any other party automatically voids the factory warranty.
Haas Technical Publications
June 6, 2013
HAAS SERVICE AND OPERATOR MANUAL ARCHIVE
Electrical Service Manual 96-0284D RevD June 2011 English
•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 qualied
and knowledgeable about the processes.
•Only authorized personnel with the proper training and certication 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
Line Voltage Adjustments ................................................................................................................................5
Front Panel ........................................................................................................................................................9
sl-10 Pendant coMPonents access ..........................................................................................................9
Jog handle ............................................................................................................................................. 11
PoweR on/oFF switches ..........................................................................................................................12
PoweR tRansFoRMeR asseMbly (t1) .........................................................................................................23
PoweR suPPly asseMb ly ..........................................................................................................................24
low voltage PoweR suPPly ..................................................................................................................... 25
Rs-232 seRial inteRFace ......................................................................................................................... 25
Spare User M Code Interface .........................................................................................................................27
M Function Relays (M-Fin) .....................................................................................................................27
Control Memory ..............................................................................................................................................29
Diagnostic Data ...............................................................................................................................................31
Cable List .........................................................................................................................................................37
PCBs, Cable Locations, and Diagrams .........................................................................................................48
oPeRato R Pendant ...................................................................................................................................75
hoRizontal Machine contRol cabinet wiRing diagRaM.............................................................................77
veRtical Machine contRol cabinet wiRing diagRaM ................................................................................ 78
lathe contRol cabinet wiRing diagRaM ..................................................................................................79
Main tRansFoRMeR (low voltage) ............................................................................................................80
Main tRansFoRMeR (high voltage) ........................................................................................................... 81
PoweR distRibution .................................................................................................................................. 82
Install lock-out clasp
and lock with padlock
to secure Circuit
Breaker in the
OFF position.
To avoid possible shock, make sure circuit breakers are appropriately locked off before attempting any
electrical work.
CAUTION! Working with the electrical services required for the machine can be extremely
hazardous. The electrical power must be off and steps must be taken to ensure
that it will not be turned on while you are working with it. In most cases this means
turning off a circuit breaker in a panel and then locking the panel door. However ,
if your connection is different or you are not sure how to do this, check with the
appropriate personnel in your organization or otherwise obtain the necessary
help before you continue.
WARNING!
The electrical panel should be closed and the three screws/latches on the
door should be secured at all times except during installation and service. At
those times, only qualied 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.
Circuit Breaker Warning
Do not reset a circuit breaker until the reason for the fault is investigated. Only Haas-trained service personnel
WO4High 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.
WO5Remote 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.
WO6Air or limit switch or motor overheat. Check that the motor is not hot. Check for any binding in the
motor. Check for overweight tooling.
WO7Z channel fault. Either the encoder or the cable is bad. Change the encoder rst, as it is easier to
change than the cable. If the problem persists, change the cable.
WO8Over-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.
INE VOLTAGE ADJUSTMENTS
L
Please read this section in its entirety before attempting to adjust the line voltage.
Tools Required: Large at tip screwdriver, Digital voltmeter
NOTE: The machine must have air pressure at the air gauge, or a “Low Air Pressure” alarm
1. Place the main circuit breaker in the Off position and hook up the three power lines to the terminals on top
of the main circuit breaker at the upper right-hand side of the electrical panel. Connect the separate ground
line to the ground bus to the left of the terminals.
NOTE: Ensure service wires go into terminal-block clamps. (Do not miss clamp and tighten
screw. Connection looks ne but machine runs poorly - servo overloads.) To check,
pull on wires after screws are tightened.
2. After the line voltage is connected to the machine, make sure that main circuit breaker is off. Turn on the
power at the source. Using an accurate digital voltmeter and appropriate safety procedures, measure the
voltage between all three pair phases at the main circuit breaker and write down the readings. The voltage
must be between 195 and 260V (360 and 480V for high voltage option).
NOTE: Wide voltage uctuations are common in many industrial areas; you need to know
CAUTION! Make sure the main circuit breaker is set to off and the power is off at the supply
the minimum and maximum voltage which will be supplied to the machine while it is
in operation. U.S. National Electrical Code species that machines should operate
with a variation of +5% to -5% around an average supply voltage. If problems with
the line voltage occur, or low line voltage is suspected, an external transformer may
be required. If you suspect voltage problems, the voltage should be checked every
hour or two during a typical day to make sure that it does not uctuate more than
+5% or -5% from an average.
panel before changing the transformer connections. Make sure that all three
black wires are moved to the correct terminal block and are tight.
3. Check the connections on the transformer at the bottom-right corner of the rear cabinet. The three black
wires labeled 74, 75, and 76 must be moved to the terminal block triple which corresponds to the average
voltage measured in step 2 above. There are four positions for the input power for the 260V transformer and
ve positions for the 480V transformer. The labels showing the input voltage range for each terminal position
are as shown in the previous illustration.
4. Transformer T5 supplies 24VAC used to power the main contactor. There are two versions of this
transformer for use on 240 and 400V machines (32-0964B and 32-0965B, respectively). The 240V
transformer has two input connectors located on the transformer bracket, which allow it to be connected
to either a 221-240V range or 180 to 220V range. Users that have 180-240V input power should place the
The 400V transformer has three input connectors located on the transformer bracket, which allow it to be
connected to either a 441-480V range, 381-440V range or 340-380V range. Users with the External High
Voltage Option should place the jumper on the connector marked with the appropriate input voltage. Failure to
place the jumper on the correct input connector will result in either overheating of the main contactor or failure
to reliably engage the main contactor.
A jumper must also be placed on the plate covering the T5 transformer, Measure voltage at the main circuit
breaker and connect the supplied shorting plug to the corresponding connector on the T5 transformer plate.
5. Set the main circuit breaker to ON and check for evidence of problems, such as the smell of overheating
components or smoke. If such problems are indicated, immediately set the main circuit breaker to OFF and
call the factory before proceeding.
T5 Transformer
441-480V
Main
Circuit
Breaker
221-240V
381-440V
180-220V
MEASURE VOLTAGEATMAIN
CIRCUIT BREAKER AND CONNECT
SUPPLIED SHORTING PLUG TO
CORRESPONDING CONNECTOR
340-380V
ON THIS TRANSFORMER
T5 24VAC
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. After the power is on, measure the voltage across the bottom terminals on the main circuit breaker. It
should be the same as the measurements where the input power connects to the main circuit breaker. If there
are any problems, check the wiring.
7. Apply power to the control by pressing the Power On switch on the front panel. Check the high voltage
buss on the Vector Drive (pin 2 with respect to pin 3 on the terminal bus at the bottom of the drive). It must be
between 310 and 360V. If the voltage is outside these limits, turn off the power and recheck steps 2 and 3.
If the voltage is still outside these limits, call the factory. Next, check the DC voltage displayed in the second
page of the Diagnostic data on the display screen. It is labeled DC BUS. Verify that the displayed voltage
matches the voltage measured at pins 2 and 3 of the Vector Drive +/- 7V DC.
If the displayed voltage exceeds the measured voltage by 12 volts or more, install a ferrite EMI lter (64-1252)
to the current command cable near its connection to the vector drive. Secure with a cable tie (See photo).
8. Electrical power must be phased properly to avoid damage to your equipment. The Power Supply
Assembly PC board incorporates a “Phase Detect” circuit with neon indicators, shown below (disregard for
single phase machines). When the orange neon is lit (NE5), the phasing is incorrect. If the green neon is lit
(NE6), the phasing is correct. If both neon indicators are lit, you have a loose wire. Adjust phasing by placing
the main circuit breaker in the Off position and swapping L1 and L2 of the incoming power lines at the main
circuit breaker.
PHASE DETECT
(FOR3PHASE ONLY)
PASSFAIL
NE5NE6
All power must be turned off at the source prior to adjusting phasing.
9. Close the door, lock the latches, and turn the power back on.
10. Remove the key from the control cabinet and give it to the shop manager.
WARNING!
F
USE REPLACEMENT
Please read this section in its entirety before attempting to replace any fuses.
The Power PCB contains two ½-amp fuses located at the top right (FU1, FU3). If the machine is subject to a
severe overvoltage or a lightning strike, these fuses may blow and turn off all power. Replace these fuses only
with the same type and ratings.
15” and Thin Pendant Machines
Size Fuse Name Type Rating (amps) Voltage Location
5x20mm F1/F3 Fast Acting 1 250V PSUP pcb, upper right
OVERVOLTAGE FUSES
The electrical panel will have residual voltage, even after power has been
shut off and/or disconnected . Never work inside this cabinet until the small
green Power On light on the servo ampliers (servo drive assembly on brush
machines) goes out. The servo ampliers/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.
WARNING!
1. Turn machine power off.
2. Place the main circuit breaker (upper right of electrical cabinet) in the off position.
Main
Switch
3. Open the cabinet door and wait until the red charge light on the servo drive assembly goes out before
2. Connect these cables directly to the SKBIF PCB. If the cables that came with the new display are not long
enough, reuse the cables from the old display.
3. Power on the machine and check the display. If the image is blurry, toggle the switches at SW2 on the
SKBIF PCB to correct the problem.
JOG HANDLE
The Jog handle is actually a 100-line-per-revolution encoder, used to move one axis at a time. If no axis
is selected for jogging, turning the handle has no effect. When the axis moved reaches its travel limits, the
handle inputs will be ignored in the direction that would exceed the travel limits. Parameter 57 bit 0 can be
used to reverse the direction of operation of the handle.
Jog Handle Replacement
1. Turn the machine power off.
2. Remove the screws holding the cover on the back of the pendant. Take care to hold the cover in place until
all screws have been removed.
3. Unplug the cable leading to the jog handle encoder.
Blank pin goes to this
side of connector
+5V
BLK
Jog Handle Encoder Jog Handle Removal Jog Handle Wiring Diagram
A
RED
GND
WHT
+5V
RED
B
GRN
4. Using the 5/64” allen wrench, loosen the two screws holding the knob to the control panel and remove.
5. Remove the three screws holding the jog handle encoder to the control panel and remove.
A
YEL
GND
WHT/
RED
B
BRN
A
WHT/
YEL
B
WHT/
BRN
6. Replacement is reverse of removal. Important! The blank pin side of the connector must face as shown
when reconnecting; otherwise, damage may occur to the machine.
The Power On switch engages the main contactor. The On switch applies power to the contactor coil and the
contactor thereafter maintains power to its coil. The Power Off switch interrupts power to the contactor coil
and turns power off. Power On is a normally open switch and Power Off is normally closed. The maximum
voltage on the Power On and Power Off switches is 24V AC and is present any time the main circuit breaker
is on.
EMERGENCY STOP SWITCH
The Emergency Stop switch is normally closed. If the switch opens or is broken, servo power is removed
instantly. This will also shut off the turret, spindle drive, and coolant pump. The Emergency Stop switch will
shut down motion even if the switch opens for as little 0.005 seconds. Note that if Parameter 57 bit 3 is set to
1, it will cause the control to be powered down when Emergency Stop is pressed.
You should not normally stop a tool change with Emergency Stop as this will leave the tool changer in an
abnormal position that takes special action to correct
If the lathe turret or mill tool changer (T/C) becomes jammed, the control will automatically come to an alarm
state. To correct this, push the Emergency Stop button and remove the cause of the jam. Push the Reset key
to clear any alarms. Push Zero Return and the Auto All Axes to reset the Z-axis and turret or T/C. Never put
your hands near the turret or T/C when powered unless E-Stop is pressed.
KEYBOARD BEEPER
There is a beeper under the control panel that is used as an audible response to pressing keyboard buttons
and as a warning beeper. The beeper is a one kHz signal that sounds for about 0.1 seconds when any
keypad key, Cycle Start, or Feed Hold is pressed. The beeper also sounds for longer periods when an autoshutdown is about to occur and when the “Beep at M30” setting is selected.
If the beeper is not audible when buttons are pressed, the problem could be in the keypad, keyboard interface
PCB or in the speaker. Check that the problem occurs with more than one button and check that the beeper
volume is not turned down or disconnected. If lamps do not turn on, check the GFCI plug.
LAMP ON/OFF SWITCH
An on/off switch is supplied for the work lamp. It is located on the side of the operator’s pendant. The lamp
uses 115V AC taken from P19 on the main power distribution board.
SWITCH REPLACEMENT
1. Turn the machine power off. Remove the screws holding the cover on the back of the pendant. Take care to
hold the cover in place until all screws have been removed.
2. Disconnect all leads to the switch connectors. Ensure all leads are properly marked for reconnecting later.
3. Unscrew the two small set screws, one on top and one on the bottom, and turn the switch counterclockwise
to loosen. Separate from the front portion and pull out.
4. To replace, screw the front and rear portions together (reverse of removal) and tighten down the two small
set screws when the switch is properly positioned.
NOTE: The Power On, Power Off, and Emergency Stop switches must all have the connectors
Load meter measures load on spindle motor as a percentage of rated continuous power of motor, with a slight
delay between a load and actual meter reection. The eighth A-to-D input also provides a measure of spindle
load for cutter wear detection. Second page of diagnostic data displays % of spindle load. Meter should
agree with display within 5%. Spindle drive display #7 should also agree with load meter within 5%. There
are different types of spindle drives used in the control, all are equivalent in performance but are adjusted
differently.
Spindle Load Meter Replacement
1. Turn the power off and disconnect power to the machine. Remove the screws holding the cover panel on
the back of the pendant. Take care to hold the cover panel in place until all screws are removed.
2. Disconnect the two leads at the back of the spindle load meter assembly. Ensure the two leads are properly
marked for reconnecting later.
3. Unscrew the four screws that hold the spindle load meter assembly to the control panel. Take care to hold
the assembly in place until all screws have been removed. Remove the assembly.
4. Installation is reverse of removal. Ensure leads go to the correct location.
KEYPAD REPLACEMENT
1. Turn the power off and disconnect power to the machine. Remove the screws holding the rear cover to the
back of the pendant. Take care to hold the cover in place until all screws are removed.
2. Unplug the keypad’s 24-pin ribbon cable from the Keyboard Interface board.
3. Remove the screws from the front of the pendant. Take care to hold the cover in place until all screws have
been removed. Remove the pieces and set aside in a safe place.
4. Using a at, blunt tool, such as putty knife, pry the keypad away from the control panel. Pull the ribbon
cable through the opening in the control to remove.
5. To replace, rst put the bezel spacer in place and fasten temporarily with screws in the top corners.
Gasket
Glass
Keypad
Keypad Installation
Front Bezel
6. Insert the ribbon cable through the opening in the control panel. Expose the adhesive strip on the back of
the keypad and press it into place in the upper right corner of the keypad recess. Press to the control panel to
mount. Plug the ribbon cable into the Keyboard Interface board, taking care to not bend the pins.
7. Replace the front and rear cover panels and fasten with the screws that were previously removed.
SERIAL KEYBOARD INTERFACE REPLACEMENT
NOTE: Refer to “Cable Locations” for a diagram of this board.
1. Follow all precautions noted previously before working in the control cabinet.
2. Turn the main switch (upper right of electrical cabinet) to the off position.
3. Remove the four screws on the back of the pendant, then remove the cover panel. Take care to hold the
panel in place until all screws have been removed.
4. Disconnect all leads to the Serial Keyboard Interface (SKBIF) board. Ensure all cables are properly labeled.
5. After all cables have been disconnected, unscrew the four screws holding the Serial KBIF board to the
control box. Take care to hold the board in place until all screws have been removed. Place the screws and
standoffs aside for later use.
6. Replace the Serial KBIF board, using the four screws previously removed. Starting at the top right, attach
each screw and standoff loosely, until all are mounted, then tighten down.
7. Reconnect all cables to the Serial KBIF board at their proper locations.
8. Verify whether the machine is equipped with either a speaker or a beeper. Align the toggle switches of
Switch 1 on the Serial KBIF board to their appropriate positions. Beeper operation requires that both S1
switches be set to ‘B’; speaker operation requires that both S1 switches be set to ‘S’.
S
OLENOIDS
Please read this section in its entirety before attempting to replace any solenoid assemblies.
TOOL RELEASE PISTON (TRP) AIR SOLENOID ASSEMBLY (HORIZ & VERT)
Removal
1. Turn machine power on and raise spindle head to uppermost position, then turn the power off. Remove air
supply from machine.
2. Remove sheet metal at rear and/or top of machine to access the back of the spindle (Mechanical Service
manual).
3. Disconnect all air lines from the air solenoid assembly (Do not remove ttings). Disconnect the two leads
from the low air pressure sensor.
4. Unscrew the air solenoid assembly from the tool release piston assembly, taking care not disturb the
position of the clamp/unclamp switches. It may be necessary to remove the tool release piston to access the
solenoid assembly.
5. Unplug the wiring leading to the plug marked on the solenoid bracket as “880 from I/O PCB to Solenoid
Valves” and the plug marked “Spare”.
6. Unscrew the air solenoid from the air solenoid assembly. Remove the SHCS holding the assembly to the
bracket and remove the assembly.
Installation
1. Install the new air solenoid. Take care to not disturb the position of the clamp/unclamp switches.
2. Replace air solenoid assembly and attach to bracket with the SHCS previously removed. Tighten securely.
3. Reinstall the tool release piston assembly if removed (see Mechanical Service).
4. Reconnect the two leads to the low air preassure sensor. Reconnect wiring to plugs on solenoid bracket.
5. Ensure all air lines are reconnected to their proper ttings. Reconnect air supply to the machine, and check
2. a. Lathe: Disconnect the lube line from the spindle lube air solenoid assembly.
b. Mill: Disconnect the air lines from the spindle lube air solenoid assembly.
3. Disconnect the electrical leads from the main air line pressure switch.
4. Lathe: Unscrew the solenoid assembly pressure gauge from the assembly.
5. Unscrew the entire solenoid assembly from the T-tting.
Installation
1. Reattach the solenoid assembly at the T-tting.
2. a. Lathe: Replace the pressure gauge on the solenoid assembly and reconnect the lube line.
b. Mill: Reconnect all air lines.
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.
ENCODERS
Damaged Encoder Strip/Read Head
The encoder read head and strip are used on SL-20/30/40 but not SL-20/30 long bed. If the encoder strip is
damaged, it is possible that it can also damage the encoder read head. Alarm 437 (Tailstock Undershoot) will
be generated.
If the read head is damaged the tailstock will not home. It will go home and then go in the negative direction.
There is no number display on the B-Axis while the axis is in motion.
When replacing the encoder strip it is recommended that the encoder read head be removed rst to avoid
damaging it.
String Encoder
The string encoder is used on all SL-20/30 long bed and all ST models (Optional on SS models). The string
is wound up and retracted on a calibrated spool (like a shing reel). If the string is not retracted properly, the
encoder will misread and eventually fail generating alarm 437- Tailstock Undershoot.
SMART AMPLIFIER TROUBLESHOOTING
The Smart Amplier has a microprocessor incorporated in the design. This allows the amplier to detect and
report detailed alarms. The software level necessary to display these new alarms is 15.02A or newer.
The Smart Amplier is backward compatible to any machine that has a Vector Drive. New Smart Ampliers
and standard ampliers may be used in any combination in the machine. However, if the machine does not
have at least 15.02A software or newer the specic Smart Amplier will not be displayed. The Smart Amplier
and the standard amplier use the same Parameters. On non-thin pendant machines, at least two of the
standard ampliers must be used.
The Smart Amplier does not have a 12VDC connector, and both the Fault (Red LED) and the Run (Green
LED) are relocated. The 320VDC (H+ and H-) and the X, Y and Z-axis connections are also relocated.
The smart amplier will calibrate utilizing the microprocessor that is present in each of the Smart Ampliers
at power up. When power is applied to the Control Cabinet the Fault (Red LED) will illuminate and stay
illuminated for a short time (approximately 5 seconds), this is called the “A” Phase Calibration. Then both
LEDs will be out for a few seconds; this is called the “B” Phase Calibration. Next the Run (Green LED) will
illuminate, indicating the Smart Amplier is ready with no faults.
See TB0008 when replacing a non-smart amp with a smart amplier.
SMART VECTOR DRIVE TROUBLESHOOTING
The smart vector drive features a microprocessor that allows it to detect and display specic alarms (software
version 15.02A or newer only). It is backward compatible to any machine with a vector drive regardless of
software version; however, the drive-specic alarms will not display in older software. Such alarms will dis-
play in the same way as with old-style drives.
Smart vector drives installed in new machines include a cover, and the machines electrical cabinet door is
cut to accommodate it. Service drives are shipped without the cover for installation in older machines. When
replacing a drive in a machine built to accommodate the cover, use the cover from the old drive.
When installing a smart vector drive without the cover, install the cover plate to the front of the vector drive.
When installing with the cover, install the cover plate to the top of the vector drive.
You will also need several cables. Please see 93-32-5558A for the 40 HP drive and 93-32-5559A for the 20
HP drive.
Troubleshooting
To properly troubleshoot the Vector Drive, use the following questions as a guide:
• What alarms are generated?
• When does the alarm occur?
• Is the Vector Drive top fault light on?
• Is there a fault light on any of the servo ampliers?
• Does the alarm reset?
• Does the spindle motor turn at all?
• Does the spindle turn freely by hand?
• Have the C-axis parameters been conrmed?
• What is the input voltage to the vector drive unit?
• What does the DC Bus voltage measure? (320 VDC to 345 VDC)
• Does the DC Bus voltage displayed on the diagnostic page match the measured DC Bus voltage?
All of the questions above must be answered. The DC Bus voltage should be between 320 VDC to 345 VDC
with the machine powered up but not running. If the voltage is not in this range, adjust the taps on the main
line transformer until this voltage range is achieved. There is a possibility the drive is faulty, but low Bus volt-
age can also be caused by a shorted REGEN load or a shorted amplier.
If the DC Bus voltage is below 50 VDC and never goes any higher, perform Steps 1-6.
1. With the machine powered up, is the green “POWER-ON” L.E.D. lit? If not, replace the Vector Drive unit.
2. Power down the machine. Disconnect the REGEN load (terminals 1 and 2 on the Vector Drive unit) and
measure the resistance from each wire-to-chassis ground (open) and between the wire leads. The resis-
tance should be 8.6 ohms for machines with 20/15 Vector drives and HT10K mills equipped with 40/30
drives. All other machines with 40/30 drives should measure 6 ohms. If not, replace the REGEN load or
cabling.
3. Disconnect cable 490 at terminals 2 and 3 of the Vector Drive and from the servo ampliers. With a mul-
timeter in the diode mode, place the red meter lead to the +HV terminal and the black meter lead to the
-HV terminal of each amplier. The meter should read open.
4. Reverse the leads: Place the red meter lead on the -HV terminal and the black lead on the +HV terminal.
The meter should read .7 ohms in both instances. If not, replace the faulty amplier.
5. Measure the resistance between terminals 1 and 3 of the Vector Drive. The meter should read greater
than 100K ohms. If not, the Vector Drive is faulty.
6. If the green “POWER-ON” L.E.D. was lit (from Step 2), leave both 490 cables (2 and 3) disconected from
the drive and power up the machine.
a. Does the DC Bus voltage come up? If not, the Vector Drive is faulty.
b. Measure the voltage between terminals 1 and 3. The voltage should be 300 VDC or more. If not, the
Vector Drive is faulty.
If both ‘a’ and ‘b’ check out okay, there is a problem with either the ampliers or the REGEN load.
If the fault occurs upon acceleration -or- the spindle accelerates slowly -or- the spindle
makes noise, do the following:
7. Disconnect the output cables to the spindle motor. Turn on the machine and press <RESET>. Do not
command the spindle to turn. With a volt meter, measure the DC voltage between each output phase (ter-
minals 9, 10, and 11) to the 320V RTN (terminal 3). The meter should read 165 VDC in each case, else
one phase is faulty.
8. Measure the resistance across the motor wires from phase to phase and from each phase to chassis. The
meter should read .1 ohms phase-to-phase and open phase-to-chassis. If the fault occurs upon decel-
eration or acceleration just as the spindle reaches its specied speed, or if an overvoltage alarm (119)
occurred, do the following:
9. Disconnect the REGEN load resistors (terminals 1 and 2) and measure the resistance from each wire
lead-to-chassis ground and between the wire leads. The meter should read open lead-to-ground, and 6
ohms between the leads for machines with 40/30 Vector drives and 8.6 ohms between the leads on ma-
chines with 20/15 Vector drives and HT10K mills.
10. Measure the resistance from terminal 1 to terminal 3. If the resistance is less than 100K, the drive is
faulty.
11. With the REGEN load left disconnected, power-up the machine and command a spindle speed of 700
RPM (300 RPM for lathes in high gear). Press <RESET> while monitoring the DC voltage between termi-
nal 1 and terminal 3. The voltage should read 330 VDC and then drop to less than 50 VDC momentarily. If
not, that drive is faulty. If the voltage at RESET was okay and the alarm was resettable, the REGEN load
should be replaced even if the resistance appears to be okay.
PCB R
EPLACEMENT
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.
Coldre II testing.
This test will erase both BBU and Flash memory. Prior to conducting this test, you will need to back up
Parameters, Offsets, Settings, Variables, Programs, etc. just as you would when doing a software load. You
will also need to be prepared to reload the software binary le that was previously loaded. If the processor
passes all the tests, you should not have to replace it.
Procedure:
1. Press and hold <PRGRM /CONVRS> while powering on the control.
2. From the prompt press <E> then <WRITE/ENTER>
3. There will be a few questions to answer. Answer “Y” to MOCON, and 16MB and “N” to Video Board Con-
nected.
4. After the third pass of tests (see Figure 2) press <RESET>.
5. Re-Load software following normal software load procedures.
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 ampliers go out. The servo ampliers are on the left
side of the main control cabinet and about halfway down. This light is at the
top of the circuit card at the center of the assembly. Until this light goes out,
there are dangerous voltages in the assembly even when power is shut off.
Ground straps must be used when handling boards.
WARNING!
NOTE: Board arrangement may differ from the order of replacement that follows. Steps for
MOTORCONTROLLER (MOCON)
Machines are equipped with a microprocessor-based brushless motor controller board (MOCON) that
replaces the motor interface in the brush type controls. It runs in parallel with the main processor, receiving
axis commands and closing the loop around the axis motors.
In addition to controlling the axis and detecting axis faults, the motor controller board (MOCON) is also in
charge of processing discrete inputs, driving the I/O board relays, commanding the spindle, and processing
the jog handle input. It also controls 6 axes, so there is no need for an additional board for a 5-axis machine.
Four LEDs are used to diagnose MOCON problems:
The RUN” LED will turn on, indicating that Mocon code was found in ROM and is being executed. This LED
will turn off if a processor exception causes the Mocon code to abort execution.
replacement will only differ in which board may need to be removed before getting
to the necessary board.
The “STAT” LED indicates the following (Specic to Mocon 11.00 or later software)
a. Continuously ON - Normal status. board passed all power-on tests; no problems encountered
b. Blinks 3 times - Communication with main processor failed
c. Blinks 4 times - Internal ±12V testing failed
d. Blinks 5 times - Internal watchdog circuit failed
e. Blinks rapidly - EPROM CRC failed
The “Halt” LED glows when the board is in use (processing).
The “+5” LED lights when the board has power.
MOCON Board Replacement
1. Turn machine power off and turn the main switch (upper right of electrical cabinet) to the off position.
2. Open the cabinet door enough to safely work on the electrical panel. Wait until the red charge light on the
servo ampliers (servo drive assembly on brush machines) goes out before beginning any work.
3. Disconnect all leads to the Motor Controller (MOCON) board, and ensure all cables are properly labeled.
4. After all cables have been disconnected, unscrew the standoffs, taking care to hold the board in place until
all standoffs have been removed.
NOTE: If the Video/Keyboard or Processor boards need replacing, skip the next step.
5. Replace the MOCON board, attaching it to the Video/Keyboard (beneath the MOCON board) with the
standoffs, and reconnect all leads (previously removed) to their proper connections.
6. If a second MOCON board is present, be sure to connect the jumper on the second MOCON board.
The Video/Keyboard PCB generates the video data signals for the monitor and the scanning signals for the
keyboard. In addition, the keyboard beeper is generated on this board. There is a single jumper on this board
used to select inverse video. The video PCB connectors are:
P1 Power connector J11 SPARE
J3 Keyboard (700) J12 Floppy
J4 Address bus J13 Video (760)
J5 Data J14 RS422 B
J10 Floppy V+ J15 RS422 A
Video/Keyboard Replacement
1. Remove the MOCON board as previously described.
2. Disconnect all leads to the Video/Keyboard. Ensure all cables are properly labeled for reconnecting later.
3. After all cables have been disconnected, unscrew the standoffs, taking care to hold the board in place until
all standoffs have been removed.
NOTE: If the Processor board needs replacing, skip the next step.
4. Replace the Video/Keyboard, attaching it to the Processor board with the standoffs.
5. Reconnect all leads (previously removed) to their proper connections.
6. Replace the MOCON board.
M
ICROPROCESSOR PCB (68ECO30)
The Microprocessor PCB contains the 68ECO30 processor running at 40 MHz, one 128K EPROM; between
1MB and 16MB of CMOS RAM and betwen 512K and 1.5MB of Fast Static RAM. It also contains a dual serial
port, a battery to backup RAM, buffering to the system buss, and eight system status LED’s.
Two ports on this board are used to set the point at which an NMI is generated during power down and the
point at which Reset is generated during power down.
The eight LEDs are used to diagnose internal processor problems. As the system completes power up testing,
the lights are turned on sequentially to indicate the completion of a step. The lights and meanings are:
RUN Program Running Without Fault Exception. (Normally On) - If this light does not come on, or goes
out after coming on, there is a problem with the microprocessor or the software running in it. Check all
of the buss connectors to the other two PCBs and ensure all three cards are getting power.
PGM Program Signature Found in Memory. (Normally On) - If this light does not come on, it means that
the main CNC program package was not found in memory, or that the auto-start switch was not set.
Check that Switch S1-1 is on and the EPROM is plugged in.
CRT CRT/LCD Video Initialization Complete. (Normally On) - If the light does not come on, there is a
problem communicating with the Video PCB. Check buss connectors to ensure it is getting power.
MSG Power-on Serial I/O Message Output Complete. (Normally On) - If light does not come on, a
problem exists with serial I/O or interrupts. Disconnect anything on the external RS-232 and retest.
SIO Serial I/O Initialization Complete. (Normally On) - If this light does not come on, there is a problem
with the serial ports. Disconnect anything on the external RS-232 and test again.
POR Power-On-Reset Complete. (Normally On) - If this light does not come on, there is a problem with
the Processor PCB. Check that the EPROM is plugged in. Test the card with buss connectors off.
HALT Processor Halted in Catastrophic Fault. (Normally Dim) - If this light comes on, there is a problem
with the Processor PCB. Check that the EPROM is plugged in. Test the card with buss connectors off.
+5V +5V Logic Power Supply is Present. (Normally On) - If this light does not come on, check the low
voltage power supply and check that all three phases of 230V input power are present.
There is 1 two-position DIP switch on the Processor PCB labled S1. Switch S1-1 must be ON to auto-start the
CNC operational program. If S1-1 is OFF, the PGM light will remain off. Switch S2-1 is used to enable Flash.
If it is disabled it will not be possible to write to Flash.
The processor connectors are:
J1 Address buss J5 Serial port #2 (for auxiliary 5th axis) (850A)
J2 Data buss J3 Power connector
J4 Serial port #1 (for upload/download/DNC) (850) J6 Battery
Alarm 124 indicates an imminent battery failure. To preserve CMOS RAM contents while the machine is pow-
ered off, the 3.3V lithium battery must be replaced within 30 days of the rst alarm. To replace the battery:
1. Backup all parameters, settings, programs, offsets, history, and macro variables.
2. Haas kit 32-1010 includes a temporary battery with a jumper connector. Plug this jumper into J6 (68K PCB)
or J15 (Coldre PCB). This ensures that memory contents are retained during the procedure.
NOTE: Do not remove the existing battery before the backup battery is installed, or remove
the backup before a fresh battery has been installed. This will result in complete machine memory loss, which cannot be reversed.
3. Properly ground yourself and unsolder the battery from the processor board.
4. Clean the battery contact areas and solder the new battery in place, observing correct battery orientation
(the positive battery connector is marked on the board and circled in the previous photograph).
5. With the new battery in place, disconnect the backup battery jumper.
Processor Board Replacement
1. Remove the MOCON board, and the Video/Keyboard as previously described.
2. Disconnect all leads to the Processor board. Ensure all cables are properly labeled for reconnecting later.
3. After all cables have been disconnected, unscrew the standoffs, taking care to hold the board in place until
all standoffs have been removed.
4. Replace the Processor board, attaching it to the electrical cabinet with the standoffs, reconnect all leads
(previously removed) to their proper connections, and replace Video/Keyboard and MOCON board.
The Input/Output Assembly consists of a single printed circuit board called the I/O PCB.
The I/O PCB also contains a circuit for sensing a ground fault condition of the servo power supply. If more
than 1.75 amps is detected owing through the grounding connection of the 160V DC buss, a ground fault
alarm is generated and the control will turn off servos and stop.
Relay K6 is for the coolant pump 230V AC. It is a plug-in type and is double-pole. Relays K9 through K12 are
also plug-in types for controlling the tool changer motors.
I/O Board Replacement
1. Follow all precautions noted previously before working in the electrical cabinet.
2. Disconnect all leads to the Input/Output board and move aside for removal. Ensure all cables are properly
labeled for reconnecting later.
3. Remove the board by rst removing the twelve screws that fasten it to the cabinet. Take care to hold the
board in place until all screws have been removed.
4. Replace the I/O board, attaching it to the cabinet with the twelve screws previously removed, and reconnect
all leads to the I/O board. Check for any additional jumper settings per I/O release notes.
POWER TRANSFORMER ASSEMBLY (T1)
The power transformer assembly converts three-phase input power (50/60Hz) to three-phase 230V and
115V power. Two transformers are used, depending on the input voltage range. The low voltage transformer
has four input connections to allow for a range of voltages from 195V RMS to 260V RMS. The high voltage
transformer has ve input connections and will accept a range of voltages from 354V RMS to 488V RMS.
The 230V is used to power the spindle drive. THe 230V also supplies the power to the vector drive, which
supplies 325V DC power for the axis servo ampliers. 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.
Ouput
Power
Input
Power
TB2
240VOUT
488-458V
457-429V
260-244V
D
A
INCOMINGLINE VOLTAGETAPS (74,75, 76)
N
428-403V
G
E
243-227V
R
!
!
402-377V
!
H
226-211V
I
G
TB1
120VOUT
376-354V
H
V
210-195V
O
L
T
A
G
E
D
A
N
G
E
R
!
!
!
.
Polyphase Bank Transformer
Primary Connection To T1
Input power to T1 is supplied through CB1, the main circuit breaker. Three-phase 230 to T1 is connected to
the rst three terminals of TB10.
Circuit breaker CB1 protects the spindle drive and shuts off all power to the control. A trip of this breaker
indicates a serious overload problem and should not be reset without investigating the cause of the trip.
Main Contactor K1
Main contactor K1 is used to turn the control on and off. The Power On switch applies power to the coil of K1
and after it is energized, auxiliary contacts on K1 continue to apply power to the coil. The Power Off switch on
the front panel will always remove power from this contactor.
When the main contactor is off, the only power used by the control is supplied through two ½ amp fuses to
the circuit that activates the contactor. An overvoltage or lightning strike will blow these fuses and shut off the
main contactor.
The power to operate the main contactor is supplied from a 24V AC control transformer that is primary fused
at ½ amp. This ensures that the only circuit powered when the machine is turned off is this transformer and
only low voltage is present at the front panel on/off switches.
Voltage Selection Taps
There are four labeled plastic terminal blocks. Each block has three connections for wires labeled 74, 75, and
76. Follow the instructions printed on the transformer.
Secondary Connection To T1
The secondary output from T1 is 115V AC three-phase CB2 that protects the secondary of transformer T1 and
is rated at 25 amps.
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 control power passes through a power supply assembly on the upper right corner of the control cabinet.
Power PCB (PSUP)
Low voltage power distribution and high voltage fuses and circuit breakers are mounted on a circuit board
called the Power PCB.
Secondary Circuit Breakers
The following circuit breakers are located on the Power supply assembly:
CB2Controls the 115V power from the main transformer to the I/O PCB and, if tripped, will turn off all
inputs and outputs. CB2 could be tripped by a short circuit in the cables.
CB3Controls the power to coolant pump only. It can be tripped by an overload of the coolant pump
motor or a short in the wiring to the TSC motor, or lathe hydraulic pump.
CB5 Controls power to the TSC coolant pump only. It can be tripped by an overload of the TSC coolant
pump motor or a short in the wiring to the motor.
CB6 Single-phase 115V protected ground fault interrupt circuit and output for the worklight.
Power PCB (PSUP) Replacement
1. Follow all precautions noted previously before working in the electrical cabinet
2. Disconnect all leads to the Power PCB (PSUP) and set aside for removal. Ensure all cables are properly
labeled for reconnecting later.
3. After all cables have been disconnected, remove the seven screws holding the Power board to the cabinet
and remove the board. Take care to hold the Power board in place until all screws have been removed.
NOTE: If replacing the Low Voltage Power Supply board, please skip the next step.
4. Replace the Power board, attaching it with the seven screws previously removed. Do not forget to use the
lower left screw for a ground connection.
5. Reconnect all cables to Power board at proper location. Refer to release notes for additional information.
LOW VOLTAGE POWER SUPPLY
The low voltage power supply provides +5V DC, +12V DC, and -12V DC to all logic sections of the control. It
operates from 115V AC nominal input power, and continues to operate correctly over 90 to 133V AC.
Low Voltage Power Supply (LVPS) Replacement
1. Remove the Power Distribution (Power) board as previously described.
2. Disconnect all leads to the Low Voltage Power Supply (LVPS) board. Ensure all cables are properly labeled
for reconnecting later.
3. After all cables are disconnected, unscrew the two standoffs at the bottom of the board. Unscrew the
remaining two screws at the top of the LVPS board. Hold the board in place until all screws are removed.
4. Replace the LVPS board, attaching it to the cabinet with the two screws and standoffs previously removed.
5. Replace the Power board as previously described.
RS-232 SERIAL INTERFACE
There are two connectors used for the RS-232 interface. The RS-232 connector on most PCs is a male DB25, so only one type of cable is required for connection to the controller, or between controllers. This cable
must be a DB-25 male on one end and a DB-25 female on the other. Pins 1, 2, 3, 4, 5, 6, 7, 8, and 20 must
be wired one-to-one. It cannot be a Null Modem cable, which inverts pins 2 and 3. To check cable type use
a cable tester to check that communication lines are correct. The controller is DCE (Data Communication
Equipment). This means that it transmits on the RXD line (pin 3) and receives on the TXD line (pin 2). The
RS-232 connector on most PCs is wired for DTE (Data Terminal Equipment), requiring no special jumpers.
The Down Line DB-25 connector is only used when more than one controller is to be used. The rst
controller’s down line connector goes to the second controller’s up line connector, etc.
Interfacing a Haas Rotary Control to the mill
The RS-232 interface sends and receives seven data bits, even parity, and two stop bits. The interface must
be set correctly. The data rate can be between 110 and 19200 bits per second. When using RS-232, it is
important to make sure that Parameter 26 (RS-232 Speed) and 33 (X-on/X-off Enable) are set to the same
value in the controller and PC.
If Parameter 33 is set to on, the controller uses X-on and X-off codes to control reception, so be sure your
computer is able to process these. It also drops CTS (pin 5) at the same time it sends X-off and restores CTS
when is sends X-on. The RTS line (pin 4) can be used to start/stop transmission by the controller or the X-on/
Xoff codes can be used. The DSR line (pin 6) is activated at power-on of the controller and the DTR line (pin
20 from the PC) is not used. If Parameter 33 is 0, the CTS line can still be used to synchronize output.
When more than one Haas controller is daisy-chained, data sent from the PC goes to all of the controllers at
the same time, requiring an axis selection code (Parameter 21). Data sent back to the PC from the controllers
is ORed together so that, if more than one box is transmitting, the data will be garbled. Because of this, the
axis selection code must be unique for each controller.
RS-232 Remote Command Mode
Parameter 21 must be non-zero for the remote command mode to operate as the controller looks for an axis
select code dened by this parameter. The controller must also be in RUN mode to respond to the interface.
Since the controller powers-on in Run mode, remote unattended operation is thus possible.
RS-232 Line Noise
To minimize line noise on the serial port, reroute the cables straight up the left-hand side of the control to the
processor stack. Do not run them above the I/O PCB or up the center wire channel to the processor.
Transmission errors may be best minimized with a good common ground between the PC and CNC control.
RS-232 Loop Back Test
If you have a communications problem between Port #1 of the machine and your external computer, use the
following procedure to isolate the problem to either internal or external causes.
1. Unplug the cable from Port #1 of the Control Panel, and plug the cable tester in (port #1).
PLUG TESTER
BACK VIEW
The RS-232 Plug Tester is a 25-pin male connector with the following pins shorted.
Pins 2 & 3 and Pins 14 & 16
In order to properly perform the test, Setting 14 must be set to CTS/RTS.
2. If the machine is on, cycle the power (power down then turn back on).
3. Press List Prog, followed by press Param Dgnos twice, then press Send RS232.
4. If the internal serial port is working, the lower left-hand part of the screen will display Serial Passed. (This
means that the system, to the output of the control panel, is working. Check the cable to the computer
set-up if you still have a communications problem.)
If the internal serial port is bad, the lower left-hand part of the screen will display Serial Failed. (This means
there is a problem inside the control panel, or that the test connector is unplugged or missing.)
RS-232 PCB Replacement
1. Follow all precautions noted previously before working in the electrical cabinet.
NOTE: It is necessary, when replacing the RS-232 board, to work from the inside and
2. On the left side of the cabinet, at the top of the side panel, are two serial port connections labeled “Serial
Port #1” and “Serial Port #2”. Serial Port #1 is the upper connection.
3. To remove the RS-232 board, unscrew the two hex screws (on the exterior of the cabinet) holding the
connector to the cabinet. From the inside of the cabinet, pull the connector through the panel, and disconnect
the cable.
4. Replace the RS-232 board by rst connecting the appropriate cable to the board (850 to Serial Port #1,
850A to Serial Port #2, then inserting the board (cable side up) through the left side panel. Attach with the two
hex screws previously removed. Ensure the board for Serial Port #1 is the upper connector and the board for
Serial Port #2 is the lower connector.
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:
RunningWaiting
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.
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 specic machine Inputs and Outputs.
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.
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.
WIRINGTHE RELAYS
Relays are marked on the I/O PCB, with their respective terminals forward of them. If the optional 8M relay
board is installed, connections on the I/O PCB are unused, since they are replaced by relays on the optional
board. Refer to the gure, and the Probe Option gure in the Electrical Diagrams section for terminal labeling.
SWITCHES
X, Y, Z Travel Limit Switches
Machine zero position is dened by a limit switch for each of the X, Y, and Z axes. After search for machine
zero is complete, these switches are used to limit travel in the positive direction. Negative direction travel is
limited by stored stroke limits. It is not normally possible to command the servo axes past the machine zero
as servo travel lookahead will decelerate and stop each motor prior to exceeding the stroke limits.
Prior to performing a Power Up/Restart or an Auto All Axes operation, there are no travel limits. You can jog
into the hard stops in either direction for X, Y, or Z. After a Zero Return has been performed, the travel limits
will operate unless an axis hits the limit switch. When the limit switch is hit, the zero returned condition is reset
and an Auto All Axes must be done again to ensure you can still move the servo back away from it.
The limit switches are normally closed. When a search for zero operation is being performed, the X, Y, and Z
axes will move towards the limit switch unless it is already active (open); then move away from the switch until
it closes again; then continue to move until the encoder Z channel is found. This position is machine zero.
On some mills, the auto search for zero in the Z-axis is followed by a rapid move from the limit switch position
down to the tool change position, making the Z-axis a little different from the other axes. The position found
with the limit switch is not machine zero but is the position used to pull tools out of the spindle. Machine zero
for Z is below this by Parameter 64. Be careful during the Z zero search and stay clear of that rapid move.
What Can Go Wrong With Switches?
Proximity switches are distance sensitive, and must be set no farther than .12” (3mm) away from an assembly
or limit ag. An improperly set proximity switch will give inconsistence results, which may be interrupted as
another problem. Any time a switch is replaced ensure the proper distance is set.
• If the machine is operated with Limit Switch inputs disabled, a Low Lube and Door Open alarm is generated.
In addition, Home search will not stop at the limit switch and instead runs into the physical stops on each axis.
• If the switch is damaged and permanently open, the zero search for that axis will move in the negative
direction at about 0.5 in/min until it reaches the physical travel stops at the opposite end of travel.
• If the switch is damaged and permanently closed, the zero search for that axis will move at about 10 in/min
in the positive direction until it reaches the physical stops.
• If the switch opens or a wire breaks after the zero search completes, an alarm is generated, the servos are
turned off, and all motion stops. The control will operate as though the zero search was never performed.
Reset can be used to turn servos on, but you can jog that axis slowly.
Clamp/Unclamp Switches
There are two switches used to sense the position of the turret or tool clamping mechanism. They are both
normally closed and one will activate at the end of travel during unclamping and the other during clamping.
When both switches are closed, it indicates that the turret or drawbar is between positions.
The diagnostic display can be used to display the status of the relay outputs and the switch inputs.
Door Hold Switch
The switch is normally closed. When the door opens, the switch opens and the machine stops with a “Door
Hold” function. When the door is closed again, operation continues normally.
If the door is open, it is not possible to start a program. Door hold will not stop a tool change operation, will not
turn off the spindle, and will not turn off the coolant pump. The door hold function can be temporarily disabled
with Setting 51, but this setting will return to Off when the control is turned off.
Tool #1 Sense Switch
The tool rotation turret has a switch activated when tool one is in position or facing toward the spindle. At
Power On this switch can indicate that tool #1 is in the spindle. If this switch is not active at power-on, the rst
tool change will rotate the turret until the switch engages and then move to the selected tool. The diagnostic
display will show the status of this input switch as “Tool #1”. A “1” indicates that tool #1 is in position.
Umbrella Tool Changer Geneva Wheel Position Mark (Vert)
The turret rotation mechanism has a switch mounted so that it is activated for about 30
Geneva mechanism. When activated, this switch indicates that the turret is centered on a tool position. This
switch is normally closed. The diagnostic display will show this status of this input switch as “TC MRK”. A “1”
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
CONTROL MEMORY
Gearbox Assembly and are difcult to reach. Removal of this assembly is necessary
to replace these switches. See the Mechanical Components Service Manual, for
Spindle Motor and Transmission removal.
The Haas processor board contains three types of memory:
• Flash Memory - stores the binary and language les (software). Information stored only changes when the
serviceperson loads a new binary le. Flash memory retains its contents even when the power is turned off.
• Random Access Memory (RAM) - When the machine is powered up the processor board copies the binary
le and the selected language text from the ash memory into RAM, which is run from there. RAM also holds
internal information that the control needs while it is running, such as current position, displays screens, etc.
When the user selects a different language, it is copied over the last language. Information stored in RAM is
not retained when the machine is turned off.
• Battery Backed-up Random Access Memory (BBU-RAM) - This type of memory uses an on-board
battery to retain its information after the machine is turned off. If battery power is low the memory gets
corrupted, and if the battery voltage goes to zero, the memory goes blank. Battery Backed up memory holds
information such as user programs, Settings, Parameters, Offsets.
Clearing Processor Memory (Coldre):
At the prompt, >, type in the following and press, “enter” to test and clear BBU Ram:
M 6000000 60FFFFF
The following message is repeatedly displayed until Reset is pressed to stop the BBU RAM memory test:
Memory test passed, press and hold reset to stop
To clear Flash Memory (Coldre Processor):
Type “FC” and press enter
The following message will be displayed:
ERASING FLASH – PLEASE WAIT…
FIRST FLASH CHIP ERASED
FLASH CLEAR COMPLETE
NOTE: This ash memory clear will not erase the ColdFire monitor program
Clearing the memory in a control
At times it is necessary to clear the memory of the machine. This may have to be done to update software, or
do remove corrupted software. To do this follow the steps for the specic type of memory. The next two steps
must be followed to prepare the machine.
1. The programs, settings and other control information must be saved before clearing the memory. It may be
necessary to turn off Setting 23 to save the macro variables. The following are the les to save:
PROGRAMS (PGM) SETTINGS (SET) OFFSETS (OFS)
PARAMETERS (PAR) MACRO VARIABLES (VAR)
Disconnect the RS-232 cables, if used.
2. Turn off the machine and then turn it back on while holding the PRGRM CONVRS button. The display will
be similar to the following:
HAAS 68030 MONITOR ddd-mmm-yy
FLASH MEMORY FOUND: 1024K @ 00080000
BBU RAM FOUND: 1024 K (1024K of BBU-RAM)
68882 COPROCESSOR NOT FOUND
This example shows 1024K of ash memory at address 80000 and 1024K of BBU-RAM. Write down what the
machine has before continuing.
Clearing the BBU-RAM (68K Processor)
1. Type in “M 3000D6C 300FFFF” and press Enter. The control responds with “Memory Test Passed” written
several times. The command “M3000D6C” checks and clears just a portion of the BBU-RAM. It avoids the
section that contains the serial number of the machine (Setting 26). Most problems can be solved without
removing the serial number.
2. Press and Hold Reset until you see “>” displayed. If the “>” does not display, continue to step 3.
3. This step will clear the BBU-RAM completely including the machine serial number. Use the following to
determine the command to clear BBU-RAM.
BBU RAM Found Board Size Command to Clear BBU-RAM
256K 256K M 3000000 303FFFF
1024K 1 megabyte M 3000000 30FFFFF
4096K 4 megabyte M 3000000 33FFFFF
8192K 8 megabyte M 3000000 37FFFFF
16384K 16 megabyte M 3000000 3FFFFFF
To Clear BBU- RAM as per the example, Type the following and press Enter:
M 3000000 30FFFFF (for 1024K)
Clearing Flash Memory:
Clearing Flash Memory will solve problems caused by fragments of code left behind from previous binary or
language les. The most common problem is BAD LANGUAGE VERSION alarm. To clear the ash memory,
a value is entered to tell the system where it is located. Following these steps will clear the memory or give
you the message, “Undened Command”, or a similar message.
If the control displayed the amount of ash memory in step 2 of “Clearing the memory in the control”, then do
one of the following depending upon how much ash Memory is found:
Enter FC 80000 200000 and press enter (for 1536K of FLASH)
Enter FC 80000 280000 and press enter (for 2048K of FLASH)
Enter FC 80000 380000 and press enter (for 3072K of FLASH)
Enter FC 8000 and press enter (for 0.5MB of FLASH)
Enter FC 100000 and press enter (for 1.0MB of FLASH)
Enter FC 180000 and press enter (for 1.5MB of FLASH)
If you get the message “Undened Command” (or similar) perform the following steps.
Enter FC 8000 FFFFF and press enter (to clear 80000 thru FFFFF)
Enter FC 100000 17FFFF and press enter (to clear 100000 thru 17FFFF)
Enter FC 180000 1FFFFF and press enter (to clear 180000 thru 1FFFFF)
The ash memory is now cleared and software must be loaded to continue.
If the control is prior to 1997, 512K x 8 bit RAM chips are used on the processor PCB. These can be cleared
as follows:
Enter the following for 4 chips: FC 20000 9FFFF and press enter
Enter the following for 5 chips: FC 20000 BFFFF and press enter
Enter the following for 6 chips: FC 20000 DFFFF and press enter
Enter the following for 7 chips: FC 20000 FFFFF and press enter
The ash memory is now cleared and software must be loaded to continue.
DIAGNOSTIC DATA
The Alarm Msgs display is the most important source of diagnostic data. At any time after the machine com-
pletes its power-up sequence, it will either perform a requested function or stop with an alarm. Refer to the
Alarms chapter for their possible causes and some corrective action.
If there is an electronics problem, the controller may not complete the power-up sequence and the monitor
will remain blank. In this case, there are two sources of diagnostic data; these are the audible beeper and the
LEDs on the processor PCB. If the audible beeper is alternating a ½ second beep, there is a problem with the
main control program stored in EPROMs on the processor PCB. If any of the processor electronics cannot be
accessed correctly, the LEDs on the processor PCB will or will not be lit.
If the machine powers up but has a fault in one of its power supplies, it may not be possible to ag an alarm
condition. If this happens, all motors will be kept off and the top left corner of the monitor will display a Power
Failure Alarm message, and all other functions of the control will be locked out.
When the machine is operating normally, a second push of the Param/Dgnos key selects the diagnostics
display page. The Page Up and Page Down keys are then used to select one of two different displays. These
are for diagnostic purposes only and are not normally needed. The diagnostic data consists of 32 discrete
input signals, 32 discrete output relays and several internal control signals. Each can have the value of 0 or 1.
There are also up to three analog data displays and an optional spindle rpm display.
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
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:
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.
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/DDToday’s date
MDL SL- __ Model number
1021 APC CE Door 1108 APC Chain Drive Forward
1022 APC Pin CLR #1 1109 APC Chain Drive Reverse
1023 APC Pin CLR #2 1121 PAL Clamp
1026 APC PAL #2 Home 1122 Door
1027 APC PAL #1 Home 1125 APC Motor
1046 APC Door Closed 1126 Beeper
1047 Door Open 1137 APC Chain Drive Power Enable
1048 APC Pallet Clamped 1138 Air Blast
1101 Pallet Clamped 1139 APC Beeper
The second page of diagnostic data is displayed using the Page Up and Page Down keys. It contains:
Inputs 2
Name Name Name
X Axis Z Channel X Overheat X Cable Input
Y Axis Z Channel Y Overheat Y Cable Input
Z Axis Z Channel Z Overheat Z Cable Input
A Axis Z Channel A Overheat A Cable Input
B Axis Z Channel B Overheat B Cable Input
X Home Switch X Drive Fault Spindle Z Channel
Y Home Switch Y Drive Fault
Z Home Switch Z Drive Fault
A Home Switch A Drive Fault
B Home Switch B Drive Fault
The following inputs and outputs pertain to the Haas Vector Drive. If it is not enabled, these will display a
value of *. Otherwise, it will display a 1 or 0.
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.
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/DDToday’s date
MDL HS__ Machine model
FV 2 11.0004 Floppy version (Ethernet Firmware)
120 TSC OVER TEMP THERMAL SENSOR (Vert)
121 THERMAL SENSOR SIGNAL
122 THERMAL SENSOR RETURN
123 SHIELD
140 230VAC 3PH POWER TO CHIP CONVEYOR MOTOR
141 PHASE A 230VAC
142 PHASE B 230VAC
143 PHASE C 230VAC
144 STARTING WINDING 230VAC
145 STARTING WINDING 230VAC
146 SHIELD DRAIN
140A 230VAC 3PH POWER IN CONDUIT TO CHIP CONVEYOR (Lathe)
141A PHASE A 230VAC
142B PHASE B 230VAC
143B PHASE C 230VAC
160 3PH 230VAC TO CHIP CONVEYOR CONTROLLER
161 PHASE A 230VAC
162 PHASE B 230VAC
163 PHASE C 230VAC
164 SHIELD DRAIN
170 AUTO OFF FUNCTION
171 UNSWITCHED LEG 1
172 SWITCHED LEG 2
173 SHIELD DRAIN
180 COOLANT SPIGOT DETENT SWITCH (Mill) SPARE (Lathe & Horiz)
181 SIGNAL
182 COMMON
183 SHIELD DRAIN
190 UNCLAMP FROM SPINDLE HEAD TO IOASM
191 INPUT 25
192 DIGITAL RETURN
193 SHIELD DRAIN
200 COOLANT SPIGOT MOTOR (12VDC) (Mill) SPARE (Lathe & Horiz)
201 MOTOR +
240 PALLETS UP & DOWN INPUTS (Vert & Horiz) BARFEEDER LOAD BAR-BARFEEDER LOAD Q (Lathe)
241 PALLETS UP (Vert & Horiz) END OF BAR (Lathe)
242 PALLETS DOWN (Vert & Horiz) LOADER OK (Lathe)
243 COMMON
244 SHIELD DRAIN
430 APC PALLET CLAMP MD PAL UP (Mill) APL LIGHT/BF EXTENDED PUSH (Lathe)
440 AUTO DOOR OPEN (Vert) SMTC CAGE DOOR OPEN - MORI ARM OUT (Horiz) DOOR OPEN (Lathe)
450 APC #2 CE DOOR OPEN (Vert) MORI ARM CW/CCW (Horiz) STEADY REST FOOT SWITCH (Lathe)
460 APC #2 DOOR CLOSED - APC #2 DOOR OPEN (Vert) MORI SLIDE 1/2 WAY - MORI SLIDE LEFT (Horiz)
APL ROTOR MARK - APL ROTOR HOME (Lathe)
470 SMTC MOTOR STOP (Vert) SMTC SHUTTLE MARK (Horiz)
490 ALL BRUSHLESS AXIS SERVO MOTOR DRIVE POWER CABLE
491 A PHASE
492 B PHASE
493 C PHASE
494 GROUND
490A A AXIS MOTOR POWER (Vert) 320VDC FROM SPINDLE DRIVE TO AMPLIFIERS (Horiz & Lathe)
490B B AXIS MOTOR POWER (Vert) 320VDC FROM AMPLIFIER TO SERVO POWER SUPPLY (Horiz & Lathe)
490X X AXIS MOTOR POWER
490Y Y AXIS MOTOR POWER
490Z Z AXIS MOTOR POWER
491A HIGH VOLT P1/+ RED (Horiz & Lathe)
492A HIGH VOLT N/- BLACK (Horiz & Lathe)
493A SHIELD DRAIN
491B HIGH VOLT + RED (Horiz & Lathe)
492B HIGH VOLT - BLACK (Horiz & Lathe)
500 OVERTEMP SENSOR FROM SPINDLE MOTOR
501 OVERTEMP WIRE 1
502 OVERTEMP WIRE 2
503 SHIELD DRAIN
510 RELAY CARD 1 DRIVE CABLE - 16 WIRE RIBBON
520 RELAY CARD 2 DRIVE CABLE - 16 WIRE RIBBON
530 RELAY CARD 3 DRIVE CABLE - 16 WIRE RIBBON
540 RELAY CARD 4 DRIVE CABLE - 16 WIRE RIBBON
550 INPUTS CARD CABLE (MOCON P10) 34 WIRE RIBBON
570 LOW VOLTAGE BRUSHLESS AMPLIFIER POWER CABLE ASSEMBLY (Horiz & Lathe)
571 +12VDC #22
572 COMMON
573 - 12VDC #22
610 X AXIS HAAS AMPLIFIER CABLE TO MOTOR CONTROLLER BOARD
610-1 +A CHANNEL
610-2 ANALOG GROUND
610-3 +B CHANNEL
610-4 ANALOG GROUND
610-5 ENABLE
610-6 LOGIC GROUND
610-7 FAULT
610-8 LOGIC GROUND
610-9 NOT USED
610-10 SHIELD/ANALOG GROUND
620 Y AXIS HAAS AMPLIFIER CABLE TO MOTOR CONTROLLER BOARD
(SAME AS 610-1 THRU 610-10) (Mill)
630 Z AXIS HAAS AMPLIFIER CABLE TO MOTOR CONTROLLER BOARD
640 A AXIS HAAS AMPLIFIER CABLE TO MOTOR CONTROLLER BOARD
(SAME AS 610-1 THRU 610-10) (Lathe)
640A A AXIS HAAS AMPLIFIER CABLE TO MOTOR CONTROLLER BOARD
(SAME AS 610-1 THRU 610-10) (Mill)
640B B AXIS HAAS AMPLIFIER CABLE TO MOTOR CONTROLLER BOARD
(SAME AS 610-1 THRU 610-10) (Mill)
640C C AXIS HAAS VECTOR CURRENT COMMAND CABLE TO MOTOR CONTROLLER BD.
(SAME AS 610-1 THRU 610-10) (Vert)
640C HAAS VECTOR DRIVE CURRENT COMMAND CABLE (Horiz & Lathe)
640C-1 A PHASE
640C-2 B PHASE
640C-3 ENABLE
640C-4 FAULT
640C-5 320VDC VOLTAGE MONITOR
640C-6 A PHASE RETURN
640C-7 B PHASE RETURN
640C-8 DIGITAL GROUND
640C-9 FAULT RETURN
640C-10 ANALOG GROUND
650 THREE PHASE POWER TO SPINDLE MOTOR
651 LEG 1 OF 230VAC
652 LEG 2
653 LEG 3
654 SHIELD DRAIN
650A THREE PHASE POWER TO SPINDLE MOTOR
651A LEG 1 OF 230VAC
652A LEG 2
653A LEG 3
654A SHIELD DRAIN
650B THREE PHASE POWER TO SPINDLE MOTOR
651B LEG 1 OF 230VAC
652B LEG 2
653B LEG 3
654B SHIELD DRAIN
660 X-AXIS ENCODER CABLE
660-1 LOGIC RETURN (D GROUND)
660-2 ENCODER A CHANNEL
660-3 ENCODER B CHANNEL
660-4 +5 VDC
660-5 ENCODER Z CHANNEL (OR C)
660-6 HOME/LIMIT SW
660-7 OVERHEAT SWITCH
660-8 ENCODER A*
660-9 ENCODER B*
660-10 ENCODER Z* (OR C*)
660-11 X HALL A (NOT USED)
660-12 X HALL B (NOT USED)
660-13 X HALL C (NOT USED)
660-14 X HALL D (NOT USED)
660-15 SHIELD DRAIN
660-16 (NOT USED)
670 Y-AXIS ENCODER CABLE (SAME AS 660-1 THRU 660-16) (Mill)
680 Z-AXIS ENCODER CABLE (SAME AS 660-1 THRU 660-16)
P-COOL/BF COLLET OPEN - BF COLLET CLOSE (Horiz) APL GRIP 1,2 (Lathe
711 FORWARD COMMAND (Vert)
712 REVERSE COMMAND (Vert)
713 RESET COMMAND (Vert)
714 COMMON (Vert)
715 SHIELD DRAIN
720 ANALOG SIGNAL FROM MOCON TO SPINDLE DRIVE TO LOAD METER (BRUSH SYSTEMS)
721 0 TO +10 VOLTS SPEED COMMAND (SPINDLE DRIVE CN1-1)
722 SPEED COMMAND REFERENCE (A GROUND) (CN1-17)
723 SHIELD DRAIN
730 POWER METER FROM SPINDLE DRIVE TO KBIF (Vert) (BRUSH SYSTEMS)
731 METER +
732 METER -
733 SHIELD DRAIN
730A POWER METER FROM KBIF TO METER (Vert) (BRUSH SYSTEMS)
733 METER + AFTER TRIM POT
734 METER - AFTER TRIM POT
734 METER - AFTER TRIM POT
730B ANALOG SIGNAL FROM SPINDLE DRIVE LOAD MONITOR (Vert) (BRUSH SYSTEMS)
731 SIGNAL 0.5V
732 GROUND
740 POWER ON/OFF CABLE TO FRONT PANEL
741 POWER ON SWITCH LEG 1 (24 VAC)
742 POWER ON SWITCH LEG 2 #24 N.O.
743 POWER OFF SWITCH LEG 1 (24 VAC)
744 POWER OFF SWITCH LEG 2 #24 N.C.
745 SHIELD DRAIN
750 JOG-CRANK DATA CABLE (REM JOG SIDE CONNECTION)
750A JOG HANDLE DATA CABLE (Horiz & Lathe)
751A +5 VDC
752A 0 VDC
753A ENCODER A CHANNEL
754A ENCODER B CHANNEL
755A SHIELD DRAIN
750B JOG HANDLE DATA CABLE (Horiz)
750B-1 +5 VDC JOG HANDLE
750B-2 0VDC
750B-3 JOG HANDLE A CHANNEL
750B-4 JOG HANDLE A* CHANNEL
750B-5 JOG HANDLE B CHANNEL
750B-6 JOG HANDLE B* CHANNEL
760 MONITOR VIDEO DATA CABLE (FROM VIDEO P3 TO CRT)
770 EMERGENCY STOP INPUT CABLE
771 SIGNAL (INPUT 8)
800 10VAC TO PALLET READY LAMP (Horiz)
801 UNSWITCHED LEG 1
802 SWITCHED LEG 2
803 SHIELD DRAIN
800A LAMP SWITCH JUMPER (Horiz)
801A JUMPER TO 802A
802A JUMPER TO 801A
810 TOOL CHANGER MOTORS
811 TURRET MOTOR + (IO P30-2 TO P6-J)
812 TURRET MOTOR - (IO P30-1 TO P6-I)
813 SHIELD DRAIN
810A TOOL CHANGER MOTORS
811A SHUTTLE MOTOR +
812A SHUTTLE MOTOR -
813A SHIELD DRAIN
820 TOOL CHANGER STATUS
821 LOGIC RETURN (Vert) TOOL CHANGER IN (Horiz) TURRET UNCLAMPED (Lathe)
822 GENEVA MARK (INPUT 5 TO P6-G) (Vert) TOOL CHANGER OUT (Horiz) TURRET CLAMPED (Lathe)
823 TOOL #1 (INPUT 3 TO P6-E) (Vert) MAIN DRAWBAR UP (Horiz) UNUSED (Lathe)
824 SHUTTLE IN (INPUT 1 TO P6-C) (Vert) MAIN DRAWBAR DOWN (Horiz) PART LOAD (Lathe)
825 SHUTTLE OUT (INPUT 2 TO P6-D) (Vert) COMMON (Horiz & Lathe)
900 LOW COOLANT STATUS (Mill) SPARE (Lathe)
901 LOW COOLANT SIGNAL
902 LOW COOLANT RETURN (D GROUND)
903 SHIELD DRAIN
910 115 VAC CIRCUIT BREAKER TO SOLENOIDS
911 LEG 1
912 LEG 2
913 SHIELD DRAIN
910A 115VAC FROM CB4 ON MAIN POWER DIST. (Mill) SPARE 115 VAC (Lathe)
910B 115VAC TO SERVO FAN
910C 115VAC TO DELTA/WYE COIL (Vert & Lathe) 115VAC TO PURGE SOLENOID (Horiz)
910D 115VAC TO WORK LIGHT (Vert) 115 VAC TO PALLET ALARM (Horiz) 115 VAC TO PART CATCHER (Lathe)
920 REGENERATIVE LOAD RESISTOR FOR SERVO (Vert)
921 LEG 1
922 LEG 2
923 SHIELD DRAIN
930 FUSED 230 VAC FOR COOLANT PUMP
931 LEG 1
932 LEG 2
933 SHIELD DRAIN
940 230 VAC TO COOLANT PUMP
941 LEG 1 (P7-A)
942 LEG 2 (P7-F)
943 SHIELD DRAIN
940A 230 VAC SINGLE PHASE POWER TO THROUGH SPINDLE COOLANT PUMP (Horiz)
941A LEG 1
942A LEG 2
943A SHIELD DRAIN
950 LOW AIR PRESSURE/OIL LUBE SENSOR
951 LOW AIR SIGNAL (INPUT 12)
952 LOW AIR/OIL RETURN (D GROUND) (65) (Vert) LOW OIL LUBE SIGNAL (Horiz & Lathe)
953 LOW OIL PRESSURE SWITCH FOR VERTICAL TRANSMISSION (Vert) COMMON (Horiz & Lathe)
954 SHIELD DRAIN
950A LOW HYDRAULIC PRESSURE SWITCH FOR LATHE
952 LOW HYDRAULIC RETURN (D GROUND)
953 LOW HYD PRESSURE SWITCH FOR VERTICAL TRANSMISSION
LOW HYD PRESSURE (Lathe)
961 LOW LUB SIGNAL (Vert) LOW TRANSMISSION OIL LUBE SIGNAL (Horiz) LOW HYD PRESSURE (Lathe)
962 LOW LUB RETURN (D GROUND) (65)
990 HOME SENSORS
991 X HOME SWITCH (Vert) COMMON (DATA GROUND) Horiz & Lathe)
992 Y HOME SWITCH (LATHE TAIL STOCK) (Vert) X-AXIS HOME SWITCH (Horiz & Lathe)
993 Z HOME SWITCH (Vert) Y-AXIS HOME SWITCH (Horiz & Lathe)
994 HOME SWITCH RETURN (Vert) Z-AXIS HOME SWITCH (Horiz & Lathe)
995 SHIELD DRAIN
1000 SPINDLE ENCODER CABLE (LATHE TAIL STOCK)(BRUSH SYSTEMS) (Vert)
1001 LOGIC RETURN (D GROUND)
1002 ENCODER A CHANNEL
1003 ENCODER B CHANNEL
1004 +5 VDC
1005 ENCODER Z CHANNEL
1006 SHIELD DRAIN
1000 SPINDLE ENCODER CABLE (MOCON SIDE CONNECTION) (Horiz & Lathe)
1000-1 LOGIC RETURN (D GROUND)
1000-2 ENCODER A CHANNEL
1000-3 ENCODER B CHANNEL
1000-4 +5 VDC
1000-5 ENCODER Z CHANNEL
1000-6 NOT USED
1000-7 NOT USED
1000-8 ENCODER A* CHANNEL
1000-9 ENCODER B* CHANNEL
1000-10 ENCODER Z* CHANNEL
1000-11 NOT USED
1000-12 NOT USED
1000-13 NOT USED
1000-14 NOT USED
1000-15 SHIELD DRAIN
1000-16 NOT USED
1010 AUX FRONT PANEL CABLE (HS-1R/RP)
1011 COMMON FOR CYCLE START AND FEED HOLD RETURN
1012 CYCLE START
1013 PART READY
1014 COMMON FOR PALLET ROTATE AND PART READY
1015 PALLET ROTATE
1016 FEED HOLD
1017 SHIELD DRAIN
1020 SPINDLE TEMPERATURE SENSOR CABLE
1021 SIGNAL
1022 ANALOG RETURN
1023 +5 VOLTS TO SENSOR
1024 SHIELD GROUND
1030 SPINDLE LOAD RESISTOR
1031 REGEN LOAD RESISTOR FOR SPINDLE DRIVE (B1)
1032 REGEN LOAD RESISTOR FOR SPINDLE DRIVE (B2)
1033 SHIELD DRAIN
1040 115 VAC TO MIKRON DOOR INTERLOCK SWITCH (OR HORIZONTAL PART READY LAMP (Vert))
1041 LEG 1
1042 LEG 2
1043 SHIELD DRAIN
1050 DOOR SWITCH WIRING THRU SUPPORT ARM
1051 DOOR OPEN SIGNAL (INPUT 9)
1052 DOOR OPEN RETURN (D GROUND) (65)
Shown below are three types of commonly used cable connectors. They are shown as seen when plugged
into the pc board. These diagrams are to aid in locating the pins for troubleshooting.
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
1
2
3
4
5
6
1
2
3
4
1
2
3
4
5
6
6
7
1
2
3
4
5
1
2
3
4
5
6
7
8
Red Wire
1
3
5
7
9
11
13
15
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
3
4
4
1
5
2
6
3
7
8
1
2
3
4
NOTE: The numbering sequence is the same regardless of the number of pins.
J1 ADDRESS ADDRESS BUSS MOCON-MOTIF ____
J2 DATA DATA BUSS MOCON-MOTIF ____
J3 (CF2) SERIAL DATA
J3, J6 (CF2) 860 LOW VOLTAGE <FROM>PSUP PCB ____
J4 850 KEYBOARD DATA KEYBOARD INT. ____
J5 PORT 2 850A SERIAL PORT #2 AUX PORT AUX SERIAL PORT ____
J6 AUX BATTERY INPUT
J10 VIDEO SIGNAL LCD
J13 USB DATA
J14 NOT USED
SERVO SYSTEM BLOCK DIAGRAM
LOW
VOLTAGE
POWER SUPPLY
& PENDANT
LV
CURRENT
COMMAND
ENCODER
CURRENT
COMMAND
ENCODER
VECTOR DRIVE/
HIGH VOLTAGE
POWER SUPPLY
HV
320V DC
BRUSHLESS
SERVOAMP
BRUSHLESS
SERVOAMP
MTR PWR
MTR
PWR
ALTERNATE
MINI MILL/
OFFICEMILL
HIGH VOLTAGE
POWER SUPPLY
MEDIUM/LARGE
AMPLIFIER
with a 10” monitor have a separate differential card in the LCD panel connected
directly to the main processor.
Electrical Service
65
Page 71
Connector Descriptions
P1 This connector supports an RS-232 ribbon cable that sends and receives data from the Main Processor.
P2 This connector is used for the operator keypad interface. It receives keyboard data, which it sends to
the SKBIF micro-controller (U8), where the data is processed and sent out over the RS-232 line to the
Main Processor.
P3 This connector is wired directly to the Cycle Start and Feed Hold buttons on the operator pendant front
panel. The signals are sent to the SKBIF micro-controller (U8), where the data is processed and
sent out over the RS-232 line to the Main Processor.
P4 This connector is used on machines with an an analog Load Meter and is wired directly to the Load
Meter on the operator pendant front panel.
P5 This connector is wired directly to the Beeper on the operator pendant front panel. The Main Processor
sends On/Off commands to the Beeper, while the ‘beeps’ associated with each key stroke are
controlled by wiring between P5 and the SKBIF micro-controller (U8).
P6 This connector is wired directly to the Cycle Start and Feed Hold buttons on a Remote Jog Handle or
an auxiliary front panel. It handles Part Ready and Pallet Rotate signals as well as mill Pallet 6
scheduling. The signals are sent to the SKBIF micro-controller (U8), where the data is processed and
sent outover the RS-232 line to the Main Processor.
P6A This connector is wired directly to an auxiliary front panel (such as a Tool Changer panel). It handles
Cycle Start, Feed Hold, Part Ready and Pallet Rotate signals as well as mill Pallet 6 scheduling. The
signals are sent to the SKBIF micro-controller (U8), where the data is processed and sent out over the
RS-232 line to the Main Processor.
P7 This connector is used by mills utilizing a pallet changer. Pallet 1 and 2 scheduling signals are sent to
the SKBIF micro-controller (U8), where the data is processed and sent out over the RS-232 line to the
Main Processor.
P8 This connector is used by mills utilizing a pallet changer. Pallet 3 and 4 scheduling and vertical mill MD
Load Table Rotation signals are sent to the SKBIF micro-controller (U8), where the data is processed
and sent out over the RS-232 line to the Main Processor.
P9 This connector is wired to the Enhanced Remote Jog Handle. RJH(E) signals are sent to the SKBIF
micro-controller (U8), where the data is processed and sent out over the RS-232 line to the Main
Processor.
P10 This connector is wired to the beacon on the operator pendant. Thin pendant signals are sent in over
the RS-232 line from the Main Processor to the SKBIF micro-controller (U8), which turns the beacon on
and off.
P11 This connector is not currently used.
P12 This connector is not currently used.
J1 This connector is wired to the Jog Handle on the operator pendant front panel. Jog Handle signals are
sent to the SKBIF micro-controller (U8), where the data is processed and sent out over the RS-232 line
to the Main Processor. If a cable is present on J3, jog handle signals are sent to the MOCON from J3.
J2 This connector is wired to the Remote Jog Handle. RJH signals may be sent to the SKBIF
microcontroller (U8), where the data is processed and sent out over the RS-232 line to the Main
Processor. Alternatively, the RJH signals may be connected to J3, from where the data is sent directly
to the MOCON.
J3 This connector is wired to the Remote Jog Handle connector J2. RJH data is sent from J3 directly to the
MOCON.
J4 This connector is wired to the pendant’s Worklight Switch on a vertical mill thin pendant. Worklight
Switch signals are sent to the SKBIF micro-controller (U8), where the data is processed and sent out
over the RS-232 line to the Main Processor.
J5 Combines E-Stop, On/Off, Jog Handle, Cycle Start/Feed Hold, Beeper and Work Light signals.
J6 This connector receives video data from the Main Processor. The video data exits the SKBIF from J16
and is sent directly to the LCD panel.
J7 This connector is not currently used.
J8 This connector is wired to the Enhanced Remote Jog Handle Switch on vertical mills. When the RJH(E)
is placed in its receiver cradle, a HOOK signal is received over J8 and sent to the SKBIF microcontroller
(U8), where the data is processed and sent out over the RS-232 line to the Main Processor.
J9 This connector is used by horizontal mills utilizing a tool changer. Tool Changer Magazine CW/CCW,
Manual, and Tool Release Pedal signals are sent from the Tool Changer box, received over J9 and sent
to the SKBIF micro-controller (U8), where the data is processed and sent out over the RS-232 line to
the Main Processor.
J10 This connector is used by machines utilizing CE Push Button, Edit Lock Key Switch, 2nd Home Push
Button, and Auto Door Push Button signals. Signals are sent from the Push Button or Switch, received
over J9 and sent to the SKBIF micro-controller (U8), where the data is processed and sent out over the
RS-232 line to the Main Processor.
J11 This connector is used by machines utilizing a pallet changer. Part Ready, Pallet Rotate, and Autodoor
signals are sent by all machines. Pallet scheduling signals are sent by mills. The signals are sent to the
SKBIF micro-controller (U8), where the data is processed and sent out over the RS-232 line to the Main
Processor.
J12 This connector provides +12V DC power to the SKBIF from a power supply built into the LCD
assemblies. This connector is not used for thin pendants, or if cabling is present on J20 and J22.
J13 This connector provides power to a high voltage power supply in the LCD panel to supply backlighting
to the LCD.
J14 This connector is used to program the SKBIF micro-controller.
J15 This connector is used to program PAL chip U12.
J16 This connector receives video data from the Main Processor by way of J6. The video data exits the
SKBIF from J16 and is sent directly to the LCD panel.
J17 This connector is wired to the E-Stop button on the operator pendant front panel and to J20. The E-
STOP signal enters at J17 and exits at J20, where it is sent to the I/O Board.
J18 This connector supports an RS-232 RJ-11 style phone cable that sends and receives data from the
Main Processor.
J19 This connector is not used at this time. A jumper is in place across the two pins.
J20 This connector receives +12V DC to power the SKBIF, Power On, Power Off and E-Stop signals.
J22 This connector is wired to the Power On and Power Off buttons on the operator pendant front panel and
to J20. The Power On and Off signals are received by J22 and sent to J20.
J25 Spare
J26 Spare
SW1 This switch determines how the beeper is being driven. The switch is set to ‘BEEP’ for a front panel
that contains a buzzer. The switch is set to ‘SPKR’ for a front panel that contains a speaker.
SW2 The COLOR switch is set based upon what LCD assembly is used. SHARP LCD assemblies require
the switch to be placed to the left (toward COLOR). LG LCD assemblies require the switch to be
placed to the right (away from COLOR). The STROBE switch should always be placed to the left
(toward STROBE).
J2 ____ VIDEO SIGNAL N/A ____
J4 ____ ADDRESS BUSS MICRO PROC.PCB ____
J5 ____ DATA BUSS MOTIF PCB ____
J13 850 SERIAL DATA N/A J1
J14 ____ SERIAL DATA KYBD ____
PLUG # CABLE # SIGNAL NAME TO LOCATION PLUG #
P1 ——- DATA BUSS VIDEO PCB ——-
MICRO PROC. PCB ——P2 610 X DRIVE SIGNAL X SERVO DRIVE AMP. P
P3 620 Y DRIVE SIGNAL Y SERVO DRIVE AMP. P
P4 630 Z DRIVE SIGNAL Z SERVO DRIVE AMP. P
P5 640 A DRIVE SIGNAL A SERVO DRIVE AMP. P
P32 640B B DRIVE SIGNAL B SERVO DRIVE AMP. P
P6 660 X ENCODER INPUT X ENCODER ——-
NAME
115VAC to LCD LVPS
115VAC to Work Light Switch
Power On/Off
Video Data
Emergency Stop
SKBIF
Door Switch Wiring
NAME
Super Speed Tool Changer
Motor Power
Super Speed Tool Changer
Encoder
NAME
X-Axis Motor Power
X Encoder,XHome Limit Switch
NAME
Z-Axis Motor Power
Z Encoder,ZHome Limit Switch
24VDC Servo Brake Release
NAME
B-Axis Motor Power
B Encoder,BHome Limit Switch
5'th Axis Brake
CONTROL
CABINET
FRONT
PANEL
SUPER
SPEED
TOOL
CHANGER
X
AXIS
Z
AXIS
A2/
5TH AXIS
SPINDLE
HEAD
PALLET
CHANGER
Y
AXIS
A1/
A-AXIS
TOOL
CHANGER
TSC
CABLE
190
200
300A
880A
890
950
CABLE
490X
660
CABLE
490Y
670
CABLE
490A
690
390
CABLE
810
810A
820
CABLE
940A
130
NAME
Unclamp from Spindle Head to
I/O PCB
Coolant Spigot Motor
115VAC to Spindle Motor Fan/Oil
Pump/Oiler
High/Low Gear Unclamp/Lock
Solenoid Power
Spindle Status Switches
Low Air Pressure Sensor
NAME
X-Axis Motor Power
X Encoder, Home Limit Switch
NAME
Y-Axis Motor Power
Y Encoder,Y-Home Limit Switch
NAME
A-Axis Motor Power
A Encoder, A-Home Limit Switch
4'th Axis Brake
NAME
Tool Changer Turret Motor
Tool Changer Shuttle Motor
Tool Changer Status
NAME
M-FIN
SP Drive Load (Coolant Level
Gauge Sensor)
NAME
APC PAL Home/MD PAL UpAPC PAL1Home PAL Down
APC CE Door Open
APC #1 Pallet Ready 1/APC #1
Pallet Ready 2
Emergency Stop Input
APC Pin CLR #1/APC Pin CLR #2
Tool Changer Motors
NAME
APC Door Open
APC #2 Door Open
APC Pallet Clamp Left Door
APC #2 Door Closed/Door Open
APC Pallet Clamp Right Door