUBOIL PUMP

300

P40

P39

PLUG # CABLE # Ö TO Ö LOCATION PLUG #

P1 140B Chip Conveyor VB1/Gantry
P2 820B TC in/SMTC Pkt down
P2 (Lathe) 820B 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

44

Electrical Service

96-0284 rev A June 2006

PLUG # CABLE # Ö TO Ö 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/Low phase
P19 (Lathe) 190 Chuck Unclamp Foot Sw/Low phase
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: Cvr Opn/Slider Rtrct/Grnd Fit
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 Beacon
P37 140A Chip Conv Enable

96-0284 rev A June 2006

Electrical Service

45

PLUG # CABLE # Ö TO Ö LOCATION PLUG #

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 Not Used
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
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

46

Electrical Service

96-0284 rev A June 2006

PLUG # CABLE # Ö TO Ö 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
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

DISCRETE INPUTS

+12V

Typical Discrete Input Circuit

(C) = Switch Normally Closed; (O) = Switch Normally Open

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

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

96-0284 rev A June 2006

Electrical Service

47

1008 1050 P8/9 (O) Door Open (O) Door Open Door Open
1009 100 P10 M-FIN M-FIN M-FIN

GR Plasma Confirm

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 (O) *TS Foot Sw

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

GR Air Curtain APC
CE 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 LO Phase LO Phase

EC-400 Spare

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

BF Load Bar (C) Old MD Pal Up

(C) New MD Pal Unclamp

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

SMTC Arm In
EC-400 Pallet Clamped

48

Electrical Service

96-0284 rev A June 2006

MACRO CABLE HORIZONTAL VERTICAL LATHE

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

SMTC Arm Out

EC-400 Pallet Unclamped

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

EC-400 Pallet Clamp Error

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

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

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

Shuttle Mark
EC-400 SMTC Motor Stop

1043 470 P27 Mori Swing Mag/SMTC SMTC Origin

Slide at Chain
EC-400 SMTC Origin

1044 470 P27 Mori Cage Door Open/ SMTC 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

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

1048 480 P28 EC-400 8-pos TC Mark APC Pal Clamped 8-pos TC Mark
1049 480 P28 EC-400 8-pos TC Home APC Pal In Position 8-pos TC Home

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

96-0284 rev A June 2006

Electrical Service

49

DISCRETE OUTPUTS

MOCON PCB

0VDC

+12VDC

LE 1

Typical Discrete Output Circuit

115/230V

V

H

N

V

SOLENOID

I/O PCB

MACRO CABLE HORIZONTAL VERTICAL LATHE

1100 350 P47/49 Servo Pwr/Brk Servo Pwr/Brk Hyd Pump En

1101 430 P51/75 TC Door Open APC Pal Clamp/Old MD APL light/BF extd push

pal up/new MD palunclamp/
GR air curtain/NSK spin fwd

1102 710 P52/75 PC Pallet Up APC#1 Pallet Ready 1/ APL Grip 1

NSK spin rev

K

1103 710 P52 PC Pallet Down APC#1 Pallet Ready 2 APL Grip 2

1104 390 P46 4th Axis Platter Up 4th Axis Brake Spin Brk

1105 940 P43 Coolant Coolant Coolant

1106 170 P42 Auto Off Auto Off Auto Off

1107 300 P40/41 Sp Fan/Oil pump/luber Sp Fan/Oil pump/luber Sp Fan/Oil pump/luber

1108 810 P58/59 SMTC ATC FWD/tool TC In/SMTC ATC FWD/ APL Rotator CW/BF load Q/

xfer fwd APC Chn Drv Fwd 8-pos TC rotate

1109 810 P58/59 SMTC ATC REV/tool TC Out/SMTC ATC REV/ APL Rotator CCW/BF load

xfer fwd APC Chn Drv Rev bar/8-pos TC rotate

1110 810 P59 SMTC CRSL CW TC CW/SMTC CRSL CW Auto door mtr open

1111 810 P59 SMTC CRSL CCW TC CCW/SMTC CRSL CCW Auto door mtr close

1112 880A P54/55 High Gear High Gear High Gear

1113 880A P54/55 Low Gear Low Gear Low Gear

1114 880A P55 Tool Unclamp Tool Unclamp Chuck Unclamp

1115 880A P53/53A/ Delta-Wye switch Delta-Wye switch/laser Delta-Wye switch

55 Hi press assist

1116 200 P35 Spigot CW Spigot CW TL TC CW

1117 200 P35 Spigot CCW Spigot CCW TL TC CCW

50

Electrical Service

96-0284 rev A June 2006

MACRO CABLE HORIZONTAL VERTICAL LATHE

1118 260 P34 Pallet Ready Light APC pal ready

1119 270 P33 TSC Purge TSC Purge T/S rapid/OM live tool #2

1120 880A P55 Precharge Precharge/laser low TT Out/TL TC up

press assist

1121 250 P32 PP pallet lift VR Shut In/APC door open/ T/S Rev/OM live tool #3

old MD niagra clnt on

1122 230 P31 5th Axis Brake 5th Axis Brake T/S Fwd/OM live tool #1

1123 1040 P29/30 Door Interlock CE Door Lock CE Door Lock

1124 310 P68 PC pallet clamp APC#2 Door open Auto door clutch

1125 310 P68 PC Air Blast/flood DES vac enable/GR Parts Catcher

coolant plasma head down

1126 220 P69 SMTC Pkt U/D Sol VR shut out/VB clamshell/ C-Axis engage

SMTC Pkt U/D Sol/laser

vac enable

1127 940A P45 TSC Clnt TSC Clnt HP coolant

1128 280 P36 Green beacon Green beacon Green beacon

1129 280 P36 Red beacon Red beacon Red beacon

1130 140 P37/38 ChipC En ChipC En ChipC En

1131 140 P37/38 ChipC Rev ChipC Rev ChipC Rev

1132 M21 TB1 M-Fin/shower coolant M-Fin (GR plasma start) M-Fin

1133 M22 TB1/P77 Probe Probe/laser aim beam on Probe

1134 M23 TB1/P77 Probe laser shut open/spin spin probe enable

probe enable

1135 M24 TB1 flood coolant probe arm up

1136 M25 TB2/P76 oil squirter oil squirter probe arm down/oil squirter

1137 810A P58/74 APC Chn Drv Pwr En 8-pos TC rotate

1138 M27 P66 Air Jet Blast Gantry oil/Air Blast Air Blast/ML BF push

1139 M28 P67 PC Beeper APC Beeper, airblast/ Sub spin chuck

old EC300 tool door/
new MD airblast

96-0284 rev A June 2006

Electrical Service

51

SERIAL KEYBOARD INTERFACE PCB WITH HANDLE JOG

J2

C50

U9

C49

P5

SPEAKER

C48

J12
GND

SUPPLY

SPARE 1

J4

SPARE 2

J6

P1

850 RS-232

RJH

PAL
READY

D1

JH

B
B

U4

U1

RP9

RP5

U10

S1

U2 U3

RP2

C25

S
S

RP8RP7

U11

Y1

U5U15 U14

P6A

J11

J9

J10

RP6

OP SWTC

U12

D2
D3

D4
D5

D6

KEYBOARD

U7

U6

AUX FRONT
PANEL

P6

U8

P8

RP4

PAL 1

PAL 2

RP3

RP1

J7

C54

P7

U13

SPARE

J14

METER

JOG ENCODER

P2

KEYPAD

R2

P4

J3

LINE 3:

LINE 2:

LINE 1:

P3

START/HOLD

PLUG# CABLE# Ö TO Ö LOCATION PLUG#

P1 850 RS-232 P1
P2 —- KEYPAD —­P3 700A CYCLE START/HOLD SWITCHES —­P4 720 LOAD METER P16
P5 33-0705A BEEPER —­P6 33-5751E AUX FRONT PANEL/RMT JOG P1
P6A —- CYCLE START/FEED HOLD —­P7 —- PAL 1 —­P8 —- PAL 2 —­J1 —- JOG HANDLE —­J2 750C REMOTE JOG HANDLE P1
J3 750 REMOTE JOG HANDLE P18
J4 850 RS-232 —­J6 —- SPARE —­J7 —- EXTERNAL KEYBOARD —­J9 33-8150C TOOL CHANGER —­J10 33-6039A OP. SW. —­J11 32-6660B/6667B PALLET READY/AUX FRNT PNL —­J12 33-8260C +12V SUPPLY P1
J14 —- SPARE —-

52

Electrical Service

96-0284 rev A June 2006

VIDEO & KEYBOARD PCB W/FLOPPY DRIVE

RS-232

PORT #1

RS-232

PORT #2

ETHERNET

TO

PROC.

J5

USB CABLE

TO PENDANT

J12

J8

J10

J11

LINE 3:

J4

RP1

FLOPPY

SPARE

LINE 1:

LINE 2:

U5

J3

FLOPPY

ICOP PCB

U18

U23

DOC

Z1

U19

U29

J1

ADDRESS

BATTERY

B10

RP4

RP4

U24

USB

CABLE

U21

J5

J2

U25

(1)

(33-0211B)

HARD

DRIVE

DATA

J13

+5V

D3

J14

J7

J2

U30
U31
U32

C34C35

P1

ÖÖ

PLUG # CABLE # SIGNAL NAME

ÖÖ

ÖTO

Ö LOCATION PLUG #

ÖÖ

ÖÖ

P1 860 LOW VOLTAGE POWER SUPPLY PCB ——
J2 ____ VIDEO SIGNAL LCD ____
J4 ____ ADDRESS BUSS MICRO PROC.PCB ____
J5 ____ DATA BUSS MOTIF PCB ____
J10 ____ FLOPPY DR. POWER FLOPPY DRIVE ____
J11 ____ SPARE N/A N/A
J12 ____ FLOPPY DR. SIGNAL FLOPPY DRIVE ____
J13 850 SERIAL DATA N/A J1

96-0284 rev A June 2006

Electrical Service

53

MOCON PCB

P24

P10

P34

P26

P27 P28

P11

P13

P18

P20

P6

P7

P8

P9

P21P17 P22

P12

P14

P16

P33

P32

P5

P4

P35

P3

P30

P31

P19

JU2

INSTALLJUMPER
FOR MOCON 2

U43

P2

P15

P1

PLUG # CABLE # SIGNAL NAME Ö TO Ö 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 ——-

54

Electrical Service

96-0284 rev A June 2006

PLUG # CABLE # SIGNAL NAME Ö TO Ö 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 ——-

(BRUSHLESS TOOL CHANGER)
P10 550 MOTIF INPUTS/I/O OUTPUTS I/O PCB P4
P11 510 I/O RELAYS 1-8I/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 980 VOLTAGE MONITOR N/A N/A
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-AXIS ENCODER INPUT SPINDLE MOTOR (lathe)
P33 640C VCTR DR CUR. CMD. VECTOR DRIVE J3
P34 SPARE
P35 PWM OUTPUT (LASER)

RS-232 PORT #1 PCB

GND

P3

PIN 1

P1

34-4090

P2

PLUG # CABLE # Ö TO Ö LOCATION PLUG #

P1 850 CABINET CONNECTION
P2 850A VIDEO & KEYBOARD J13
P3 850A PC104 OPTION J9

96-0284 rev A June 2006

Electrical Service

55

WYE-DELTA SWITCH ASSEMBLIES

TO K5 AUX

TO

SPINDLE

MOTOR

K4

TO K5 COIL

650A

K5

650B

WYE

TO K5 COIL

TO K4 COIL

TO I/O PCB, P12

COM

TO I/O PCB, P58

DELTA

TO K4 COIL

TO HAAS VECTOR DRIVE

56

TO

SPINDLE

MOTOR

650A

1

2

CA7

-37

A2

L3

5

L2

21

NC

32

1

A1

3L1

CA7

A1

L1

3

A2

L2

5

L3

21

NC

32

DELTA WYE

-37

22

NC

31

4

T1

T2

T3

6

2

4

T1

6

T2

Electrical Service

22

NC

31

T3

650B

TO HAAS

VECTOR DRIVE

96-0284 rev A June 2006

M CODE RELAY BOARD

M28

NO COM NC NO COM NC

121110987654321 121110987654321

K8

LED8

P3

OUTPUT

U7

U2 U4 U1

U3

LED9

U6 U5

32-3085B

M CODE RELAY BOARD

U10

JP4 JP8
JP3 JP7
JP2 JP6
JP1 JP5

U11

12 VOLTDC

540/P6

OUTPUT

U9

P2

M21M25 M22M26 M23M27 M24

K1

LED1

540/P1

INPUT

Addressing Jumpers

PLUG # CABLE # SIGNAL NAME Ö TO Ö LOCATION PLUG #

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

96-0284 rev A June 2006

Electrical Service

57

HYDRAULIC PCB

TB3 P4 P3

K5

OFF

T1

K4

C1

K1K2

K6

P5

CB1

K3

TB2

NE1

P9

FU1

P1P2 P6

PLUG # CABLE # Ö TO Ö 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)

TSC MOTOR DRIVE/HIGH PRESSURE COOLANT PCB

OVR TMP

C3

R9

C1

R10

P3

C4

LE1

U3

R6

R7

R2

R5

R8

P2

MOTOR EN

R11

R1

U2

U1

TSC MTR DRV CCA

LINE 1:

P4 P1

78

79

77

230V AC IN

OFF

LINE 2:

LINE 3:

R4 Q3

HS2

HS3

230V AC

MTR OUTPUT

R3

Q2

CB1

HS1

Q1

C2

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

58

Electrical Service

96-0284 rev A June 2006

HAAS VECTOR DRIVE UNIT

TO I/O PCB P18

Over Voltage

Power to

Servo Amps

DC Bus

+

-

E

S

R

T

230 VAC

TO MOCON

P17

78 79

(Horiz)

C 640C

Haas Vector Drive

J3

J1

1234567891011

+ - ABC ABC

R

+ - RSTGGUVW

PCBA

HOPT-A

Delta-Wye

Contactors

(Horiz & Vert)

U

X

VW ZY

TO I/O PCB

P58 & P12

REGEN

RESISTOR

X
Y

Z

SPINDLE

MOTOR

M

UVW

G

RENISHAW TOOL PRESETTER (LATHE)

N/C C N/ON/C C N/O

P22

WORK
PROBE

RY BRY B

Y
W
B

DG

LG

WH

M22M22

I/O

BR

YEL

GREY

B

LTP

R

OMM 1

OMM 2

CONTROL O/P

POWER IN

N/C C N/O

1 SIGNAL Y
2 SIGNAL GY
3 START W
4 0V GN
5 10V BN
6 0V GN
7 SIGNAL Y
8 SIGNAL GY

9 START W

10

ERROR

11
12

LOW
BATT

13
14

SEE
NOTE 2

15
16 +24V
17 0V
18 GND/SCN

M23

RENISHAW

BOX

O/P

CONTROL

JUMPER

MC STARTIN 21 & 22

19 SIG.STRENGTH
20 AUDIO EXT.
21 +

M/C START
1ms - 150 ms

22 ­23 +

SEE
NOTE 2

24 -

M52 LTPON
M62 LTPOFF
M53 PROBE ON
M63 PROBEOFF

NOTES:

1. SW2 SHOULD BE SET BALOW

AUTO START

1

ERROR

4

D

ERROR

2. SW3 SHOULD BE SET BELOW

BUZZER OFF

22334

1

AABBCCD

BUZZER ON

3. OTHER SWITCH CONFIGURATIONS
AS DEFINED IN USER HANDBOOK

O/P O/P

14 & 15 23 & 24

STATUS STATUS

N/O N/O

96-0284 rev A June 2006

Electrical Service

59

OPERATOR PENDANT

POWER ON

PENDANT SUPPORT ARM

TO POWER SUPPLYPCB

TO VIDEO BOARD

750B
TO MOCON

TO 850 CPU BOARD

16 PIN RIBBON CABLE

700A

B
E

705

E

12V DC

P
E
R

720

TO MOCON P16

770

TO I/O BOARD.. INPUT #8

210A DATAFROM
J12 VIDEO BOARD

TO WORK LIGHT ASSY

FROM GFI

115VAC

LIGHT

SWITCH

(H)

VIDEO
DIFF REC.

750

BEEPER

P5

FLOPPY

DRIVE

J2

12V DC

P1

P6A

J12

KEYBOARD
INTERFACE

740

760

750C

J1

REMOTE

JOG HANDLE

BOARD

BOARD

START/

AUX

PWR

P6

+12V DC

POWER
SUPPLY

FEED
HOLD

FPANEL

LCD

750

J10

LOAD METER

ADJUST

METER

P3 P4

+5

J3

CYCLE START

FEED HOLD

EMERGENCY

STOP

POWER OFF

REMOTE JOG HANDLE

(OPTION)

CYCLE
START

HAAS

P2

24 PIN FLEX CABLE

720

++-

FEED

HOLD

MEMORY KEY LOCK (OPTION)

LOAD METER

USER'S AUX F-PANEL

PALLETROTATE

PARTREADY

EMERGENCY

STOP

2ND HOME

(OPTION)

KEYPAD

JOG HANDLE

HAAS

+5VDC
0 VDC
A ENC
B ENC

FRONT PANEL

(H)

-

CE DOOR
(EUROPE)

CONTROL CABINET

60

TO

Electrical Service

96-0284 rev A June 2006

EC-300/EC-400 CONTROL CABINET WIRING DIAGRAM

S
E
R

I

A

L
P
O
R

T
1

S
E
R

I

A

L
P
O
R

T
2

E

T

H

E
R
N
E

T

S
P

A

R
E

-

1

S
P

A

R
E

-

2

-

A

-

A

X

I

S

-

Z

-

A

X

I

S

-

Y

-

A

X

I

S

-

X

-

A

X

I

S

L

I

M

I

T

S

W
I

T

C

H

E
S

T

S
C

T

O
O
L
C

H
A

N
G
E
R

5

T

H
A

X

I

S

S
P

A

R
E

-

4

S
P

A

R
E

-

3

C
O
O
L

A

N

T

M
F

I

N
/

C
L
G

C

H
I

P
C
O
N

V
E
Y
O
R

S
P

A

R
E

-

5

A

P
C

D
R
/

R
E
C
V
R

Q

A

P
C

-

R

Q

A

P
C

-

L

I

N
D
L
E

H

E

A

D

T

O

I

/

O
P

C
B

O

T

O
R

M
O

T

O
R
F

A

N
/

O

I

L
P

U

M
P
/

O

I

L
E
R

C
L

A

M
P
/

L
O

C
K
S
O
L
E
N
O

I

D
P

O

W

E
R

I

T

C

H

E
S

S
E
N
S
O
R

E

L
E

H

E

A

D

F
R
O
N

T

P

A

N
E
L
S

U

P
P
O
R

T
A

R
M

F
L
E
X

I

B
L
E
C

A

B
L
E

C
O
N
D

U
I

T

W
I

T

C

H

A

B
L
E

R
P

O

W

E
R

C

A

B
L
E

I

O
N

N

A

M
E

T

I

O
N
N

A

M
E

I

O
N

N

A

M
E

I

O
N

N

A

M
E

E
R

S

T

A

T

U

S

E
R

S

H
U
T

T

L
E

M
O

T

O
R

E
R

T

U

R
R
E

T

M
O

T

O
R

I

O
N
N

A

M
E

M
P

O

T

S
C

C
O
O
L

A

N

T

P

U

M
P

I

O
N
N

A

M
E

A

D
(

C
O
O
L

A

N

T

L
E
V
E
L

O
R
)

T

I

O
N

N

A

M
E

S

T

O
P

I

N
P

U
T

C

A

B
L
E

T

R
E

A

D
Y

1

/

A

P
C

#

1

Y

2

O
P
E
N

E
/

M
D
P

A

L

U

P

-

A

P
C

P

A

L

1

W

N

I

O
N
N

A

M
E

C
L
O
S
E
D

-

A

P
C

#

2

L

A

M
P
L

E
F

T

D
D
O
R

O
P
E
N

E
N

R
P

O

W

E
R

C

A

B
L
E

S

W
I

T

C

H

A

B
L
E

T

S

W
I

T

C

H

R
P

O

W

E
R

C

A

B
L
E

C

A

B
L
E

K
E

#

1

/

A

P
C

P

I

N
C

L
R

#

2

E
R

M
O

T

O
R
S

L

A

M
P
R

I

G

H
T

D
O
O
R

FONT PANE L/

PALLET CHANGER

SIGNA L

SPA RE

CHIP CO NVEYOR

LUBE PANEL

SPEEDTOOL

A2/

5THAXIS

-Z- AXIS

-X- AXI S

CHANG ER

SUPER

WIRE NUMBER

990

960

300

X/Y/Z HOME SENSORS

LOW LUB

115VACTO OILER

FUNCTION NAME

CHANGER

TSC

WIRE NUMBER

820

130

940A

TSC OVE R TE

230 VAC 3PH T

810A

TOOL CHAN G

TOOL CHAN G

FUNCT

WIRE NUMBER F UNCTION NAME

230-690B

490B

B-HOME LIMIT SWITCH

B-AXIS MOTOR POWER CABL E

5'thAXIS BRAKE

B-ENC ODER CAB LE

A1/

TOOL

810

TOOL CHAN G

-A- AXIS

WIRE N UMBER

-

690

390

A-HOME LIMI

A-ENCODER

4'th AXIS BRA

FUNCT

WIRE NUMBER FU NCTION NA ME

680-490Z

350A

Z-HOME LIMIT SWITCH

Z-AXIS MOTOR POWER CABLE

Z-EN CODER CAB LE

24VDC SRVO BRAKE RELEASE

WIRE NUMBER FUNCT

490A

A-AXIS MOTO

670

-

Y-HOME LIMIT

Y-ENCODER C

WIRE NUMBER FUNCTION NAME

-

660

490X

X-HOME LIMIT SWITCH

X-AXIS MOTOR POWER CABL E

X-ENC ODER CAB LE

-Y- AX IS

490Y

Y-AXIS MOTO

CHANG ER

WIRE NUMBER FUNC

X-ENCODER C

HOME LIMITS

WIRE NUMBER

690B

490B

SUPER SPEED TOOL CHANGER

MOTOR PO WER CABLE

SUPER SPEED TOOL CHANGER

ENCO DER CABLE

FUNCTION NAME

PALLET

WIRE NUMBER

490X-660

X-AXIS MOTO

FUNCT

WIRE NUMBER

90A

740

750

720

280

90B

770 EMERGENCY STOP INPUT CABLE

1050 DOOR S WITCH WIR ING THRU SU PPORT ARM

JOG-CRANK DATA CABLE "RJH"

POWER ON /OFF CAB LE TO FRON T PANE L

ANALOG SPEED COMMAND TO SPINDLE " SPINDLE LOAD METER"

RED/GREEN STATUS LIGHT WIRING "BEACON"

115 VAC TO LCD LVPS

115 VAC TO WORK LIGHT SWITCH

FUNCTION NAME

730B

SP. DRIVE LO

WIRE N UMBER

140

230VAC 3PH POWER TO CHIP

CONVEYOR MOTOR

FUNC TION NAME

MFIN/ CLG

WIRE NUMBER

100

M-FIN

FUNCT

WIRE NUMBER

880B

450

770B

420 APC #2 CLR #1 & #2/APC #2 PAL#2

810

EMERGANCY STOP INPUT CABLE

APC MOTOR

& #1 HOME

TRANSMISSIO N HIGH/LOW GEAR

SOL ENOIDS

APC #2 CE DOOR OPEN

FUNCTION NAME

TOOLCHANGER

REMOTE BOX/

FRON T PANEL

WIRE NUMBER

480 APC PALLET C

460

430

310

250

APC #2 DOO R

APC DO OR OP

APC #2 D OOR

DOOR OPEN

APC PALLET C

FUNC T

COOL ANT

770B

410

710

M28

790

810A

EMERG ANCY

APC PIN CLR

APC #1 PALLE

PALLET READ

APC CE DOOR

TOOL CH ANG

WIRE NUMBER

940

230 VAC TO COOLANT PUMP

FUNCTION NAME

WIRE NUMBER

240

APC PAL HOM

HOM E PAL DO

GAUG E SENS

FUNC

FRONT PANEL

96-0284 rev A June 2006

CONTROL CABI NET

Electrical Service

WIRE N UMBER

190

200

300A

880A

890

950

UNCLAMP FROM SP

COOLANTSPIGOT M

115VAC TO SPINDLE

HIGH/LOW GEAR UN

SPINDLE STATUS SW

LOW AIR PR ESSURE

FUNCTION NAM

SPIND

61

VERTICAL MACHINE CONTROL CABINET WIRING DIAGRAM

480 APC PALLETCLAMP RIGHT DOOR

DOOR OPEN

SOLENOIDS

SPARE-5/ APC

DR/RECVR

460

430

310

250

APC #2 DOOR OPEN

APC DOOR OPEN

APC #2 DOOR CLOSED - APC #2

APC PALLET CLAMP LEFT DDOR

880B

810

APC MOTOR

TRANSMISSION HIGH/LOW GEAR

WIRE NUMBER

FUNCTION NAME

450

770B

EMERGANCY STOP INPUT CABLE

APC #2 CE DOOR OPEN

SPARE-4/ QAPC-L

& #1 HOME

M28

420 APC #2 CLR #1 & #2/APC #2 PAL#2

810A

TOOL CHANGER MOTORS

WIRE NUMBER

FUNCTION NAME

770B

790

EMERGANCY STOP INPUT CABLE

APC PIN CLR #1/APC PIN CLR #2

SPARE-3/

QAPC-R

710

PALLETREADY 2

APC #1 PALLET READY 1/APC #1

410

APC CE DOOR OPEN

240

HOME PAL DOWN

APC PAL HOME/MD PALUP-APC PAL1

940

230 VAC TO COOLANT PUMP

WIRE NUMBER

FUNCTION NAME

COOLANT

WIRE NUMBER

FUNCTION NAME

MFIN/CLG

730B

100

M-FIN

GAUGE SENSOR)

SP.DRIVE LOAD (COOLANT LEVEL

CONVEYOR MOTOR

WIRE NUMBER

FUNCTION NAME

CHIP CONVEYOR

WIRE NUMBER

140

230VAC3PH POWER TO CHIP

FUNCTION NAME

130

TSC OVER TEMP

TSC

940A

230 VAC 3PH TO TSC COOLANT PUMP

990

960

X/Y/Z HOME SENSOR

LOW LUB

S

WIRE NUMBER

FUNCTION NAME

LIMIT SWITCHES

WIRE NUMBER

300

115VACTO OILER

FUNCTION

NAME

CHANGER

820

810A

TOOL CHANGER

TOOL CHANGER

ST

SHUTTLE

ATUS

MOT
O

R

TOOL

WIRE NUMBER

810

TOOL CHANGER TURRET MOTOR

FUNCTIO

N NAME

230

5'th AXIS BRAKE

5TH AXIS

-

690B

490B

B-HOME LIMIT

B-ENCODER

B-AXIS

MOT
OR POWER CABLE

CABLE

SWITCH

WIRE NUMBER

FUNCTION

NAME

-A- AXIS

390

-

690

4'th AXIS BRAKE

A-HOME LIMIT

A-ENCO

DER CABLE

SWITCH

490A

A-AXIS

MOT
OR POWER CABLE

350A

-

24VDC SR

Z-HOME LIMIT

VO BRAKE

SWITCH

RELEASE

WIRE NUMBER FUNCTION NAME

-Z- AXIS

680

490Z

Z-ENCO

Z-AXIS MOT

DER CABLE

OR POWER CABLE

WIRE NUMBER

FUNCTIO

N NAME

-Y-AXIS

-

670

Y-HOMELIMIT

Y-ENCODERCABLE

OR POWER CABLE

SWITCH

WIRE NUMBER

490Y

Y-AXISMOT

FUNCTION NAME

-X- AXIS

-

660

490X

X-HOME LIMIT

X-ENCODER

X-AXIS

MOT
OR POWER CABLE

CABLE

SWITCH

WIRE NUMBER

FUNCTION

NAME

FASTTOOL

CHANG

ER

-

660

490X

HOME LIMIT

X-ENCODER

X-AXIS

MOT
OR POWER CABLE

SWITCH

CABLE

CHANG

ER

690B

ENCODER CABLE

SUPER

SPEED

TOOL CHANGER

WIRE NUMBER

FUNCTION NAME

SPARE-1/SUPER

SPEED TOOL

490B

MOTOR POWER CABLE

SUPER

SPEED

TOOL CHANGER

WIRE NUMBER

FUNCTION

NAME

CONTROL CABINET

SPARE-5

SPARE-4

QAPC-L

APC DR/RECVR

SPARE-3

QAPC-R

MFIN/CLG

COOLANT

TSC

CHIP CONVEYO

R

LIMIT SWITCHES

TOOL CHANG

ER

5TH AXIS

-A- AXIS

-Z- AXIS

-Y-AXIS

-X- AXIS

SPARE-2

ETHERNET

SPARE-1

750

740

720

POWER ON/OFF CABLE

ANALOG SPEED

COMMAND

TO FRONT PANEL

TO SPINDLE

"SPINDLE

LOAD METER

"

890

880A

SPINDLE

HIGH/LO

W GEAR UNCLAM

ST
ATUSSWITCHES

P/LOCK

SOLENOID POWER

WIRE NUMBER

280

90B

90A

RED/GREEN ST

115VAC TO WORK LIGHT

115VAC TO LCD LVPS

FUNCTIO

N NAME

ATUSLIGHT WIRING "BEACO

SWITCH

N"

WIRE NUMBER

300A

200

190

115VACTO SPINDLE

COOLANT SPIGOT MOTOR

UNCLAMP

FUNCTION

FROM SPINDLE

NAME
MOT
OR FAN/OIL PUMP/OILER

HEAD

TO I/O PCB

FRONT PANEL

SPINDLE

HEAD

1050 DOOR SWITCH WIRING

770 EMERGENCY

JOG-CRANK DA

STOP INPUT CABLE

TACABLE

THRU SUPPOR

"RJH"

FRONT PANEL SUPPO

R
TARM

FLEXIBLE

CABLE

CONDUIT

SERIAL PORT 1

SERIAL PORT 2

TARM

950

LOW AIR PRESSURE

SENSOR

62

Electrical Service

96-0284 rev A June 2006

CABLES
CABLE 71/72/73, POWER - K1 TO POWER SUPPLY (33-0952A)

12.0 IN

71-73 33-0952A
OVR VLTPROTC

12345

PSUP P25

CABLE 77/78/79, 230V TRANSFORMER - POWER SUPPLY (33-0078A)

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

48.0 IN

77-79 33-0078A
230V IN
PSUP P10

RED

WHT

13

BLK

2.0 IN

96-0284 rev A June 2006

Electrical Service

63

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
115V3PH
I/O PCB P56

90, 33-0095A
115V3PH
PSUP P19

3: WHT

12

1: BLK

CABLE 90, 115V 1PH POWER SUPPLY - I/O MINIMILL (33-0195A)

27.0 IN

2: BLK

12
1: WHT

90, 33-0195
115V1PH
I/O PCB P56

3: RED

90, 33-0195
115V1PH
PSUP P19

3: RED

1.5 IN1.5 IN

3: RED

4

2: WHT

2: WHT

1: BLK

3

1: BLK

34

12

12

64

Electrical Service

96-0284 rev A June 2006

CABLE 90A, 115V LCD LOW VOLTAGE POWER SUPPLY - VF0-2 (33-8250M)

LENGTH

2.00 IN
<LINE 1>

115VLCD LVPS
LCD LVPSTB1

RED

BLK

1

<LINE 1>
115VLCD LVPS
<LINE 3>

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

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

<LINE 1>
90A, <ASSY#>

90C, <ASSY#>
90C, <ASSY#>
90A, <ASSY#>
90A, <ASSY#>
90A, <ASSY#>
90A, <ASSY#>
90A, <ASSY#>
90C, <ASSY#>
90A, <ASSY#>
90A, <ASSY#>

CABLE 90B, POWER TO LOW VOLTAGE POWER SUPPLY 5-PIN (33-0219A)

22.0 IN

90B, 33-0219A
LVPS115V
PSUP P2

5: RED

90B, 33-0219A
LVPS115V
LVPSPCB J1

2.00 IN

<LINE 3>
PSUP P11

PSUP P16
PSUP P16
PSUP P11
PSUP P11
PSUP P11
PSUP P11
PSUP P11
PSUP P16
BASE CARRIER
PSUP P11

12

2: BLK

3: BLK

1

96-0284 rev A June 2006

Electrical Service

1: RED

65

CABLE 90B, SWITCHED DOOR FAN (33-0305C)

<LINE 1>
<LINE 2>
<LINE 3>

2

1

LENGTH

LABEL

ASSY. #
33-0305C

33-1021E
33-0307A
33-1028

LENGTH

80.00 IN

38.00 IN

80.00 IN

24.00 IN

<LINE 1>
90B, 33-0305C

90B, 33-1021E
90B, 33-0307A
90A, 33-1028

<LINE 2>
SW DOOR FAN

SERVO DR FAN
DOOR FAN
SERVO FAN

CABLE 90C, SPINDLE PURGE AIR SOLENOID - GR (33-3550A)

2: BLK

1

1: RED

90C, 33-3550
115SP PRG SOL
SP PRGAIR SOL

TP/20AWG

4.0 FT

90C, 33-3550
115SP PRG SOL
PSUP PCB P14

<LINE 3>
PSUP P5

PSUP P6
PSUP P10
PSUP P6

TOLERANCE

3.00"

±

2.00"

±

3.00"

±

0.50"

±

2: BLK

1: RED

23

1

CABLE 90C, 115V TRANSFORMER POWER SUPPLY - 26” (33-6405A)

LENGTH

90C, <ASSY #>
115VAC
<LABELA>

ASSY. #
33-6405A

33-6406
33-6407

LENGTH

26.0 IN

30.0 IN

46.0 IN

<LABELA>
PSUP P17

PSUP P18
PSUP P17

Electrical Service

66

1

2

3

1: RED

2: BLK

90C, <ASSY #>
115VAC
<LABEL B>

<LABELA>
TRANS P2

TRANS P4
TRANS P2

1

RED
BLK

96-0284 rev A June 2006

CABLE 90C, SPINDLE FAN - TL-15/SL-20 (33-8310C)

LENGTH

3

4

3: RED

4: BLK

LABELA

90C, <ASSY #>
<LINE #2>
<LINE #3>

1
2

213

2: BLK

1: RED

LABEL B

90C, <ASSY #>
<LINE #2>
<LINE #3>

LABELA TEXT

ASSY#

33-8310C
33-8311C

33-8312

LENGTH

8.00 FT

10.00 FT

8.00 FT

<LINE #2> <LINE #3> <LINE #2> <LINE#3>

SP FAN PWR

SP FAN PWR

HPU FAN PWR

SP FAN

SP FAN

HPU FAN

CABLE 94/95/96, 115V 3PH TO POWER SUPPLY (33-0905D)

38.0 IN

2.0 IN

WHT

95
XFMR

RED

94
XFMR

BLK

94-96 33-0905D
115V3PH OUT
XFMR TB1

94-96 33-0905D
115V3PH IN
PSUP P1

LABEL B TEXT

SP FAN PWR

SP FAN PWR

HPU FAN PWR

2.0 IN
BLK

WHT

RED

PSUP P14
PSUP P14
PSUP P16

14

96
XFMR

96-0284 rev A June 2006

25.0 IN

Electrical Service

GRN/YEL

67

CABLE 100, M-FIN FUNCTION W/MCD (33-0101B)

LENGTH

10.0 INCH

BLK <GND>

RED <SIG>

100, <ASSY #>
M-FIN
I/O PCB P10

1

ASSY. #
33-0100A

33-0301
33-0101

1: RED

2: BLK

L-1

17.0 INCH

17.0 INCH

69.0 INCH

LENGTH

2.25 FT

2.25 FT

6.60 FT

4: RED

3: BLK
<LINE 3>
I/O PCB TB1-M21

MCD PCB M21
MCD PCB M21

CABLE 140A, CHIP CONVEYOR ENABLE/REVERSE (33-0149A)

140A 33-0149
CHIPC ENA/REV

BLK
WHT
YEL

<REV>
<ENA>
<COM>

CHIPC PCB P4

L-1

100, <ASSY #>
M-FIN
<LINE 3>

BLK

RED

N/O
P4-3

COM
P4-2

RED
BLK

140A 33-0149

<COM>
<REV>

YEL
BLK
WHT<ENA>

CHIP ENA/REV
HOPT PCB P5

CABLE 140A, LEFT CHIP CONVEYOR ENABLE/REVERSE (33-0164B)

RED

WHT

BLK

SHIELD

1

140A, <ASSY. #>
CHIPC EN/REV
IOPCB P37

CABLE 160, CHIP CONVEYOR 230V (33-0160D)

SHIELD

160, 33-0160D
CHIPC 230V
PSUP P21

4
2 1

BLK

3

RED

WHT

140A 33-0149
CHIP ENA/REV
I/O PCB P37

140A, <ASSY. #>
CHIPC EN/REV
CHIPC PCB P4

160, 33-0160D
CHIPC 230V
IOPCB P39

SHIELD
RED

WHT

BLK

1

3

4

2

1

YEL

<COM>

WHT

<ENA>

BLK

<REV>

RED <+12V>
WHT <EN.>
BLK <REV.>
SHIELD

68

Electrical Service

96-0284 rev A June 2006

CABLE 170, AUX/COIL 30HP CONTACTOR (33-0179A)

WIRE SIDE OF

CONNECTOR

RED
BLK

RED
BLK

BLK
RED

170 <ASSY#>
AUTO/OFF
PSUP P23

CABLE 190, TOOL RELEASE VF0-2 (33-0190C)

TOP VIEW

190, <ASSY #>
REM UNCLAMP
I/O PCB <LINE3>

RED

BLK

RED
BLK

RED

BLK

LENGTH

190, <ASSY #>
REM UNCLAMP
REM UNCL SW

170 <ASSY#>
AUTO/OFF
I/O PCB P42

RED

BLK

3

4

2: RED

21

1: BLK

1

<LOGIC RETURN>

SHIELD DRAIN

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

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

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

<LINE 3>
P19

P19
P19
P19
P19
P19
P19
P19
P19
P19
P49

CABLE 200, PROGRAMMABLE COOLANT VF0-5 (33-0202H)

BLK

ORN

3

4

12

WHT

RED

200 ,<ASSY.#>
SPIGOT MTR/SW
PROG COOLASSY

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

200, <ASSY.#>
SPIGOT MTR/SW
I/O PCB P35

TOLERANCE

3.50 IN

±

1.5% OF LENGTH

±

IN

2.00

±

1.5% OF LENGTH

±

1.5% OF LENGTH

±

3.50 IN

±

1.5% OF LENGTH

±

1.5% OF LENGTH

±

1.5% OF LENGTH

±

1.5% OF LENGTH

±

3.00 IN

±

1

RED
BLK
ORN
WHT

SHIELD

96-0284 rev A June 2006

Electrical Service

69

CABLE 210, FLOPPY DRIVE DTA VF0-2/VB-1 (33-0210A)

1

SHLD DRN

6.0 IN 22AWG

3: BLK <DRAIN>

1

FRONT VIEW

OF SOCKET

CENTER

KEY

<VIDEO PCB END>

VIDEO J11

RED

STRIP

210, ASSY #
FL DR DATA
FRNT PNL FLD

210, ASSY #
FL DR DATA
VIDEO PCB J12

2.0 IN 2.0 IN

RED

STRIP

<FLOPPY DRIVE END>

1

BACK VIEW

OF SOCKET

ASSY. #
33-0210A

33-1210B
33-6210A
33-7210A
33-8210A
33-6211

LENGTH

MACHINE
VF0-2, VB-1

CSM (ALL)
VF/R6-11
VF3-5, SL (ALL)
HS (ALL)
TM-1/2 OFFICE MACHINES

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

±

3.50 IN

±

2.00 IN

±

2.00 IN

±

70

Electrical Service

96-0284 rev A June 2006

CABLE 230, TAILSTOCK CONTROL - FORWARD (33-0041B)

LENGTH

1.0 IN

PDL-2 PDL-2

230 ASSY #
FORWARD (TS)
SOLENOID

CONN. 1

BLK

2

CONN. 2

1

RED

ASSY. #
33-0041B

33-0064
33-0131

CABLE 240, PALLET UP/DOWN SWITCH (33-0113A)

11.50FT

230 ASSY #
FORWARD (TS)
I/O PCB P31

MACHINE
SL-20/30/40

SL-10
SL-40LB

LENGTH

6.00 FT

15.00 FT

18.00 FT

PALUP

3: BLK

6

4

1 BLK
2 RED
3 SHLD

3

2

1

43

1

PALUP

PALDWN

GND

2: RED
3: WHT
4: BLK

SHLD

96-0284 rev A June 2006

240, 33-0113
PALUP/DWN SW
I/O PCB P21

240, 33-0113
PALUP/DWN SW
PALCHNGR

Electrical Service

1: RED

PALDWN

2: WHT

3 IN

1

2

3" BLK

JUMPER

4: BLK

43

1

2

71

CABLE 250, TAILSTOCK CONTROL - REVERSE (33-0042B)

LENGTH

1.0 IN

PDL-2 PDL-2

250 ASSY #
REVERSE (TS)
SOLENOID

CONN. 1

BLK

1

2

CONN. 2

RED

ASSY. #
33-0042B

33-0065
33-0132

CABLE 260, READY LAMP - EC-300 (33-8105B)

RDY
LAMP

RED
RDY

LAMP

BLK

260 33-8105
READY LAMP
AUX F-PNL

250 ASSY #
REVERSE (TS)
I/O PCB P32

MACHINE
SL-20/30/40

SL-10
SL-40LB

LENGTH

6.00 FT

15.00 FT

9.00 FT

260 33-8105
READY LAMP
I/O PCB P34

4

3

2

11

TOLERANCE

3.00 IN±

±±3.50 IN

3.00 IN

3 SHLD

1 BLK
2 RED

1 3

RED
BLK
DRAIN

CABLE 270, TAILSTOCK CONTROL - RAPID (33-0043C)

LENGTH

ASSY. #
33-0043C

33-0063

Electrical Service

72

1

2

CONN. 1

BLK

CONN. 2

RED

1.0 IN

PDL-2 PDL-2

270 ASSY #
RAPID (TS)
SOLENOID

270 ASSY #
RAPID (TS)
I/O PCB P33

MACHINE
SL-20/30

SL-40/LB

LENGTH

6.00 FT

13.50 FT

213

1 BLK
2 RED
3 SHLD

TOLERANCE

3.00 IN±

±3.50 IN

96-0284 rev A June 2006

CABLE 280, HAAS BEACON VF0-5, SL-20/30 (33-1035A)

2

RED

3
1

WHT

BLK

280, <ASSY.#>
BEACON 115V
BCON FRNT PNL

CABLE 300, SPINDLE FAN/LUBE PUMP (33-1333C)

300, <ASSY #>
LUB OIL PUMP
LUBE RACK

32

1

1:RED

2:BLK

300
LUBE
PUMP

1: RED

2: BLK

CABLE 300A, GEARBOX OIL PUMP - SL-30/40 (33-8168B)

300A, <ASSY #>
GBOX OIL PUMP

RED

BLK

OIL PUMP CON

280, <ASSY.#>
BEACON 115V
<LINE 3>

300, <ASSY #>
LUB OIL PUMP
I/O PCB P40

300A, <ASSY #>
GBOX OIL PUMP
I/O PCB P41

SHLD

SHLD

432 1

BLK

WHT

BLK

RED

RED

SHIELD

312

BLK

RED

3 2

1

CABLE 350, AXIS BRAKE (33-0904B)

<LINE1>
<LINE2>
<LINE3>

RED
BLK

<LINE 1> <LINE 2> <LINE 3> <LINE 4> LENGTH
350 33-0904B
350A 33-0906B
350A 33-0908

AXIS BRAKE
HYD PMP EN

1AXIS BRAKE

TABLE

BRAKE PCB P6
TRANS PCB P4
BRAKE PCB P6

<LINE1>
<LINE2>
<LINE4>

I/O PCB P47
I/O PCB P49
I/O PCB P49

123

1 RED
2 BLK

25.00"

23.00"

27.00"

96-0284 rev A June 2006

Electrical Service

73

CABLE 350, Z-AXIS BRAKE (33-0907B)

18.0 IN

1

2: RED

3: BLK

350 33-0907
Z-AXIS BRK
TRANS PCB P1

CABLE 350A, HYDRAULIC PUMP CONTACTOR (33-0352B)

A1 COIL

BLK

A2 COIL

RED

350A33-0352B
115HYD CNTCR
CONTACTRCOIL

40"

350 33-0907
Z-AXIS BRK
I/O PCB P47

350A33-0352B
115HYD CNTCR
I/O PCB P49

2: BLK

BLK

1: RED

23

RED

23

1

1

CABLE 390, 115V 4TH AXIS BRAKE (33-8511B)

LENGTH

23

3: BLK

4

1: SHLD

1

2: RED

390, <ASSY.#>
<LINE 2>
I/O PCB P46

ASSY. #
33-8511

33-8512

MACHINE
HS-3R

VTC

6

LENGTH

9.50 FT

11.00FT

390, <ASSY.#>
<LINE 2>
BRAKE SOLENOID

<LINE 2>
115V4TH BRAKE

115VSP BRAKE

2: BLK

1: RED

1

74

Electrical Service

96-0284 rev A June 2006

CABLE 410, TOOL CHANGER DOOR SWITCH (33-9825A)

410 <ASSY #>

RED

3

1

4

2

TC DOOR LS
TC DOOR L/SWITCH

BLK

LENGTH
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/

LENGTH

15.00 FT

5.50 FT

20.75 FT

28.00 FT

48.00 FT

710/712

CABLE 510, I/O PCB TO MOCON - NO SHIELD (33-0515A)

LABELA LABEL BLENGTH

See Table

<(LINE 1>

RELAYCABLE

<(LINE 3>

410 <ASSY #>
TC DOOR LS
I/O PCB P17

TOLERANCE

3.00 IN
.00 IN

2±±

3.50 IN

±

4.00 IN

±

5.00 IN

±

<(LINE 1>
<(LINE 2>
<(LINE 3>

1

RED
BLK

DRAIN

PIN 1

ASSY. #
33-0515

33-0525
33-0535
33-0545

RED EDGE

LABELA & B

<LINE 1>

510, 33-0515
520, 33-0525
530, 33-0535
540, 33-0545

16COND/28AWG

LABEL B
<LINE 2>

RELAYCABLE
RELAYCABLE
RELAYCABLE
PRE I/O-S P3

LABELA
<LINE 3>

MOCON P11
MOCON P12
MOCON P13
MOCON P14

RED EDGE

LABEL B
<LINE 3>

I/O PCB P65
I/O PCB P64
I/O PCB P70
I/O PCB P61

PIN 1

LENGTH

70.0 IN

70.0 IN

70.0 IN
62

.0 IN

96-0284 rev A June 2006

Electrical Service

75

CABLE 550, INPUT I/O TO MOCON - NO SHIELD (33-0552A)

550, ASSY #

PIN 1 PIN 1

INPUTS CABLE
MOCON PCB P10

550, ASSY #
INPUTS CABLE
LINE <3> I/O PCB P63

46.0"

CABLE 610, AXIS CURRENT COMMAND (33-0610E)

AMP END

YEL

BLK
ORN
BRN

1

WHT/YEL
WHT/BLK

WHT/ORN

WHT/BRN

2

2 1

WHT/YEL <FAULT>

WHT/BLK <ENABLE>

WHT/ORN <+B>

WHT/BRN <+A>

SHIELD <ANALOG GND>

YEL <LOGIC GND>

BLK <LOGIC GND>

ORN <ANALOG GND>

BRN <ANALOG GND>

MOCON END

1

33-0610E

AMP-MOCON

2

2 1

CABLE 640C, VECTOR DRIVE CURRENT COMMAND (33-4048B)

2

1

WHT/BRN <A>
WHT/ORG <B>

WHT/BLK <ENBL>

WHT/YEL <FLT P>

WHT/RED <320VA>

2

BRN <A>
ORG <B>
BLK <DG GND>
YEL <FLT>

RED <A GND>

1

640C, <ASSY. #>
C-AXIS VD CUR
<LINE 3A>

640C, <ASSY. #>
C-AXIS VD CUR
<LINE 3B>

2

1

1

WHT/BRN <A>
WHT/ORG <B>

WHT/BLK <ENBL>

WHT/YEL <FLT P>

2

BRN <A>
ORG <B>
BLK <DG GND>
YEL <FLT>

DRAIN

MOCON

PCB P17

WHT/RED <320VA>

RED <A GND>

1

76

Electrical Service

96-0284 rev A June 2006

CABLE 700A, FEED HOLD/CYCLE START (33-0700A)

15.0 IN

BLK

13.0 IN

FEED HOLD
N/O SW 3

YEL

2.5 IN

FEED HOLD
N/O SW 4

BLK

CYCL STRT
N/O SW 4

RED

CYCL STRT
N/O SW 3

2.5 IN

TP/22AWG

TP/22AWG

CABLE 710, FORWARD/REVERSE RELAY - OM-1 (33-8154C)

FWD
I/O PCB P51

2

1

WHT

ORG

REV
I/O PCB P52

64

2 13
RED

BLK

SHLD

710 33-8154
FWD/REV
I/O PCB P51/P52

710 33-8154
FWD/REV
NSK 120V RLY

700A, 33-0700A
C STRT/F HLD
SKBIF P3

NSK RLY
K3-1

RED

NSK RLY
K3-5

BLK

NSK RLY
K2-5

ORG

NSK RLY
K2-1

WHT

BLK

YEL
BLK
RED

1

96-0284 rev A June 2006

Electrical Service

77

CABLE 720, SPINDLE LOAD METER VF0-2/VB (33-0733M)

LENGTH-A

720, <ASSY#>
SP LOAD METER
MOCON P16

RED

1

BLK

721 METER "+"

721 METER "-"

ASSY. #
33-0733

33-4733
33-2733
33-5733
33-6733
33-6737
33-7733
33-8733A

MACHINE
VF 0-2, VB-1

VF 3-5
TM-1/2
ML
VF 6-11, SL-40
SL-40LB
SL-20/30
HS (ALL)

CABLE 740, ON/OFF F P - VF3-5 (33-4740C)

RED

BLK

2.0 IN

LENGTH-A

12.00 FT

15.00 FT

8.50 FT

8.00 FT

19.00 FT

22.50 FT

14.00 FT

6.00 FT

720, <ASSY#>
SP LOAD METER
SKBIF P4

720, <ASSY#>
SP LOAD METER
LOAD METER +/-

28.0 IN

TOTAL LENGTH

14.33 FT

17.33 FT

10.83 FT

10.33 FT

21.33 FT

24.85 FT

16.33 FT

8.33 FT

RED
BLK
BLK
RED

1

SEE DRAWING 33-0740C,
REVISION 'A' OR LATER

78

Electrical Service

96-0284 rev A June 2006

CABLE 750, REMOTE JOG HANDLE DATA - 11 FT (33-0750C)

2

1

WHT/YEL

RED
BLK
YEL

WHT/ORN
WHT/BLU

WHT/RED
WHT/BRN

WHT/BLK

BRN

ORN

BLU

SHIELD

ASSY. #
33-0750C

33-4750
33-5750C
33-5757
33-6750B
33-7750C
33-8750B

2.0"

750, <ASSY. #>
JOG DATA
RJOG/SKBIF J3

24AWG/6TP

2

1

LENGTH

MACHINE
VF 0-2, MM, GRs, VF-2SS, HS-3, VB-1/3

TM-1/2, EC-300/400/1600, MDC-500, ML
SL-40
SL-40LB
VF 6-11, VR-8/9/11B
VF3-5, VF3/4SS, SL-10/20/30, TL-1/2/3/15/25
HS-1/2, MDC-1

750, <ASSY. #>
JOG DATA
MOCON PCB P18

WHT JUMPER

1

LENGTH

11.00FT

8.00 FT

18.00 FT

22.50 FT

15.00 FT

13.50 FT

6.00 FT

2.0"

WHT/YEL

RED
BLK
YEL

WHT/ORN
WHT/BLU

RED

JUMPER

WHT/RED

WHT/BRN

WHT/BLK

BRN

2

ORN

BLU

SHIELD

2

<LOGIC GND>
<JB>
<JC>

<JOVRHT>
<JB*>
<JHA>

<JHC>

<LOGIC GND>

1

<JA>
<JS5V>
<HOME>

<JA*>
<JC*>
<JHB>
<JHD>
<LOGIC GND>

TOLERANCE

3.0 IN

2.0 IN

3.5 IN

1.5% OF L

3.0 IN

3.0 IN

1.0 IN

CABLE 750C, JOG HANDLE ASSEMBLY (33-0750D)

JOG HANDLE

RJH-5
B ENC

RJH-3
A ENC

RJH-2
0 VDC

RJH-1
+5 VDC

96-0284 rev A June 2006

BLK

BLK

YEL

BLK

RED

2.0 IN

Electrical Service

24.0 IN

TP/22AWG

1

BLK <B ENC>
YEL <A ENC>
BLK <0 VDC>

RED <+5 VDC>

TP/22AWG

750C, 33-0750D
JOG INT J1
JOG HNDL

SERIAL KB INT/

REMOTE JOG PCB

79

CABLE 770, MOCON 2 AUXILIARY E-STOP (33-0773C)

BLK
RED

1

770, 33-0773
MOCON 2 ESTOP
MOCON P34

770, 33-0773
MOCON 2 ESTOP
I/O P7/P72/P81

CABLE 780, SPINDLE OVERVOLTAGE (33-4047A)

BLACK

1

RED

780, 33-4047
SP VD OVRVLT
SP VDR J1

780, 33-4047
SP VD OVRVLT
I/O PCB P16

CABLE 790, TOOL PRESETTER HOME SWITCH “I/O S” SL-20/30 (33-0557A)

LENGTH

790 <ASSY>
LTPHOME
I/O PCB P18

4: RED
43

790 <ASSY>
LTPHOME
HOME SWITCH

1

RED

SHIELD

RED

BLACK

SHIELD

RED

BLK

1

1

2

2: BLK

ASSY. #
33-0557A

33-0757

MACHINE
SL-20/30

SL-40

LENGTH

8.00 FT

11.50FT

CABLE 820, TOOL TURRET STATUS - 14.5 FT (32-0821C)

8.00 IN

4.00 IN
TURRET

CLAMPED

TURRET
UNCLAMPED

LENGTH

820 <ASSY#>
TT STATUS SWS
I/O PCB P2

ASSY. #
32-0821
32-0822
32-0823

TOLERANCE

3.00 IN±

±3.50 IN

MACHINE
SL-10
SL-20
SL-30

BLK
BRN
BLU

SHIELD

LENGTH

14.50 FT

15.20 FT

17.00 FT

BLK
DRAIN

1

UNCLAMPED

CLAMPED
GND
SHIELD

4

80

Electrical Service

96-0284 rev A June 2006

CABLE 820, 8-STATION TOOL TURRET STATUS (33-4820A)

9.0 FT

1

820 33-4820A
LUBE RACK
T/S ENCODER

10: WHT TOOL 1

8: RED TOOL MK
7: BLK TOOL MK

TC MARK

TC HOME

GND

SHIELD

8

RED
WHT

BLK

I/O PCB
P28

2: SHIELD

UNLOCKED

GND

SHIELD

1

4

WHT
BLK

I/O PCB
P2

2: SHIELD
3: BLK GND

5: WHT UNLOCKED

7.8 FT

CABLE 820, C-AXIS ENABLE/DISABLE SL-20/30 (33-6820A)

LENGTH

3: RED

6

1

10

5

DIS.

ENG.

JUMPER

BLK

ENG.

1:

BLK

4" BLK

1:

34

12

1: BLK

3: WHT

4

3

1 2

ASSY. #
33-6820A

33-6821A
33-6822
33-6823

820, <ASSY.#>
C AXIS
EN/DISEN

MACHINE
SL-20/30

SL-40
VTC
SL-30

LENGTH

10.50 FT

14.50 FT

25.00 FT

12.50 FT

820, <ASSY.#>
EN/DISEN
I/O PCB P3

TOLERANCE
±

3.5 IN

±

3.5 IN

±

4.0 IN

±

3.5 IN

RED
WHT

BLK

SHLD

1

<DISEN>
<ENGAGE>

<COMM>
<DRAIN>

96-0284 rev A June 2006

Electrical Service

81

CABLE 850, SKBIF VF0-2, SL-20/30 (33-0700B)

FACE UP

ASSY. #
33-0700B

33-6700A
33-6702
33-7700A
33-8700B

850, <ASSY. #>
SKBIF RS232
<LINE 3>

RED STRIPE

MACHINE
VF0-2, SL-20/30, VB-1

VF6-11,VF5-11/50T
VS-3
VF3-5, SL-40
EC-300/MDC-500/EC-400/EC-1600

850, <ASSY. #>
SKBIF RS232
PROCESSOR J4

LENGTHPIN 1

LENGTH

12.00 FT

19.00 FT

13.50 FT

15.00 FT

8.50 FT

CABLE 860, +5V/+12V/-12V/GND TO MOCON 1 (33-0865B)

17.0 IN

1

<LINE 1>
<LINE 2>
MOCON PCB P15

ASSY #
33-0865
33-0866

LINE 1
860, 33-0865
860, 33-0866

LINE 2
MOCON-1 PWR
MOCON-2 PWR

LINE 3
PSUP P32
PSUP P33

RED STRIPE

<LINE 3>
SKBIF P1

SKBIF P1
BASE CARRIER
SKBIF P1
SKBIF P1

1

<LINE 1>
<LINE 2>
<LINE 3>

FACE DOWN

PIN 1

RED <+5V>
BLK <GND>
BLK <GND>
YEL <+12V>
WHT <-12V>

CABLE 860, 12V DC - MCD RELAY PCB (33-8040B)

860 <ASSY #>
+12V DC
<LINE 3A>

RED
BLK

1

LENGTH
ASSY. #
33-8040B

33-8142A
33-8240
33-8241

82

LENGTH

38.0 IN

54.0 IN

60.0 IN

26.0 IN

<LINE 3A>

MCD PCB P2
SMTC PCB P2
MCD PCB P2
MCD PCB P2

Electrical Service

860 <ASSY #>
+12V DC
<LINE 3B>

<LINE 3B>

PSUP P35
PSUP P34
PSUP P35
I/O PCB P15

BLK
RED

<12V RTN>
<+12V DC>

96-0284 rev A June 2006

CABLE 860A, +5V/+12V/GND TO I/O PCB (33-0861B)

4: BLK

4

3

12

1: RED

2: WHT

860A, 33-0861B
+5/+12/GND
I/O PCB P60

41.0"

860A, 33-0861B
+5/+12/GND
PSUP P27

CABLE 860A, +5V/+12V/GND TO I/O PCB (33-0982A)

35.0 IN

860A, 33-0982
+12/GND

860A, 33-0982
+5/+12/GND
I/O PCB P60

#20 TP YEL/BLK

3: BLK

3: BLK

4

3

12

2: YEL
2: YEL

4: BLK

1: RED

BL320VPS P3

YEL

BLK

#20 TP YEL/BLK

#18 TP RED/BLK

1

1

860A, 33-0982
+5/+12/GND
PSUP P27

YEL

BLK

BLK

RED

RED <+5V>

BLK <GND>

WHT <+12V>

<+12V>
<GND>
<GND>

<+5V>

1

44.0 IN

CABLE 880A, SPINDLE HEAD SOLENOID (33-0881L)

BLU

ORN

BLK

4

3 261

RED

BRN

WHT

96-0284 rev A June 2006

880A, <ASSY.#>
SP HD SOLEN
SPIN HEAD

880A, <ASSY.#>
SP HD SOLEN
I/O PCB P55

Electrical Service

8 5

34 12

1:BLK <TOOL UNCLAMP>

2:WHT <LOW GEAR>
3:BRN <HIGH GEAR>
4:RED <COMMON>
5:BLUE <SPIN LOCK>

7:SHIELD <DRAIN>

8:ORN <PRE CHARGE>

83

CABLE 880B, 120V AC TO GEAR RELAY (33-0370D)

880B, 33-0370D

RED <LOW GEAR>

1

115H/L GEAR

TRANS P1
WHT <HIGH GEAR>
BLACK <COMMON>
SHIELD

CABLE 880C, DELTA/WYE RELAY - 115V (33-0882A)

RELAY
COIL

RELAY
COIL

RED

BLK

CABLE 890, SPINDLE STATUS VF0-2 (33-0890M)

SIDE VIEW

REAR VIEW

ORN

BLU

GRN

456
123

RED

WHT

BRN

890
<ASSY#>
SPNDL STATUS

880B, 33-0370D
115H/L GEAR
I/O PCB P54

880C, <ASSY. #>
I/O PCB P53

890
SPNDL STATUS
I/O PCB P15

RED <LOW GEAR>

BLACK <COM.>

WHT <HI GEAR>

6

4

231

SHIELD

SHLD

3 2 1

BLK

RED

REAR VIEW

WHT

RED

BLU

BRN
ORN
GRN

HI GEAR
LO GEAR
UNCLAMPED
CLAMPED
SP LOCKED
GROUND
DRAIN

CABLE 890, SPINDLE STATUS SWITCH VF0-2 (33-0891H)

6: ORANGE

6

5: GREEN

4

4: RED

890, <ASSY.#>
SPNDL STATUS
SPIN. HEAD

890, <ASSY.#>
SPNDL STATUS
I/O PCB P15

1: YEL

231

2: BROWN

3: BLK

CABLE 900, THROUGH THE SPINDLE COOLANT PRESSURE SENSOR - 11.5 FT (33-0900C)

SHIELD DRAIN

BLK

RED

1

900, <ASSY. #>
TSC PRES SENS
I/O PCB P4

900, <ASSY.#>
TSC PRES SENS
TSC PRES CON.

1

<+12V>

YEL <HI GEAR>
RED <LO GEAR>
BLK <UNCLAMPED>
BRN <CLAMPED>

ORN <SP LOCKED>

GRN <GROUND>

SHIELD <DRAIN>

RED
BLK

12

84

Electrical Service

96-0284 rev A June 2006

CABLE 900, TSC LOW PRESSURE SWITCH - GR (33-6908B)

SHIELD DRAIN

BLK

RED

1

900, 33-6908B
TSC PRES SW
I/O PCB P4

CABLE 930, 230V I/O COOLANT - TSC (33-0930F)

900, 33-6908B
TSC PRES SW
TSC PRES CON.

BLK

RED

4

3

21

BRN <TSC>

ORN <TSC>

GRA <TSC>

RED <COOL>

5

8

324

1

BLK <COOL>

WHT <COOL>

930, 33-0930F
COOL/TSC 230
PSUP P20

CABLE 940, COOLANT PUMP RECEPTACLE (32-0942B)

FRONT VIEW REAR VIEW

RED

BLK

GRN/YEL

930, 33-0930F
COOL/TSC 230
IOPCB P44

940 32-0942B
CLNT PUMP 230V
I/O PCB P43

BRN <TSC>

ORN <TSC>

RED <COOL>

GRA <TSC>

BLK <COOL>
WHT <COOL>

REAR VIEW

1234

RED

BLK

483

5

2

1

96-0284 rev A June 2006

Electrical Service

85

CABLE 940, COOLANT PUMP RECEPTACLE - OM (32-0949B)

FRONT VIEW

GFCI
GND

REAR VIEW

BLK

GRN/YEL

Green Screw

RED

GRN/YEL

CABLE 940A, HYDRAULIC PUMP POWER (33-0340D)

940A, ASSY #

1-BLK
2-WHT
3-RED
4-GRN

4 3 21

TSC COOLANT
I/O PCB P45

940 32-0949
CLNT PUMP 230V
I/O PCB P43

940A, ASSY #
HYD PUMP

REAR VIEW

RED

BLK

TO HYD PUMP

1234

GND
STRIP

BLK

RED

WHT

CABLE 940A, TSC 1000 EXT. (32-5126B)

WHT

BLK

GRN

F

A

G

E

D

B

C

940A, <ASSY. #>
TSC CNTCR EXT
I/O PCB P45

DRAIN

GRN

BLK

RED

GRN

43

21

86

Electrical Service

96-0284 rev A June 2006

CABLE 950, LOW AIR/OIL - 13 FT (33-9506H)

WHT

BLK

34

2

1

3

4

RED

LOW OIL

BLK

12

BLK

LOW AIR

3.0 IN

ASSY. #
33-9506

33-9509
33-9512
33-9514
33-9515

MACHINE
VF3-5

VS-1/3
VF-1/2
VR-11,HS3-7
EC-1600, VF6-11

CABLE 960, LOW LUBE (33-1334D)

950, <ASSY #>
LOW AIR/OIL
PRESS SW

TRIO/22AWG

LENGTH

LENGTH

13.00 FT

32.00 FT

10.50 FT

22.75 FT

20.50 FT

TOLERANCE

3.00 IN±

1.5% of L

3.00 IN

±

3.50 IN

±

3.50 IN

±

RED

WHT

BLK

SHIELD

950, <ASSY #>
LOW AIR/OIL
I/O PCB P12

1

LOW AIR

LOW OIL PRS.

COMM. RTN

DRAIN

960,<ASSY #>
LOW LUBE

2: RED

LOW PRES SW

1: BLK

CABLE 960, LOW LUBE SPINDLE PUMP (33-1960B)

960, 33-1960

2: RED

LOW LUBE
SP LUBE PUMP

1: BLK

CABLE 960, LOW LUBE SPINDLE PUMP - GR-510 (33-1961A)

2: RED

1: BLK

960, 33-1961
LOW LUBE
SP LUBE PUMP

960,<ASSY #>
LOW LUBE
I/O PCB P13

960, 33-1960
LOW LUBE
I/O PCB P13

960, 33-1961
LOW LUBE
I/O PCB P13

RED
BLK

1

1

RED
BLK
SHIELD

RED
BLK
SHIELD

96-0284 rev A June 2006

Electrical Service

87

CABLE 970, VECTOR DRIVE OVERVOLTAGE (33-4049A)

BLACK

1

RED

970, <ASSY. #>
<LINE 2>
<LINE 3>

CABLE 970, POWER SUPPLY FAULT - MINIMILL (33-4149A)

PIN 1

2
3

BACK VIEW

RED
BLK

33-4149A
PS FAULT
PS J6

CABLE 1040, TRIPLE INTERLOCK SOLENOID POWER (33-1065A)

4: RED

4

132

2: BLK

4

3

12

3

21

1: SHLD

4: RED

2: BLK

4: GRN

4

2: WHT

1040, 33-1065
INTLK SOL PWR
INTLK SOL EXT

970, <ASSY. #>
<LINE 2>
I/O PCB P11

33-4149A
PS FAULT
I/O PCB P11

1040/A,33-1065
INTLK SOL PWR
IOPCB P30/29

1040A
IOPCB P29

RED

SHIELD

SHIELD

SHIELD

BLK

RED

GRN

WHT

RED

1040
IOPCB P30

3

2

1

2 1

1

BLACK

1

BLACK

CABLE 1050, CE INTERLOCK SWITCH (33-1151A)

1: RED

2: BLK

1050, <ASSY #>
SAFTY SW CE
FRONT PNL

88

Electrical Service

1: RED

2: BLK

3

1050, <ASSY #>
SAFTY SW CE

12

I/O PCB P8

3: RED

4: BLK

5: BLK

96-0284 rev A June 2006

1

CABLE 1070, SKIP DUAL PROBE (33-9103B)

15.0 IN

1070, 33-9103B
SKIP
I/O PCB P22

BLK <GND>

WHT <GND>

YEL <SIG>

RED

YEL

BLK

1

M22 N/C

M22 COMN

78.0 IN

SKIP RTN

WHITE
BLACK

SKIP RTN

YELLOW
TOTAL L = 18 IN

M22 N/C

RED

BLK

M22 N/O

CABLE 1070, SKIP DUAL PROBE W/8M (33-9108A)

15.0 IN

1070, 33-9108
SKIP
I/O PCB P22

BLK <GND>

WHT <GND>

YEL <SIG>

1

M22 N/C

RED

YEL

M22 COMN

BLK

M22 N/O

78.0 IN

SKIP RTN

WHITE
BLACK

SKIP RTN

YELLOW
TOTAL L = 78 IN

M22 N/C

RED

BLK

96-0284 rev A June 2006

M22 N/O

Electrical Service

M22 N/O

89

CABLE, 115V POWER SUPPLY - SWITCH (33-0098C)

18.0 FT

115V/LINE
GOLD SCREW

BLK

RED

115V/LINE
SLVRSCREW

33-0098C
115VSW
GFCI LOAD

CABLE, ETHERNET DATA OPTION ICOP 18” (33-0215B)

(WIRE SIDE)

1

2

1

3

4

5

6
8

7

1

ORG/WHT (Tx+)
GRN/WHT (Rx+)
BLU/WHT (CMT)
BRN/WHT (CMT)

<ASS#> ENET
DATA ICOP J1

ORG (Tx-)
BLU (CMT)
GRN (Rx-)
BRN (CMT)

<ASSY#>
ENET
DATA

PANELCOUPLER

33-0098C
115VSW
HIL J-BOX

115VAC
SW-1

BLK

RED

115VAC
SW-4

1

TIA/EIA 568B STANDARD

ORG/WHT (Tx+)
GRN/WHT (Rx+)
BLU/WHT (CMT)
BRN/WHT (CMT)

ORG (Tx-)
BLU (CMT)
GRN (Rx-)
BRN (CMT)

90

Electrical Service

96-0284 rev A June 2006

CABLE, LOW VOLTAGE POWER SUPPLY - SINPRO 9 AMP (33-0577A)

33-0577A
LOW VOLTPS

DETAILDWG

13. YEL<+12V DC>

12. BLK <GND>

11.BLK <GND>

10. WHT <-12V DC>

9. BLK <GND>

8. BLK <GND>

7. BLK <GND>

6. RED <+5V DC>

5. RED <+5V DC>

4. RED <+5V DC>

3. RED <+5V DC>

2. YEL<+12V DC>

1. YEL<+12V DC>

YEL
BLK

WHT

13

1

16

BLK

PSUP P8

RED

YEL

WHT

13

1

33-0577A VIDEO PWR
VIDEO PCB P1

RED
BLK

1

RED
BLK

33-0577A PROC PWR
PROCESSOR J3

WHT

33-0577A
MOCON-1 PWR
MOCON PCB P15

1

RED
YEL

1

BLK

YEL
BLK

WHT

33-0577A
LVPSPWR OUT (LVPS J2)

DELTA CONTACT - VECTOR DRIVE CABLE 10HP (33-0696A)

DELTA
T1

BLK

DELTA
T2

RED

DELTA
T3

BLU

12V BEEPER CABLE (33-0705A)

12.0 IN

BEEP
POS

BEEP
NEG

RED

BLK

VD
A/T9

VD
B/T10

VD
C/T11

1

RED (POS)
BLK (NEG)

33-0705A
SKBIF P5

96-0284 rev A June 2006

Electrical Service

91

SIDE-MOUNT TOOL CHANGER BRAKE RESISTOR CABLE (33-0815B)

25.0 IN

33-0815B
BRAK RESISTOR

4

3

1

2

I/O PCB P57

1: BLK

4: RED

SIDE-MOUNT TOOL CHANGER AMPHENOL CABLE ASSEMBLY (33-0822B)

KEY

810, 33-0822
TC MOTORS
I/O PCB P59

A: RED
B: BLK
C: YEL
D: BRN
E: YEL
F: ORN
G: BRN
H: RED
J: ORG
L: BLK
P: GRN/YEL
M: RED #2
N: BLK #2
R: RED #1
S: BLK #1
T: RED

A

B

M

L

N

C

P

T

K

J

H

D

S

E

R

G

F

420, 33-0822
CAROUSL INPUT
I/O PCB P23

470, 33-0822
CAM BOX INPUT
I/O PCB P27

1

BRN (PKT DOWN)
RED (PKT UP)
ORG (TOOL ONE)
YEL (TC MARK)

SHIELD

33-0815B
BRAK RESISTOR
SMTC BRAK RES

RED

BLK

3: RED #1 (CAROUSEL MOTOR)
4: BLK #1 (CAROUSEL MOTOR)
6: SHIELD

7: BLK #2 (ATC MOTOR)
8: RED #2 (ATC MOTOR)

5

8

324

1

1
234 56

1 RED (+12VDC)
2 BRN (ATC MOTOR STOP)
3 ORN (ATC ORIGIN)
4 YEL (ATC TOOLCLAMP)
5 BLK (+12V RTN)
6 SHIELD

430, 33-0822
PKT U/D SOLEN
I/O PCB P51

21

92

Electrical Service

1: RED (PKT U/D SOL)
2: BLK (PKT U/D SOL COMM.)

96-0284 rev A June 2006

RS-232 16-PIN RIBBON CABLE (33-0850A)

<LINE 1>
<LINE 2>

FACE UP

<LINE 3>

1

<LINE 1>
850, 33-0850

850A, 33-0855

CABLE, USB ASSEMBLY - ICOP (32-0859A)

26.5 IN
<LINE 2>
RS232 P10

RS232 P11

(WIRE SIDE)

1

1

3

5

77

9

RED STRIPE

<LINE 3>
VIDEO J13

PROC. J5

RED

2

WHT

4

GRN

6

BLK

8

CLR

10

<LINE 1>
<LINE 2>
<LINE 3>

FACE DOWN

1

(VCC)

(-DATA 0)

(+DATA 0)

(GND)

(SHIELD)

1

1.5 IN

96-0284 rev A June 2006

32-0859
ICOP USB
PC104 J13

9.0 IN

Electrical Service

1 VCC
2 -DATA
3 +DATA
4 GND

RECEPTACLE

FRONT VIEW

93

CABLE, EXTERNAL DELTA/WYE RELAY - 115V (33-0884A)

880C 33-0884
D/WYE SW
D/Y SW ASSY

90B,33-0884
115VD/Y SW
D/Y SW ASSY

4
2

WHT

BLK

3

1

BLK
RED

CABLE, FAN CORD - VECTOR DRIVE 2HD (33-1024A)

UPPER

FANFAN

5.75 IN

880C, 33-0884
D/WYE SW
I/O PCB P53

90B, 33-0884
115VD/Y SW
PSUP P7

90B, 33-1024
FAN CORD 2 HD
PSUP P6

LOWER

29.0 IN

DRAIN

BLK

WHT

DRAIN

RED

BLK

3 2 1

2

3

1

12

94

Electrical Service

96-0284 rev A June 2006

CABLE, AXIS MOTOR/ENCODER - 41.25 FT (32-1422B)

MOTOR ENCODER

HOME SWITCH CONNECTOR

CABLE

GRN/YEL

RED

A: WHT/YEL <A>
B: YEL </A>
C: WHT/BRN <B>
D: BRN </B>
E: ORN <C>
F: WHT/ORN </C>
G: WHT/RED 18AWG <GND>
H: RED 18AWG <+5 VDC>
M: BLK <GND>
N: WHT/BLK: <HOME SW>

G: SHIELD <DRAIN>

WIRE SIDE OF SOCKET CONNECTOR

D: GRN/YEL

D

C

A

A: RED

B

B: WHT

C: BLK

MOTOR END OF CABLE

MOTOR POWER
CABLE

WIRE SIDE OF
CONNECTOR

A

M

B

C

N

L

K

P

T

S

R

J

H

F

G

H: RED <+5VDC>

N: WHT <HOME SW>

M: BLK <GND>

WHT

BLK

WHT/YEL <A>

RED <+5V>

2

WHT/BLK <HOME SW>

YEL </A>

WHT/ORG </C>

D

E

WHT/RED <GND>

WHT/BRN <B>

BLK <GND>

1

ORN <C>

BRN </B>

SHIELD <DRAIN>

WIRE SIDE VIEW

1

WHT <HOME>

2

BLK <GND>

RED <+5V>

GRN/YEL

SRVOAMP
PH A

RED

SRVOAMP
PH B

WHT

SRVOAMP
PH C

BLK

96-0284 rev A June 2006

Electrical Service

95

CABLE, AXIS MOTOR/ENCODER - 41.25 FT (32-1425F)

HOME SWITCH CONNECTOR

MOTOR POWER
CABLE

WIRE SIDE OF
SOCKET CONNECTOR

A: WHT/YEL <A>
B: YELLOW </A>
C:WHT/BRN <B>
D:BROWN </B>
E:ORANGE <C>
F:WHT/ORN</C>
G:WHT/RED <GND>
H:RED <+5 VDC>

M: WHT/BLU <GND>

N: BLU <HOME>
DRAIN SHIELD

WIRE SIDE OF SOCKET CONNECTOR
MOTOR END OF CABLE

D: GRN/YEL

A: RED

DA

B

C: BLK

B: WHT

C

K

A

M

B

N

L

P

T

S

R

G

J

F

H

H: RED <+5 VDC>
N: WHT <HOME>
M: BLK <GND>

C

D

E

14AWG / 4 COND.

MOTOR ENCODER
CABLE

24AWG/ 5TP

WIRE SIDE VIEW

24AWG /TRIO

GRN/YEL

WHT

BLK

WHT/YEL
RED
BLU
YEL
WHT/ORN

WHT/BLU
WHT/RED

WHT/BRN
ORN

BRN

SHIELD

WHT <HOME>

BLK <GND>

RED <+5V>

2

<A>
<+5VDC>
<HOME>
</A>
</C>

<GND>

1

<GND>
<B>
<C>

</B>

<DRAIN>

WIRE SIDE OF CONNECTOR
MOCON END OF CABLE

GRN/YEL

RED

WHT

BLK

SRVOAMP
PH C

SRVOAMP
PH A

SRVOAMP
PH B

RED

1

2

96

Electrical Service

96-0284 rev A June 2006

CABLE, AXIS MOTOR/ENCODER - 28.9 FT (32-1434D)

HOME SWITCH CONNECTOR

WIRE SIDE
OF SOCKET
CONNECTOR

A: WHT/YEL <A>
B: YELLOW </A>
C:WHT/BRN <B>
D:BROWN </B>
E:ORANGE <C>
F:WHT/ORN</C>
G:WHT/RED <GND>
H:RED <+5 VDC>
M: WHT/BLU <GND>
N: BLU <HOME>

DRAIN SHIELD

A

B

M

N

L

T

K

J

C

P
RS

D

E

G

F

H

H: RED <+5 VDC>
N: WHT <HOME>
M: BLK <GND>

MOTOR ENCODER CABLE

MOTOR POWER CABLE

MOTOR BRAKE CABLE

WHT/BLU
WHT/RED

WHT/BRN

WIRE SIDE VIEW

WHT <HOME>

BLK <GND>

RED <+5V>

WHT/YEL
RED
BLU

YEL

WHT/ORN

ORN
BRN

SHIELD

DRAIN WIRE

GRN/YEL

BLK

2

<A>
<+5VDC>
<HOME>
</A>
</C>

<GND>

1

<GND>
<B>
<C>

</B>

<DRAIN>

RED

WHT

RED
DRAIN

12

WIRE SIDE
OF
CONNECTOR

BLK

A: RED <PH-A>
B: WHT <PH-B>
C: BLK <PH-C>
D: GRN/YEL <GND>
D: SHLD <DRAIN>
E: RED <20AWG> <BRK>

F: BLK <20AWG> <BRK>

96-0284 rev A June 2006

F

E

A

G

C

D

WIRE SIDE OF
CONNECTOR

SRVOAMP
PH C

BLK

SRVOAMP
PH B

WHT

B

GRN/YEL

I/O P79

TRANS P9

Electrical Service

SRVOAMP
PH A

RED
DRAIN

RED

BLK

97

CABLE, AXIS MOTOR/ENCODER - 8.25 FT (32-1491B)

A: WHT/YEL <A>

Motor End

B: YELLOW </A>
C:WHT/BRN <B>
D:BROWN </B>
E:ORANGE <C>
F:WHT/ORN</C>
G:WHT/RED <GND>
H:RED <+5 VDC>
M: WHT/BLU <GND>

K

A

M

L

T

J

B

N

P

S

R

G

F

H

DRAIN SHIELD

C

D

E

N: BLU <HOME>

D: GRN/YEL

A

D

C

A: RED

B

B: WHT

C: BLK

WIRE SIDE OF SOCKET CONNECTOR
MOTOR END OF CABLE

14AWG / 4 COND.

24AWG/ 5TP

WHT/YEL
RED
BLU
YEL
WHT/ORN

WHT/BLU
WHT/RED

WHT/BRN
ORN

BRN

SHIELD

2

<A>
<+5VDC>
<HOME>
</A>
</C>

<GND>

1

<GND>
<B>
<C>

</B>

<DRAIN>

MOCON END OF CABLE

GRN/YEL

RED

WHT

BLK

SRVOAMP
PH C

SRVOAMP
PH A

SRVOAMP
PH B

1

2

CABLE, I/O PCB TO MCD CONTROLS (33-1515G)

FACE UP FACE DOWN

PIN 1

<LINE 1A>
540 33-1515

540A 33-1516
850 33-0854
540 33-1517

<LINE 1A>
<LINE 2>
<LINE 3A>

<LINE 1B>

540A 33-1515
540A 33-1516
850 33-0854
540A 33-1517

LENGTH

<LINE 2>

MCD CONTROLS
SMTC DRIVER
CSM SERIAL KBD
MCD CONTROLS

RED STRIPE

<LINE 3A>

MCD PCB P1
SMTC DRVR P1
SKBIF P1
MCD PCB P1

<LINE 1B>
<LINE 2>
<LINE 3B>

<LINE 3B>
I/O PCB P62

I/O PCB P62
PROCESSOR J4
I/O PCB P17

PIN 1

LENGTH

1.00 FT

0.75 FT

1.50 FT

2.20 FT

98

Electrical Service

96-0284 rev A June 2006

CONTACTOR INTERCONNECTION CABLE - 10HP (33-1963A)

BLK

RED

BLU

CABLE, REMOTE JOG HANDLE ASSEMBLY - MOLDED (33-5751F)

1

2

.28

4.5 IN

WHT/BRN <GND>
WHT/YEL <X10>
WHT/ORG <Z>

WHT/BLK <Y>

VIO <B>
BRN <0VDC>

WHT/GRY <FH>
GRN <X1>
YEL <4>

BLK/WHT <C/S>

BLU <X>
BLK <+5VDC>
RED <A>

1.32
.59

FRONT

PANEL

END

33-5751F
JOG HNDL
RJOG P1

16

2

1.13
.56

.56

15

1

1.13

3.06

MADEIN U.S.A.

ASSY#

REM JOG IF SIDE

33-5751F
JOG HNDL
SKBIF J2

2

1

15

16

WIRE SIDE OF
CONNECTOR

RED <A>
BLK <+5>
BLU <X>

YEL <4>
GRN <X1>

BRN <0VDC>

VIO <B>

WHT/BLK <Y>

WHT/ORG <Z>

WHT/YEL <X10>

CLEAR <SHLD>

BLK/WHT

WHT/BRN

WHT/GRY

33-5751E
JOG HNDL
SKBIF P6

6 IN

20 IN

2

1

1

CYC.
STRT

GND
FEED

HOLD

WIRE SIDE OF
CONNECTOR

(0.145)

96-0284 rev A June 2006

(0.750)

(0.980)

(0.500)

(0.855)

(0.160)

(0.570)

(0.60)R., THREE SIDES

(0.050)

(2.300)

(0.586)

(0.050) TYP. 'RIBS'

(0.210)

Electrical Service

R(0.06)

°

(3.78 )

REMOTE JOG HANDLE END

(0.075)

(0.100) TYP. 'SLOTS'

99