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

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.

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Electrical Service

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.

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

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.

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

High Volt Low Volt

Ground Line

75 76

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

HIGH VOLT

LOW VOLT

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

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

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.

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Electrical Service

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

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.

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

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)

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

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).

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Electrical Service

10A230V

P24

PHASE

DETECT

TB3

FU13

FU12

PASS FAIL

NE6

NE5

NE2

NE3

FU8

NE13

NE7

NE12

FU1

NE1

FU2 FU3

NE2

NE3

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).

LE1

R2 R15 R11

FUSE

FU2

FU1

TB1

P11

P12

P13

P10

FUSE

TB2 FU3

F1 & F2

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

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

RED

GND WHT

+5V

RED

GRN

YEL

GND WHT/ RED

BRN

WHT/

YEL

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.

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

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.

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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

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

400

Motor Shroud

Air Solenoid

Assembly

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.

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Spindle Lube Solenoid

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

Lube Line

Main Air Line

Pressure Switch

Electrical Service

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.

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Electrical Service

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.

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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

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

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

HIGH VOLT

LOW VOLT

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

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

Polyphase Bank Transformer

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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.

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Electrical Service

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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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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Electrical Service

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

* 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

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

Electrical Service

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.

M-Code Output Relay Normally Open

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

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

1 M-FIN, Input Signal

2 Input GND

M-FIN DISCRETE INPUT

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

WIRING THE RELAYS

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.

Electrical Service

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

Electrical Service

+ 172 hidden pages

haas 96-0284A Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual