haas 96-0284E Service Manual

Haas Technical Publications

Manual_Archive_Cover_Page Rev A

any other party automatically voids the factory warranty.

June 6, 2013

HAAS SERVICE AND OPERATOR MANUAL ARCHIVE

Electrical Service Manual 96-0284E RevE English June 2008

• This content is for illustrative purposes.

• Historic machine Service Manuals are posted here to provide information for Haas machine owners.

• Publications are intended for use only with machines built at the time of original publication.

• As machine designs change the content of these publications can become obsolete.

• You should not do mechanical or electrical machine repairs or service procedures unless you are qualied
and knowledgeable about the processes.

• Only authorized personnel with the proper training and certication should do many repair procedures.

WARNING: Some mechanical and electrical service procedures can be

extremely dangerous or life-threatening.
Know your skill level and abilities.

All information herein is provided as a courtesy for Haas machine owners
for reference and illustrative purposes only. Haas Automation cannot be held
responsible for repairs you perform. Only those services and repairs that are
provided by authorized Haas Factory Outlet distributors are guaranteed.

Only an authorized Haas Factory Outlet distributor should service or repair a
Haas machine that is protected by the original factory warranty. Servicing by

SAFETY

RED

WHT

40

BLK

ON

OFF

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

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

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

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

WARNING!

The electrical panel should be closed and the three screws/latches on the
door should be secured at all times except during installation and service. At
those times, only qualifi ed electricians should have access to the panel. When
the main circuit breaker is on, there is high voltage throughout the electrical
panel (including the circuit boards and logic circuits) and some components
operate at high temperatures. Therefore extreme caution is required.

GENERAL ELECTRICAL TROUBLESHOOTING

MACHINE NOT RUNNING

Machine cannot be powered on.

• Check input voltage to machine.

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

• Check overvoltage fuses.

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

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

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

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

• Check I/O PCB.

• Check Power PCB.

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Electrical Service

1

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

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

• Check alarm history for Overvoltage or Overheat shutdown.

• Check AC power supply lines for intermittent supply.

• Check low voltage power supply for intermittent supply.

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

• Check connection between 24V transformer and K1 contactor.

• Check I/O PCB.

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

• Check MOTIF or MOCON PCB.

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

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

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

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

• Check for lights on the processor.

• Replace LCD/CRT.

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

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

• Check keypad.

• Check SKBIF PCB.

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

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

Quad APC trouble shooting

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

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

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

LECTRICAL ALARM TROUBLESHOOTING

E

Axis Drive Fault Alarm

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

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

normally for a while.

To check an amplifi er, switch the motor leads and control cables between the amplifi er and the one next to
it. If the same problem occurs with the other axis, the amplifi er must be replaced. If the problem stays on the

same axis, either the MOCON or control cable. The problem could also be the axis motor itself, with leads
either shorted to each other or to ground.

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Electrical Service

96-0284 rev E June 2008

• Amplifi er faulting out for valid reason, such as overtemp, overvoltage, or +/-12V undervoltage condition. This

usually results from running a servo intensive program, or unadjusted 12V power supply. Adjust voltage to

correct specifi cations or replace the power supply.

Overvoltage could occur if regen load is not coming on, but this does not usually happen. The problem could
also be the axis motor itself, with leads either shorted to each other or to ground.

Axis Overload

• The fuse function built into the MOCON has been overloaded. This may be caused by a lot of motor accel/

decels, or hitting a hard stop with the axis. This safety function protects the amplifi er and motor. If the current

program is the cause, change the program. If the axis hits a hard stop the travel limits may be set wrong.

Phasing Error

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

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

Servo Error Too Large

• This alarms occurs when the difference between the commanded axis position and the actual position be­comes larger than the maximum that is set in the parameter.

This condition occurs when the amplifi er is blown, is not receiving the commands, or the 320V power source
is dead. If the MOCON is not sending the correct commands to the amplifi er, it is probably due to a broken

wire, or a Phasing Error that was generated.

Axis Z Fault or Z Channel Missing

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

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

leads of another axis.

Axis Cable Fault

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

Alarm 101, “MOCON Comm. Failure”

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

Alarm 157, MOCON Watchdog Fault

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

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

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

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

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

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

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Electrical Service

3

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

5. If problem persists, replace main processor board.

Alarm 261, Rotary CRC Error (Horiz & Vert)

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

Alarm 354, Aux Axis Disconnected (Lathe)

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

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

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

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

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

tent connection at both ends of the motor cable.

WO3 Emergency Stop. The E-STOP button was pressed, or an E-STOP condition occurred.
WO4 High load. Check for binding in the tool changer gearbox and motor. Rotate the carousel by hand

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

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

Check for 115V AC (minimum) to the Aux Axis PCB from the main transformer. Check the fuse
holder and the fuse that is protecting this circuit.

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

motor. Check for overweight tooling.

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

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

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

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

WO9 Encode ES. Z channel is missing. Bad encoder or cable. See WO7.
WOA High voltage. Check the incoming voltage to the Aux Axis PCB. Incoming voltage must be 115V

AC. See WO5.
WOB Cable fault. Check the cable from the motor to the Aux Axis PCB. Check for loose connections at

each end.

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Electrical Service

96-0284 rev E June 2008

LINE VOLTAGE ADJUSTMENTS

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

Tools Required: Large fl at tip screwdriver, Digital voltmeter

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

will be present on power up.

Low Voltage Power Supply

T5 Transformer

MOCON-2

(if equipped)

LCD Video/Floppy

MOCON-1

Processor

3-Phase Breaker

Power PCB

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

Optional Servo
Tool Changer Amp

SERVODRIVE
ASSEMBLY

Haas Vector Drive

Wye-Delta Contactors

(underneath)

I/O Board

Single Axis Brake PCB

(if so equipped)

Transformer

Control Cabinet General Overview

ELECTRICAL CONNECTIONS

Ouput
Power

Ground Line

Main

Circuit

Breaker

L1 L2

L3

TB2

240VOUT

D

A

488-458V

N

G

E

R

!

120VOUT

457-429V
260-244V

INCOMINGLINE VOLTAGETAPS (74,75, 76)

428-403V

243-227V

!

!

H

I

G

H

V

O

L

TB1

T

A

402-377V
226-211V

376-354V
210-195V

G

E

D

A

N

G

E

R

!

!

!

Input

Power

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 fi ne but machine runs poorly - servo overloads.) To check,

pull on wires after screws are tightened.

96-0284 rev E June 2008

Electrical Service

5

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 fl uctuations are common in many industrial areas; you need to know

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

in operation. U.S. National Electrical Code specifi es that machines should operate

with a variation of +5% to -5% around an average supply voltage. If problems with
the line voltage occur, or low line voltage is suspected, an external transformer may
be required. If you suspect voltage problems, the voltage should be checked every

hour or two during a typical day to make sure that it does not fl uctuate more than

+5% or -5% from an average.

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

panel before changing the transformer connections. Make sure that all three
black wires are moved to the correct terminal block and are tight.

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

wires labeled 74, 75, and 76 must be moved to the terminal block triple which corresponds to the average
voltage measured in step 2 above. There are four positions for the input power for the 260V transformer and
fi ve positions for the 480V transformer. The labels showing the input voltage range for each terminal position

are as shown in the previous illustration.

4. Transformer T5 supplies 24VAC used to power the main contactor. There are two versions of this trans­former for use on 240 and 400V machines (32-0964B and 32-0965B, respectively). The 240V transformer has
two input connectors located on the transformer bracket, which allow it to be connected to either a 221-240V
range or 180 to 220V range. Users that have 180-240V input power should place the jumper on the appropri­ate connector.

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

A jumper must also be placed on the plate covering the T5 transformer, Measure the 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

6

Electrical Service

221-240V

381-440V
180-220V

MEASURE VOLTAGEAT MAIN

CIRCUIT BREAKER AND CONNECT

SUPPLIED SHORTING PLUG TO
CORRESPONDING CONNECTOR

340-380V

ON THIS TRANSFORMER

T5 24VAC

WARNING:

96-0284 rev E June 2008

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.

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

(FOR 3 PHASE ONLY)

PASS FAIL

WARNING!

NE5NE6

WARNING!

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

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

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

96-0284 rev E June 2008

Electrical Service

7

FUSE REPLACEMENT

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

Some of the brushless amplifi ers have one 15 amp fuse, F1. If this fuse blows, the associated motor will stop;
a light on the amplifi er will tell of a blown fuse. Use the Amplifi er Fuse Kit (Haas P/N 93-1089) to replace the
fuse. If the fuse blows again, the amplifi er may be damaged, and needs to be replaced.

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

Size Fuse Name Type Rating (amps) Voltage Location

5mm FU1-FU3 Slo-Blo ½ 250V PSUP pcb, upper right

1/4 F1 Ultra fast 15 250V Amplifi er (X, Y, Z, A, B)

5mm FU4, 5 Fast blow 5A 250V PSUP, bottom right corner

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 amplifi ers (servo drive assembly on brush
machines) goes out. The servo amplifi ers/servo drive assembly is on the left
side of the main control cabinet and about halfway down. This light(s) is at the
top of the circuit card at the center of the assembly. Until this light goes out,
there are dangerous voltages in the assembly even when power is shut off.

1. Turn machine power off.

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

WARNING!

Main

Switch

3. Open the cabinet door and wait until the red charge light on the servo drive assembly goes out before be­ginning any work inside the electrical cabinet.

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Electrical Service

96-0284 rev E June 2008

4. The two overvoltage fuses are located beside each other at the upper right of the Power Supply board. An
orange light will be on to indicate the blown fuse(s).

PHASE DETECT

(FOR3 PHASE ONLY)

+5V

GND

10A230V

FAILPASS

GND

+5V

NE6

WORKLIGHT

GFI/

71 73

NE5

F1

NE1

TSC COOLANTPUMP

TSCCOOLANT PUMP

930

COOLANT/TSC

1A250V

10A230V

POWER SUPPLYASSY

SEC

PRI

TOT5

F3

NE3

PSUP-K

230VIN

CHIPCONVEYOR

CHIPCONVEYOR

170

AUTOOFF/CONTACTOR

740

ON/OFF

P10

5A230V

CB4

160

CHIPC230V

GND

+5V

PHASE DETECT

(FOR 3 PHASE ONLY)

GND

+5V

NE6

FAILPASS

71 73

NE5

F1

NE1

1A 250V

PRI

TO T5

F3

NE3

IOPCB

GND

GND

+5V

+12V

P30

GND

GND

-12V

+12V

COOLANTPUMP

COOLANTPUMP

92A

DELTA-WYE

LOWVOLT PS

SWDOOR FAN

MONITOR

PROBEPS

SERVOFAN

90A

AC GROUND

90C

MCD1

MCD2

LVINPUT

GND

GND

GND

GND

+12V

90A

90A

90A

90A

96

90C

95

94/N

-12V

+12V

+12V

LE2

Z3

LE3

+12V

-12V

TS1

MAIN115V XFRMR

P1

ON ON ON ON ON

10A115V

115VINPUT

MAIN

XFRMR

CB2

115VSPARES

90C 90C

90C90C 90C

MOTIF

MOCON2

GND

GND

+5V

+5V

+5V

-12V

+12V

Z4

+12V

LE1

Z1

+5V

P18

AMPS

GND

+12V

-12V

GFI

7A115V

GFI

CB6 CB3 CB5

90

3PH115V TOIOPCB

Power Supply Board; Fuse Locations

5. Using a fl at tip screwdriver, turn the fuse(s) counterclockwise to remove the fuses. Replace the fuse(s) with

one having the same type and rating (½ amp, type AGC, 250V).

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

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

FRONT PANEL

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

SL-10 PENDANT COMPONENTS ACCESS

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

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

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Electrical Service

9

LCD ASSEMBLY REPLACEMENT

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

pendant.

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

2. Remove the screws holding the cover on the back of the control panel. Take care to hold the cover in place
until all screws have been removed.

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

4. Remove the four (4) hex nuts and washers beginning with the bottom, then remove the LCD assembly and
set aside in a safe place.

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

5. Use gloves to avoid getting fi ngerprints on the new LCD. Position the assembly onto the four bolts (two

each on top and bottom). Place the washers and hex nuts on the bolts to hold in place. Once all washers
have been attached and nuts have been hand-tightened, tighten down completely.

Video Out
to LCD Pnl

Video

In

RS-232 Data

to/from

Microprocessor

SKBIF

Power

In

Kybd
Data

In

Back of Operator’s Pendant

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

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

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Electrical Service

96-0284 rev E June 2008

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

A

YEL

GND
WHT/
RED

B

BRN

A

WHT/

YEL

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

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

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

POWER ON/OFF SWITCHES

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

B
WHT/
BRN

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.

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Electrical Service

11

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 con-

nectors on the bottom of the switch.

5. Reconnect all leads to the correct switch.

SPINDLE LOAD METER

Load meter measures load on spindle motor as a percentage of rated continuous power of motor, with a slight

delay between a load and actual meter refl ection. The eighth A-to-D input also provides a measure of spindle

load for cutter wear detection. Second page of diagnostic data displays % of spindle load. Meter should agree
with display within 5%. Spindle drive display #7 should also agree with load meter within 5%. There are differ­ent types of spindle drives used in the control, all are equivalent in performance but are adjusted differently.

Spindle Load Meter Replacement

1. Turn the power off and disconnect power to the machine. Remove the screws holding the cover panel on
the back of the pendant. Take care to hold the cover panel in place until all screws are removed.

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

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

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

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.

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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 fl 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, fi 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 control box, then remove the cover panel. Take care to hold the
panel in place until all screws have been removed.

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

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

6. Replace the Serial KBIF board, using the four screws previously removed. Starting at the top right, attach
each screw and standoff loosely, until all are mounted, then tighten down.

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

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

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SOLENOIDS

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

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

Removal

1. Turn machine power on and raise spindle head to uppermost position, 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 fi 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 fi ttings. Reconnect air supply to the machine, and check

for leaks.

6. Replace the sheet metal.

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Air Solenoid

Assembly

EC

400

Motor Shroud

Air Solenoid

Assembly

EC

Sheet Metal

Tray

Low air pressure

sensor

Air solenoid

assembly

Check Valve Switch

Pre-

Charge

TRP Solenoid

To TSC

TSC Solenoid

Inlet

Pressure
Switch

Regulator

Check Valve Switch

TRP
Solenoid

Basic Air Solenoid Assembly

Check
Valve
Switch

Junction
Elbow

Air Solenoid Assembly
With TSC Feature Added

Disconnect
all air lines

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

SPINDLE LUBE AIR SOLENOID

Removal

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

Pressure Gauge

Disconnect

all air lines

Spindle
Lube
Solenoid

Lube Line

Main Air Line

Pressure Switch

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

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

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

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

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

Installation

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

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

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15

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

4. Restore the air supply to the machine.

NEUMATIC CHUCK/TURRET CLAMP/UNCLAMP SOLENOID (LATHE)

P

Removal

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

2. Pneumatic Chuck: Disconnect the two air hoses from the pneumatic chuck clamp/unclamp solenoid.
Turret: Disconnect the three air hoses from the turret clamp/unclamp solenoid (see the Turret In/Out

Adjustment), and disconnect exhaust lines.

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

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

Installation

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

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

3 Reconnect the two (three for Turret) air lines and turret exhaust lines, ensuring that all connections are tight
and do not leak.

4. Restore the air supply to the machine.

SMART AMPLIFIER

The Smart Amplifi er has a microprocessor incorporated in the design. This allows the amplifi er to detect and

report detailed alarms. The software level necessary to display these new alarms is 15.02A or newer.

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

The Smart Amplifi er does not have a 12VDC connector, and both the Fault (Red LED) and the Run (Green

LED) are relocated. The 320VDC (H+ and H-) and the X, Y and Z-axis connections are also relocated.

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The smart amplifi er will calibrate utilizing the microprocessor that is present in each of the Smart Amplifi ers at

power up. When power is applied to the Control Cabinet the Fault (Red LED) will illuminate and stay illumi­nated for a short time (approximately 5 seconds), this is called the “A” Phase Calibration. Then both LEDs will
be out for a few seconds; this is called the “B” Phase Calibration. Next the Run (Green LED) will illuminate,

indicating the Smart Amplifi er is ready with no faults.

MART VECTOR DRIVE

S

The smart vector drive features a microprocessor that allows it to detect and display specifi c alarms (software

version 15.02A or newer only). It is backward compatible to any machine with a vector drive regardless of

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

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

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

When installing a smart vector drive without the cover, install the cover plate to the front of the vector drive.
When installing with the cover, install the cover plate to the top of the vector drive.

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

PCB REPLACEMENT

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

MICROPROCESSOR ASSEMBLY

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

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17

MOCON, VIDEO/KEYBOARD, & MICROPROCESSOR

The electrical panel will have residual voltage, even after power has been
shut off and/or disconnected. Never work inside this cabinet until the small
red Charge light on the servo amplifi ers go out. The servo amplifi ers are on
the left side of the main control cabinet and about halfway down. This light
is at the top of the circuit card at the center of the assembly. Until this light
goes out, there are dangerous voltages in the assembly even when power
is shut off.

Ground straps must be used when handling boards.

WARNING!

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

MOTOR CONTROLLER (MOCON)

Machines are equipped with a microprocessor-based brushless motor controller board (MOCON) that re­places the motor interface in the brush type controls. It runs in parallel with the main processor, receiving axis
commands and closing the loop around the axis motors.

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

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

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

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

a. Continuously ON - Normal status. board has passed all power-on tests, and no problems have been
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 amplifi ers (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.

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VIDEO/KEYBOARD

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

P1 Power connector J11 SPARE
J3 Keyboard (700) J12 Floppy
J4 Address bus J13 Video (760)
J5 Data J14 RS422 B
J10 Floppy V+ J15 RS422 A

Video/Keyboard Replacement

1. Remove the MOCON board as previously described.

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

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

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

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

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

6. Replace the MOCON board.

MICROPROCESSOR PCB (68ECO30)

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

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

The eight LEDs are used to diagnose internal processor problems. As the system completes power up test­ing, the lights are turned on sequentially to indicate the completion of a step. The lights and meanings are:

RUN Program Running Without Fault Exception. (Normally On) - If this light does not come on, or goes

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

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

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

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

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

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

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

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

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

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.

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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

Memory Retention Battery

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

To replace the battery, the 4-pin jumper, attached to a fresh battery, has to be temporarily attached to J6 be­fore the old battery is removed. With the jumper in place, un-solder the old battery and remove. Install a new
battery and solder in place, then remove the temporary jumper.

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

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

chine memory loss, which cannot be reversed.

Processor Board Replacement

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

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

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

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

INPUT/OUTPUT ASSEMBLY

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

The I/O PCB also contains a circuit for sensing a ground fault condition of the servo power supply. If more

than 1.75 amps is detected fl 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 fi 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.

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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.

OWER TRANSFORMER ASSEMBLY (T1)

P

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 trans-

former has fi 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 amplifi ers. The 115V is used by the video monitor, solenoids, fans

and pumps, in addition to supplying power to the main LVPS used by the control electronics.

The transformer assembly is located in the lower right hand corner of the main cabinet. Besides the high/low
voltage variations, two different power levels are available depending on the spindle motor used. The small
and large transformers have power ratings of 14 KVA and 28 KVA, respectively, and are protected by the main
circuit breaker.

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 fi rst three terminals of TB10.

Circuit breaker CB1 is used to protect the spindle drive and to shut 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.

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21

Secondary Connection To T1

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

Optional 480V Transformer

60Hz 50Hz

Input Voltage Range Tap Input Voltage Range Tap

493-510 1 (504) 423-440 1 (504)
481-492 2 (492) 412-422 2 (492)
469-480 3 (480) 401-411 3 (480)
457-468 4 (468) 391-400 4 (468)
445-456 5 (456) 381-390 5 (456)
433-444 6 (444) 371-380 6 (444)
420-432 7 (432) 355-370 7 (432)

Power-Up Low Voltage Control Transformer (T5)

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

Operator’s Work Light

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

POWER SUPPLY ASSEMBLY

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

Power PCB (PSUP)

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

Secondary Circuit Breakers

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

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

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

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

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

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

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

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

Power PCB (PSUP) Replacement

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

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

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

NOTE: If you need to replace the Low Voltage Power Supply board, please skip the next

step.

4. Replace the Power board, attaching it with the seven screws previously removed. Do not forget to use the
lower left screw for a ground connection.

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

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LOW VOLTAGE POWER SUPPLY

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

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

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

5. Replace the Power board as previously described.

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 fi rst control-

ler’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 defi ned by this parameter. The controller must also be in RUN mode to respond to the interface.

Since the controller powers-on in Run mode, remote unattended operation is thus possible.

RS-232 Line Noise

To minimize line noise on the serial port, reroute the cables straight up the left-hand side of the control to the
processor stack. Do not run them above the I/O PCB or up the center wire channel to the processor.

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

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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
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.

1

2

3

R

R

R

V

V

V

1

RS-232
PORT 1

RS-232
PORT 2*

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

P

PIN1

2

3

1

C

C

C

D
N
G

outside of the cabinet at the same time.

5

4

R

R

V

V

J13

J14

Video &

Keyboard

PCB

Micro

Processor

J4

2
P

5
R

4
R

3
R

2
R

1
R

4

5

C

C

3
P

RS-232 Wiring Diagram (with Serial Keyboard)

To

SKBIF

P1

5

1

2

3

4

R

R

R

R

R

V

V

V

V

V

2

1

P

RS-232
PORT 1

RS-232
PORT 2*

P

5
R

4
R

3
R

2
R

1
R

PIN1

2

3

4

5

1

C

C

C

C

C

D
N

3
P

G

J3

Coldfire

Processor

J14

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

J4

Micro

To

SKBIF

P1

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.

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4. Replace the RS-232 board by fi 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.

PARE USER M CODE INTERFACE

S

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).

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:

WARNING!

M21

M-FIN Discrete
Input 1009

CNC is:

Running Waiting

for M-fin

.05 ms
delay

Waiting for

end M-fin

Running

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

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 specifi c machine Inputs and Outputs.

3

M-Code
Output Relay
Normally Open

4

1 M-FIN, Input Signal

2 Input GND

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.

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WIRING THE RELAYS

Relays are marked on the I/O PCB, with their respective terminals forward of them. If the optional 8M relay
board is installed, connections on the I/O PCB are unused, since they are replaced by relays on the optional

board. Refer to the fi gure, and the Probe Option fi gure in the Electrical Diagrams section for terminal labeling.

SWITCHES

X, Y, Z Travel Limit Switches

Machine zero position is defi ned by a limit switch for each of the X, Y, and Z axes. After the search for ma-

chine zero is complete, these switches are used to limit travel in the positive direction. Travel in the negative
direction is limited by stored stroke limits. It is not normally possible to command the servo axes past the ma­chine zero as servo travel lookahead will decelerate and stop each motor prior to exceeding the stroke limits.

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 .012” (3mm) away from an assem-

bly or limit fl 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 direc-

tion 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.

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Tool #1 Sense Switch

The tool rotation turret has a switch that is activated when tool one is in position or facing toward the spindle.
At Power On this switch can indicate that tool #1 is in the spindle. If this switch is not active at power-on, the

fi rst tool change will rotate the turret until the switch engages and then move to the selected tool. The diag-

nostic 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 30o of travel of the
Geneva mechanism. When activated, this switch indicates that the turret is centered on a tool position. This
switch is normally closed. The diagnostic display will show this status of this input switch as “TC MRK”. A “1”
indicates the Geneva wheel is in position.

Umbrella Tool Changer Shuttle In/Out Switches (Vert)

Two switches are used to sense the position of the tool changer shuttle and the arm that moves it. One switch
is activated when the shuttle is moved to full travel inward and one is activated when it is in full travel outward.
These switches are normally closed, so that both are closed between in and out. The diagnostic display will
show the status of the input switch. A “1” indicates the associated switch is activated or open.

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

The Haas processor board contains three types of memory:

Gearbox Assembly and are diffi cult to reach. Removal of this assembly is necessary

to replace these switches. See the Mechanical Components Service Manual, for
Spindle Motor and Transmission removal.

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

serviceperson loads a new binary fi 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

fi le and the selected language text from the fl 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 bat-

tery 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 (Coldfi re):

At the prompt, >, type in the following and press, “enter” to test and clear BBU Ram:
M 6000000 60FFFFF

The following message is repeatedly displayed until Reset is pressed to stop the BBU RAM memory test:
Memory test passed, press and hold reset to stop

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27

To clear Flash Memory (Coldfi re Processor):

Type “FC” and press enter

The following message will be displayed:
ERASING FLASH – PLEASE WAIT…
FIRST FLASH CHIP ERASED
FLASH CLEAR COMPLETE

NOTE: This fl 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 specifi c type of memory. The next two steps

must be followed to prepare the machine.

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

necessary to turn off Setting 23 to save the macro variables. The following are the fi 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 fl 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)

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Clearing Flash Memory:

Clearing Flash Memory will solve problems caused by fragments of code left behind from previous binary or

language fi les. The most common problem is BAD LANGUAGE VERSION alarm. To clear the fl 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, “Undefi ned Command”, or a similar message.
If the control displayed the amount of fl ash memory in step 2 of “Clearing the memory in the control”, then do

one of the following depending upon how much fl 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 “Undefi ned Command” (or similar) perform the following steps.

Enter FC 8000 FFFFF and press enter (to clear 80000 thru FFFFF)
Enter FC 100000 17FFFF and press enter (to clear 100000 thru 17FFFF)
Enter FC 180000 1FFFFF and press enter (to clear 180000 thru 1FFFFF)

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

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29

DIAGNOSTIC DATA

The Alarm Msgs display is the most important source of diagnostic data. At any time after the machine com­pletes its power-up sequence, it will either perform a requested function or stop with an alarm. Refer to the
Alarms 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 fl 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 will select the diagnostics
display page. The Page Up and Page Down keys are then used to select one of two different displays. These
are for diagnostic purposes only and the user will not normally need them. The diagnostic data consists of 32
discrete input signals, 32 discrete output relays and several internal control signals. Each can have the value
of 0 or 1. In addition, there are up to three analog data displays and an optional spindle rpm display. Their
number and functions follow.

DISCRETE INPUTS/OUTPUTS (LATHE)

Discrete Inputs
# Name # Name

1000 Tool Turret Unlock 1016 Spare
1001 Tool Turret Lock 1017 Spare
1002 Spare 1018 Spare
1003 Low Coolant 1019 Spare
1004 Automatic Door 1020 Low hyd pressure
1005 Spindle In Hi Gear 1021 T.S. Foot Switch
1006 Spindle In Low Gear 1022 Probe Not Home
1007 Emergency Stop 1023 Spare 2b
1008 Door Switch 1024 Tool Unclamp Rmt*
1009 M Code Finish 1025 Low Phasing 115V
1010 Over Voltage 1026 B F End of Bar
1011 Low Air Pressure 1027 Bar Feeder Fault
1012 Low Lube Press. 1028 Ground Fault
1013 Regen Overheat 1029 G31 Block Skip
1014 Spare 1030 B F Spindle Intlk
1015 Spare 1031 Conveyr Overcrnts

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96-0284 rev E June 2008

Discrete Outputs
# Name # Name

1100 Hyd Pump Enable 1116 Move Spigot CW
1101 Spare 1117 Move Spigot CCW
1102 Spare 1118 Pal Ready Light
1103 Spare 1119 T.S. High Pressure
1104 Spindle Brake 1120 Tool Turret Out
1105 Coolant Pump on 1121 T.S. Reverse
1106 Power Off 1122 T.S. Forward
1107 Way Lube Pump 1123 (CE) Door Locked
1108 SB Motor Load PR 1124 M21 (Auto Door Clutch)
1109 SB Motor Load Bar 1125 M22 (Parts Catcher)
1110 Auto Door Open 1126 M23 (C Axis Engage)
1111 Auto Door Close 1127 HPC Coolant
1112 Spindle Hi Gear 1128 Green Beacon On
1113 Spindle Low Gear 1129 Red Beacon On
1114 Unclamp Chuck 1130 Enable Conveyor
1115 Lock Spindle 1131 Reverse Conveyor

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

Inputs 2

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

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

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

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

Haas Vector Drive
Name Name

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

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Analog Data
Name Description

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

MDL SL- __ Model number

DC BUSS Mocon II

ISCRETE INPUTS/OUTPUTS (MILLS)

D

# Name # Discrete Input Name

1000 TC Changer In/SMTC Pocket Down 1023 Spare 3/APC Pin Clr #2
1001 TC Changer Out/SMTC Pocket Up 1024 Tool Unclmp Rmt*
1002 Tool One In Pos. 1025 Spare
1003 Low TSC Pressure 1026 Spare 3A/APC Pal #2 Home
1004 Tool In Position 1027 Spare 3B/APC Pal #1 Home
1005 Spindle High Gear 1028 Ground Fault
1006 Spindle Low Gear 1029 G31 Block Skip
1007 Emergency Stop 1030 Spigot Position
1008 Door Safety Switch 1031 Conveyr Overcrnt
1009 M Code Finish*/APC: APC Pal Clamp 1032 Spare 4A
1010 Over Voltage (Mini-Mill - P.S. Fault) 1033 Spare 4B
1011 Low Air Pressure 1034 Spare 5A
1012 Low Lube Press. 1035 Spare 5B
1013 Regen Over Heat 1036 Spare 6A
1014 Drawbar Open 1037 Spare 6B
1015 Drawbar Closed 1038 Spare 7A
1016 Spare 1039 Spare 7B
1017 Spare 1040 Spare 8A
1018 Spare 1041 Spare 8B
1019 Spare 1042 Spare 9A (SMTC: Motor stop)
1020 Low Trans Oil Prs 1043 Spare 9B (SMTC: Origin)
1021 Spare 1/APC Door 1044 Spare 10A (SMTC: Clamp / Unclamp)
1022 Spare 2/APC Pin Clr #1 1045 Spare 10B

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

0.

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# Discrete Output Name # Discrete Output Name

1100 Powered Servos 1120 Unclamp Pre-Chrg
1101 Spare 1121 HTC Shuttle Out

(Air Drive Shuttle in/ APC Door)

1102 Spare 1122 Brake 5TH Axis

1103 Spare 1123 CE Door Lock

1104 Brake 4th Axis 1124 M21
1105 Coolant Pump On 1125 M22
1106 Auto Power Off 1126 M23 (Air Drive Shuttle: Move Shuttle Out)
1107 Spind. Motor Fan 1127 TSC Coolant
1108 Move T.C. In/APC Chain Dr Fwd 1128 Green Beacon On
1109 Move T.C. Out/APC Chain Dr Rev 1129 Red Beacon On

1110 Rotate T.C. CW 1130 Enable Conveyor

1111 Rotate T.C. CCW 1131 Reverse Conveyor

1112 Spindle Hi Gear 1132 M-fi n

1113 Spindle Low Gear 1133 Probe
1114 Unclamp Tool 1134 spare
1115 Spare 1135 spare
1116 Move Spigot CW 1136 spare
1117 Move Spigot CCW 1137 spare

1118 Pal Ready Light 1138spare

1119 TSC Purge 1139 spare

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

# Discrete Output Name # Discrete Output Name

1021 APC CE Door 1108 APC Chain Drive Forward
1022 APC Pin CLR #1 1109 APC Chain Drive Reverse
1023 APC Pin CLR #2 1121 PAL Clamp
1026 APC PAL #2 Home 1122 Door
1027 APC PAL #1 Home 1125 APC Motor
1046 APC Door Closed 1126 Beeper
1047 Door Open 1137 APC Chain Drive Power Enable
1048 APC Pallet Clamped 1138 Air Blast
1101 Pallet Clamped 1139 APC Beeper

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

Inputs 2
Name Name Name

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

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33

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

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

Spindle Cable Fault

Spindle Over Heat

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

Discrete Inputs 2
Name Name

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

Discrete Outputs 2
Name Name

Spare Output 32 Spare Output 44
Spare Output 33 Spare Output 45
Spare Output 34 Spare Output 46
Spare Output 35 Spare Output 47
Spare Output 36 Spare Output 48 (SMTC: Serp. ATC Enable)
TC MTR SW Spare Output 49 (SMTC: Serp. ATC Rev.)
Spare Output 38 Spare Output 50 (SMTC: Serp. Carsl CW)
Spare Output 39 Spare Output 51 (SMTC: Serp. Carsl CCW)
Spare Output 40 Spare Output 52 (SMTC: Serp. Carsl Ena.)
Spare Output 41 Spare Output 53
Spare Output 42 Spare Output 54
Spare Output 43 Spare Output 55

Analog Data
Name Description

DC BUSS Voltage from Haas Vector Drive (if equipped)
uP TEMP Displayed when Parameter 278 bit “μP Encl Temp” is set to 1)
SP LOAD Spindle load in %
SP SPEED Spindle rpm CW or CCW
RUN TIME Machine total run time
TOOL CHANGES Number of tool changes
VER X.XXX Software version number
MOCON MOCON software version
YY/MM/DD Today’s date
MDL HS__ Machine model
FV 2 11.0004 Floppy version (Ethernet Firmware)

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CABLE LIST

WIRE/
TERMINAL FUNCTION NAME:
NUMBER

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

L1 INCOMING 195-260VAC, PHASE 1, TO CB1-1
L2 INCOMING 195-260VAC, PHASE 2, TO CB1-2
L3 INCOMING 195-260VAC, PHASE 3, TO CB1-3

71 PROTECTED 195-260 VAC FROM MAIN CB1-4 TO K1-1
72 PROTECTED 195-260 VAC FROM MAIN CB1-5 TO K1-2
73 PROTECTED 195-260 VAC FROM MAIN CB1-6 TO K1-3

74 195-260 VAC FROM K1-4 TO XFORMER T1
75 195-260 VAC FROM K1-5 TO XFORMER T1
76 195-260 VAC FROM K1-6 TO XFORMER T1

77 230VAC PHASE 1 , FROM XFORMER T1 TO VECTOR/CHIP CONV
78 230VAC PHASE 2 , FROM XFORMER T1 TO VECTOR/CHIP CONV
79 230VAC PHASE 3 , FROM XFORMER T1 TO VECTOR/CHIP CONV

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

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

90A 115 VAC TO CRT
91A LEG 1
92A LEG 2
93A SHIELD DRAIN

90B 115 VAC TO HEAT EXCHANGER (CABINET DOOR FAN)
91B LEG 1
92B LEG 2
93B SHIELD DRAIN

90C 115 VAC TO CB4
91C LEG 1
92C LEG 2
93C SHIELD DRAIN

100 M-FIN
101 SIGNAL
102 COMMON
103 SHIELD DRAIN

100A MFIN OUTPUT M21 (MCD RELAY BOARD M21)
101A UNSWITCHED LEG 1
102A SWITCHED LEG 2
103A SHIELD DRAIN

110 SPARE

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Cable List

35

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

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

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

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

170 AUTO OFF FUNCTION
171 UNSWITCHED LEG 1
172 SWITCHED LEG 2
173 SHIELD DRAIN

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

190 UNCLAMP FROM SPINDLE HEAD TO IOASM
191 INPUT 25
192 DIGITAL RETURN
193 SHIELD DRAIN

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

210 DATA CABLE TO 3” FLOPPY DISK DRIVE

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

230 5’th AXIS BRAKE (Vert & Horiz) TAILSTOCK FORWARD OPTION (Lathe)
231 115VAC COMMON
232 115VAC SWITCHED
233 SHIELD DRAIN

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

36

Cable List

96-0284 rev E June 2008

250 VR SHUT IN / APC DOOR OPEN/ MD NIAGRA COOLANT ON (Vert option) HTC SHUTTLE/MORI MANUAL
TOOL RELEASE (Horiz) TAILSTOCK REVERSE OPTION (Lathe)
251 LEG 1 (Mill) 115 VAC (Lathe)
252 LEG 2 (Mill) 115 VAC RETURN (Lathe)
253 SHIELD DRAIN

260 K210 CABLING FOR EC (Mill) SPARE (Lathe)
261 SWITCHED LED
262 UNSWITCHED LEG
263 SHIELD DRAIN

270 K111 CABLING FOR EC (Mill) TAILSTOCK RAPID OPTION (Lathe)
271 UNSWITCHED LEG 1 (Mill) 115 VAC (Lathe)
272 SWITCHED LEG 2 (Mill) 115 VAC RETURN (Lathe)
273 SHIELD DRAIN

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

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

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

310 APC #2 DOOR OPEN (Vert) PC PALLET CW/CCW (Horiz)
AUTO DOOR CLUTCH - PARTS CATCHER (Lathe)

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

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

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

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

410 TOOL CHANGER DOOR/APC CE DOOR OPEN (Mill) TAILSTOCK FOOT SWITCH (Lathe)
411 SIGNAL (Lathe)
412 RETURN (Lathe)
413 SHIELD DRAIN

420 APC #2 PIN CLR #1 / APC #2 PIN CLR #2 / APC #2 PAL #2 HOME / APC #2 PAL #1 HOME (Vert)
MORI ARM IN/OUT - SMTC ARM CW/CCW (Horiz)

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Cable List

37

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

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

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

460 APC #2 DOOR CLOSED - APC #2 DOOR OPEN (Vert) MORI SLIDE 1/2 WAY - MORI SLIDE LEFT (Horiz)
APL ROTOR MARK - APL ROTOR HOME (Lathe)

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

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

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

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

500 OVERTEMP SENSOR FROM SPINDLE MOTOR
501 OVERTEMP WIRE 1
502 OVERTEMP WIRE 2
503 SHIELD DRAIN

510 RELAY CARD 1 DRIVE CABLE - 16 WIRE RIBBON

520 RELAY CARD 2 DRIVE CABLE - 16 WIRE RIBBON

530 RELAY CARD 3 DRIVE CABLE - 16 WIRE RIBBON

540 RELAY CARD 4 DRIVE CABLE - 16 WIRE RIBBON

550 INPUTS CARD CABLE (MOCON P10) 34 WIRE RIBBON

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

610 X AXIS HAAS AMPLIFIER CABLE TO MOTOR CONTROLLER BOARD
610-1 +A CHANNEL
610-2 ANALOG GROUND
610-3 +B CHANNEL
610-4 ANALOG GROUND
610-5 ENABLE
610-6 LOGIC GROUND
610-7 FAULT
610-8 LOGIC GROUND
610-9 NOT USED
610-10 SHIELD/ANALOG GROUND

620 Y AXIS HAAS AMPLIFIER CABLE TO MOTOR CONTROLLER BOARD
(SAME AS 610-1 THRU 610-10) (Mill)

630 Z AXIS HAAS AMPLIFIER CABLE TO MOTOR CONTROLLER BOARD
(SAME AS 610-1 THRU 610-10)

38

Cable List

96-0284 rev E June 2008

640 A AXIS HAAS AMPLIFIER CABLE TO MOTOR CONTROLLER BOARD
(SAME AS 610-1 THRU 610-10) (Lathe)

640A A AXIS HAAS AMPLIFIER CABLE TO MOTOR CONTROLLER BOARD
(SAME AS 610-1 THRU 610-10) (Mill)

640B B AXIS HAAS AMPLIFIER CABLE TO MOTOR CONTROLLER BOARD
(SAME AS 610-1 THRU 610-10) (Mill)

640C C AXIS HAAS VECTOR CURRENT COMMAND CABLE TO MOTOR CONTROLLER BD.
(SAME AS 610-1 THRU 610-10) (Vert)

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

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

650A THREE PHASE POWER TO SPINDLE MOTOR
651A LEG 1 OF 230VAC
652A LEG 2
653A LEG 3
654A SHIELD DRAIN

650B THREE PHASE POWER TO SPINDLE MOTOR
651B LEG 1 OF 230VAC
652B LEG 2
653B LEG 3
654B SHIELD DRAIN

660 X-AXIS ENCODER CABLE
660-1 LOGIC RETURN (D GROUND)
660-2 ENCODER A CHANNEL
660-3 ENCODER B CHANNEL
660-4 +5 VDC
660-5 ENCODER Z CHANNEL (OR C)
660-6 HOME/LIMIT SW
660-7 OVERHEAT SWITCH
660-8 ENCODER A*
660-9 ENCODER B*
660-10 ENCODER Z* (OR C*)
660-11 X HALL A (NOT USED)
660-12 X HALL B (NOT USED)
660-13 X HALL C (NOT USED)
660-14 X HALL D (NOT USED)
660-15 SHIELD DRAIN
660-16 (NOT USED)

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

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

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Cable List

39

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

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

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

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

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

710 APC #1 PALLET READY 1 / APC #1 PALLET READY 2 (Vert)
P-COOL/BF COLLET OPEN - BF COLLET CLOSE (Horiz) APL GRIP 1,2 (Lathe
711 FORWARD COMMAND (Vert)
712 REVERSE COMMAND (Vert)
713 RESET COMMAND (Vert)
714 COMMON (Vert)
715 SHIELD DRAIN

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

730 POWER METER FROM SPINDLE DRIVE TO KBIF (Vert) (BRUSH SYSTEMS)
731 METER +
732 METER ­733 SHIELD DRAIN

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

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

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

750 JOG-CRANK DATA CABLE (REM JOG SIDE CONNECTION)
750-1 LOGIC RETURN (D GROUND) 0VDC
750-2 ENCODER A CHANNEL
750-3 ENCODER B CHANNEL
750-4 +5 VDC
750-5 NC (Vert) JUMPER TO 750-1 (0 VDC) (Horiz & Lathe)
750-6 X-AXIS
750-7 Y-AXIS
750-8 N/C (Vert) ENCODER A* CHANNEL (Horiz & Lathe)
750-9 N/C (Vert) ENCODER B* CHANNEL (Horiz & Lathe)
750-10 N/C (Vert) JUMPER TO 750-4 (+5 VDC) (Horiz & Lathe)
750-11 Z-AXIS
750-12 A-AXIS
750-13 X 10
750-14 X 1
750-15 SHIELD DRAIN
750-16 N/C (Vert) NOT USED (Horiz & Lathe)

40

Cable List

96-0284 rev E June 2008

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

750B JOG HANDLE DATA CABLE (Horiz)
750B-1 +5 VDC JOG HANDLE
750B-2 0VDC
750B-3 JOG HANDLE A CHANNEL
750B-4 JOG HANDLE A* CHANNEL
750B-5 JOG HANDLE B CHANNEL
750B-6 JOG HANDLE B* CHANNEL

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

770 EMERGENCY STOP INPUT CABLE
771 SIGNAL (INPUT 8)
772 RETURN (D GROUND) (65)
773 SHIELD DRAIN

770A SECOND E-STOP INPUT / COUNTERBALANCE (Horiz) / BARFEEDER OPTION (Lathe)
771A SIGNAL
772A RETURN (D GROUND)
773A SHIELD DRAIN

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

790 APC PIN CLR #1 / MD OP DOOR OPEN - APC PIN CLR #2 / MD OP DOOR CLOSED (Vert)
PALLET CHANGER CW/CCW (Horiz) SPARE INPUTS PROBE HOME OPTION (Lathe)
791 SPARE 1 (Vert & Lathe) PALLET CW (Horiz)
792 SPARE 2 (Vert & Lathe) PALLET CCW (Horiz)
793 COMMON
794 SHIELD DRAIN

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

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

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

810A TOOL CHANGER MOTORS
811A SHUTTLE MOTOR +
812A SHUTTLE MOTOR ­813A SHIELD DRAIN

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

96-0284 rev E June 2008

Cable List

41

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

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

850 SERIAL PORT #1 TO SERIAL KEYBOARD INTERFACE CABLE

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

860 +12V/+5V/Gnd POWER CABLES (Vert) +5V/+12V/-12V/Gnd FROM MAIN POWER SUPPLY (Horiz & Lathe)
861 +12 VOLTS (Vert) +5 VOLTS (Horiz & Lathe)
862 -12 VOLTS FROM LOW V SUPPLY TO 68020 PCB (Vert) LOGIC POWER RETURN (Horiz & Lathe)
863 +5 VOLTS (Vert) LOGIC POWER RETURN (Horiz & Lathe)
864 -5 VOLTS (Vert) +12 VOLTS (Horiz & Lathe)
865 LOGIC POWER RETURN (D GROUND) (Vert) -12 VOLTS (Horiz & Lathe)
866 POWER GOOD SIGNAL FROM SUPPLY (Vert)

860A 12 VOLT POWER TO IOPCB (Vert & Lathe) 12 VDC POWER TO M CODE RELAY BOARD (Horiz)
861A +12 VOLTS
862A LOGIC POWER RETURN (D GROUND)
863A SHIELD DRAIN

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

860C +5,+12,-12 POWER TO 68030 (Vert & Lathe) 12 VDC POWER TO MONITOR FAN (Horiz)
861A +12 VOLTS
862A LOGIC POWER RETURN (D GROUND)
863A SHIELD DRAIN

870 115VAC TO OILER (Vert & Lathe)
871 115VAC LEG 1
872 115VAC LEG 2
873 SHIELD DRAIN

880A HIGH/LOW GEAR UNCLAMP/LOCK SOLENOID POWER (Vert)
115 VAC TO SPINDLE HEAD SOLENOIDS (Horiz & Lathe)
881A 115 VAC SOLENOID COMMON (IO P12-5) (Vert) WYE-DELTA SWITCH COMMAND (Horiz)
SPINDLE LOCK (Lathe
882A HIGH GEAR SOLENOID (IO P12-4) (Vert) TOOL UNCLAMP (Horiz & Lathe)
883A LOW GEAR SOLENOID (IO P12-3)
884A TOOL UNCLAMP SOLENOID (IO P12-2) (Vert) HIGH GEAR (Horiz & Lathe)
885A SPINDLE LOCK SOLENOID (IO P12-1) (Vert) 115 VAC COMMON (Horiz & Lathe)
886A PRE-CHARGE SOLENOID #18 (IO P12-7) (Vert) SHIELD DRAIN (Horiz & Lathe)
887A SHIELD DRAIN (Vert) PRECHARGE (Horiz & Lathe)

880B TRANSMISSION HIGH/LOW GEAR SOLENOIDS FOR LATHE (Vert & Lathe)
881B 115 VAC SOLENOID COMMON (IO P12-5)
882B HIGH GEAR SOLENOID (IO P12-4)
883B LOW GEAR SOLENOID (IO P12-3)
884B SHIELD DRAIN

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

42

Cable List

96-0284 rev E June 2008

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

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

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

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

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

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

940A 230 VAC SINGLE PHASE POWER TO THROUGH SPINDLE COOLANT PUMP (Horiz)
941A LEG 1
942A LEG 2
943A SHIELD DRAIN

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

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

960 LOW LUB/DOOR OPEN SENSORS (Vert) LOW TRANSMISSION OIL LUBE (Horiz)
LOW HYD PRESSURE (Lathe)
961 LOW LUB SIGNAL (Vert) LOW TRANSMISSION OIL LUBE SIGNAL (Horiz) LOW HYD PRESSURE (Lathe)
962 LOW LUB RETURN (D GROUND) (65)
963 SHIELD DRAIN

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

980 VOLTAGE MONITOR
981 VOLTAGE MONITOR 0 TO
982 VOLTAGE MON RET
983 SHIELD DRAIN

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Cable List

43

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

1000 SPINDLE ENCODER CABLE (LATHE TAIL STOCK)(BRUSH SYSTEMS) (Vert)
1001 LOGIC RETURN (D GROUND)
1002 ENCODER A CHANNEL
1003 ENCODER B CHANNEL
1004 +5 VDC
1005 ENCODER Z CHANNEL
1006 SHIELD DRAIN

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

1000-16 NOT USED

1010 AUX FRONT PANEL CABLE (HS-1R/RP)
1011 COMMON FOR CYCLE START AND FEED HOLD RETURN
1012 CYCLE START
1013 PART READY
1014 COMMON FOR PALLET ROTATE AND PART READY
1015 PALLET ROTATE
1016 FEED HOLD
1017 SHIELD DRAIN

1020 SPINDLE TEMPERATURE SENSOR CABLE
1021 SIGNAL
1022 ANALOG RETURN
1023 +5 VOLTS TO SENSOR
1024 SHIELD GROUND

1030 SPINDLE LOAD RESISTOR
1031 REGEN LOAD RESISTOR FOR SPINDLE DRIVE (B1)
1032 REGEN LOAD RESISTOR FOR SPINDLE DRIVE (B2)
1033 SHIELD DRAIN

1040 115 VAC TO MIKRON DOOR INTERLOCK SWITCH (OR HORIZONTAL PART READY LAMP (Vert))
1041 LEG 1
1042 LEG 2
1043 SHIELD DRAIN

1050 DOOR SWITCH WIRING THRU SUPPORT ARM
1051 DOOR OPEN SIGNAL (INPUT 9)
1052 DOOR OPEN RETURN (D GROUND) (65)
1053 SHIELD DRAIN

44

Cable List

96-0284 rev E June 2008

1060 GROUND FAULT DETECTION SENSE INPUT
1061 + INPUT FROM SENSE RESISTOR
1062 - INPUT FROM SENSE RESISTOR
1063 SHIELD DRAIN

1070 SKIP INPUT FROM SENSOR (Vert & Lathe) PROBE INPUT OPTION (Horiz)
1071 LOGIC COMMON (Vert & Lathe) PROBE SIGNAL (Horiz)
1072 SKIP SIGNAL (Vert & Lathe) LOGIC COMMON (Horiz)
1073 SHIELD DRAIN

1070A PROBE OUTPUT (MCD RELAY BOARD M22) (OPTION) (Horiz)
1071A UNSWITCHED LEG 1
1072A SWITCHED LEG 2
1073A SHIELD DRAIN

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Cable List

45

PCBS, CABLE LOCATIONS, AND DIAGRAMS

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

Red Wire

1
2
3

1
2
3

4
5

6

1
2
3
4

1
2
3

4
5

6

6
7

Friction Lock

2
4

6
8

10

12

14
16

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

1
2
3
4
5

1
2
3

4
5

6
7
8

Red Wire

1
3
5
7
9
11
13
15

Ribbon Cables

2
4

6
8

10

12

14
16
18
20
22
24
26
28
30
32
34

1
2
3

4
5
6

1
2
3

Mini Fit

1
2

3

3

4

4

5
6
7
8

1
2

1
2
3
4

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

Pin 1

Pin 5

Connection Example

46

Electrical Service

96-0284 rev E June 2008

MICROPROCESSOR PCB

U1 U2

U7

C6

Plug numbers and descriptions are on the next page

1MB 16MB

U3

U11

J6

512K

R52

R53

9.6K

BAUD

38.4K

U8

C5

128K

S2

RUN

BT1

U24

Y1

850A 850

C9

D1
D2
D3
D4
D5
D6
D7
D8

U15

U7

J4J5

C39

C37

C38

C40

FLASHMEMORY

U1 U2 U3

J6

U8

BT1

S2

9.6K

38.4K
RUN

BT2

BAUD

C7

D1

RUN

D2

PGM

D3

CRT

D4

MSG

D5

SIO

D6

POR

D7

HALT

D8

+5V

Y1

J4

850

U22

J5

850A

C46

C43

C45

C47

C82

U38

U41

U37

C76

J1 J2

ADDRESS BUS DATABUS

3.3V DC

BATTERY

U16

DRAM

U17

BATTERY BACKED UP

RAM 1MB OR 16MB

COLDFIRE

PROCESSOR

LINE 1:

LINE 2:

LINE 3:

U39

J3

STATUS

LEDS

FLASH

RAM

SUBASSY

U53

C75

ADDRESSBUS

U59

DATABUS

STATUS

LEDS

FLASH

RAM

C74

U58

C92

J1 J2

D1
D2
D3
D4
D5
D6
D7
D8

3.3V DC

BATTERY

U35

J4

DRAM

850

U34

J5

850A

BATTERY BACKED UP

RAM 1MB OR 16MB

U43

LINE 1:

LINE 2:

LINE 3:

U60

PAL4.9x

C91

C94

J3

D6

RUN

D5

PGM

D1

VIDEO

D2

MSG

D3

SIO

D4

POR

D7

STAT

D9

+5V

J4

850

J5

850A

J10

J3

COLDFIRE

PROCESSOR

J14

USB

J13

J1 J2

DATA BUSADDRESS BUS

J3

J1

ADDRESS BUS DATA BUS

J2

Coldfi re Coldfi re 2 (CF2)

96-0284 rev E June 2008

Electrical Service

J6

47

PLUG # CABLE # SIGNAL NAME  TO  LOCATION PLUG #

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

J10 VIDEO SIGNAL LCD
J13 USB DATA
J14 NOT USED

SERVO SYSTEM BLOCK DIAGRAM

LOW
VOLTAGE
POWER SUPPLY

LV HV

CURRENT
COMMAND

ENCODER

CURRENT
COMMAND

ENCODER

+/- 12V DC

VECTOR
DRIVE/HIGH
VOLTAGE
POWER SUPPLY

320V DC

BRUSHLESS
SERVOAMP

BRUSHLESS
SERVOAMP

MTR PWR

MTR
PWR

BRUSH

CONVERTER

BOX

AXIS

CABLE

MTR PWR

ENCODER

BRUSHLESS
AXIS
MOTOR/
ENCODER

TYPICAL

BRUSH
AXIS
MOTOR/
ENCODER
(Opt)

TYPICAL

48

MOCON BOARD

C-AXIS COMMAND

C-AXIS ENCODER

SPINDLE ENCODER

VECTOR DRIVE
OR
LARGE AMP

Electrical Service

DELTA-

WYE
(Opt)

SPINDLE
MOTOR

MOTOR/
ENCODER
(Opt)

SPINDLE
ENCODER

96-0284 rev E June 2008

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

SERVO DRIVE

CURRENT COMMAND

( FROM MOCON)

FAULT PWR ON

HAAS

Servo Amplifier

30A

CAUTION

HIGH VOLTAGE

A

B

C

-H.V.

+H.V.

PLUG # CABLE # SIGNAL NAME  TO  LOCATION PLUG #

POWER TO

SERVO MOTOR

335VDC

(FROM HAAS

VECTOR DRIVE)

X AXIS AMP

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

Y AXIS AMP

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

Z AXIS AMP

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

A AXIS AMP

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

96-0284 rev E June 2008

Electrical Service

49

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

LEDs

A
B
C

H-

H+

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

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

Y AXIS AMP

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

Z AXIS AMP

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

A AXIS AMP

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

50

Electrical Service

96-0284 rev E June 2008

SYSTEM BLOCK DIAGRAM - HIGH/LOW VOLTAGE

INPUT VOLTAGE

195-260V AC

(353-480V AC)

230V AC

MAIN
POWER
DISTRIBUTION

12V DC

115VAC

195-260V AC

(353-480V AC)

INPUT

115VAC

230V AC

MAIN
TRANSFORMER

OPERATOR
PENDANT

115VAC

115VAC

230V AC

TSC
OPTION
(Vert)

M CODE
RELAY
BOARD
(Opt)

MICRO
PROCESSOR
(CNC UNIT)

DISCRETE
INPUTS
AND
OUTPUTS

DC
MTR DRV
BOARD
(Opt)

LOW VOLTAGE

CMDS

STATUS

230V AC

COOLANT PUMP &
CHIP CONVEYOR

CMDS

FAULTS

POSITION DATA

HOME
SWITCH
(Vert &
Lathe)

SENSORS

CMDS

VIDEO, KEYBOARD, AND JOG

(FLOPPY DRIVE & RJH)

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

PWR

SPINDLE COMMANDS

SPINDLE ENCODER

SERVO MOTORS

335V DC

(325V DC

Horiz)

HAAS
VECTOR DRIVE

EXCESS PWR

CONTACTORSCOIL

FAULTS

REGEN
ASSY

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

230V AC

SP PWR

SPINDLE MOTOR

CHIP CNVYR
BOARD

(Opt)

CHIP CNVYR
MTRS

(Opt)

PWR

PWR

WYE-DELTA
CONTACTORS

(Opt)

96-0284 rev E June 2008

Electrical Service

51

POWER PCB VERSION K/L

P5

P11

P3
P7
P6
P2

P12

P35 P34 P8 P33 P28

MCD 1

MCD 2

LVINPUT

GND

SW DOOR FAN

MONITOR

PROBE PS

DELTA-WYE

SERVO FAN

LOW VOLTPS

90A

90A

90A

90A

90A

90C

94/N

AC GROUND

90C

P13

GND

+12V

P1

96

95

+12V

LE2

+12V

115VINPUT

115VSPARES

P14

GND

GND

+5V

+5V

-12V

+12V

Z3

TS1

90C90C 90C

Z4

LE3

-12V

MAIN 115V XFRMR

ON ON ON ON ON

10A 115V

MAIN

XFRMR

CB2

90C 90C

P15 P16

P27

PHASE DETECT

(FOR 3 PHASE ONLY)

IOPCB

MOCON 2

-12V

P17

MOTIF

GND

GND

GND

GND

GND

+5V

+12V

+12V

P30

LE1

Z1

+5V

P18

AMPS

-12V

GND

+12V

-12V

GFI

7A 115V

GFI

CB6 CB3 CB5

90

3PH 115VTO IOPCB

+5V

GND

+12V

GND

+12V

GND

+5V

COOLANT PUMP

10A 230V

COOLANT PUMP

92A

GFI/

+5V

WORKLIGHT

P19 P36 P20

FAILPASS

NE6

NE5

TSC COOLANT PUMP

930

P25

71 73

F1

NE1

10A 230V

TSC COOLANT PUMP

POWER SUPPLY ASSY

COOLANT/TSC

1A 250V

NE3

PSUP-K

P24 P4

SEC

PRI

TO T5

F3

230V IN

CHIP CONVEYOR

P9

P10

5A 230V

CHIP CONVEYOR

CB4

160

CHIPC 230V

P21

P23

170

AUTO OFF/CONTACTOR

P22

740

ON/OFF

PLUG # CABLE # SIGNAL NAME  TO  LOCATION PLUG#

P1 94-96 3-PHASE Transformer
P2 90C 115VAC LVPS
P3 90A 115VAC Spare
P4 Jumper Jumper
P5 90B 115VAC Switch Door Fan
P6 90A 115VAC Servo Fan
P7 90A 115VAC Delta-Wye
P8 Jumper +12/-12/+5 VDC In From LVPS
P9 Jumper Jumper
P10 77/79 230VAC 3/PHASE Transformer
P11 90A 115VAC Front Pnl P.S. (spare)
P12 90C 115VAC spare
P13 90C 115VAC spare
P14 90C 115VAC spare
P15 90C 115VAC spare
P16 90C 115VAC spare
P17 90C 115VAC spare

P18 860 115VAC Amplifi ers

P19 90 3PH 115VAC I/O PCB P56
P20 930 230V CLNT PUMP/TSC I/O PCB P44
P21 160 Chip Conv. 230V 3PH I/O PCB P39
P23 170 Auto Off/Contactor Contactor K1/ I/O PCB P42
P22 740 On/Off Front Panel (SKBIF) J20
P24 T5 Main Cont Frmr To T5
P25 71, 72, 73 230VAC IN From Contactor K1
P27 860 +12/+5 VDC I/O PCB P60
P28 860 +12/+5 VDC Motif PCB P15
P30 860 +12/-12/+5 VDC spare
P33 860 +12/-12/+5 VDC Mocon 2 PCB P15
P34 860A +12 VDC SMTC PCB P2
P35 860 +12 VDC MCD Relay PCB P2
P36 92A Worklight

52

Electrical Service

96-0284 rev E June 2008

OFFICE MILL POWER SUPPLY

C10

DZ1

LE1

HIGH

VOLTAGE

PRESENT

BL 320V PS

R21

C8

C13

DZ3

CR3

Q2

U2

CR2

VR1

C7

C9

P7

230VAC

P1

CR7

860A+12V

C1

Q3

U1

P3

TP3

12VRTN

P8

R23

320VDC

P2

K1

CR12

U3

CR10

TP1

320VRTN

C19

U4

TP2

LE2

FAULT

JP1

C11

CR5

CR4

T1

C14

C12

DZ4

CR6

C31

R5

CR9

U9

C28

U8

U7

VOLTMON

P6

FAULT

P4

U6

U5

970

ISP

Q1

R14

R7

CR1

REGEN

CR18

DZ2

R1

P5

C3

P5

PLUG # CABLE # LOCATION PLUG#

P1 32-5827A Ofi ce machine main transformer LV 1PH Main transformer
P2 N/A
P3 33-0982 Cable 860A +5/+12 GND I/O PCB I/O PCB P60

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

96-0284 rev E June 2008

Electrical Service

53

I/O PCB VERSION W, Z, AA

140B

CHIPCOC

P1
P2

P3
P4

P5
P6

P7
P8

P10
P11
P12
P13

P14
P15

P16
P17
P18
P19

P20
P21

P22

P23
P24

P25
P26

P27
P28

P71

P29
P30

820B

TCSTATSHIN/OUT

820

LOTSC

900

E-STOP-A/B/C

770

770A

770B

DOOR-A M-FIN

1050

100

970

LOAIR/OIL LOLUBOVERV

950

960

OVERH

830

SPHD STAT SPARE5 SPARE1

890

780

410

790

REMUNCL A/BSPARE2

190

190A

240

SKIPSPARE3

1070

420

SPARE6SPARE4

440

450

SPARE8SPARE7

460

470

SPARE9

SPARE10

480

PHLS

CEDOOR LOCK-A/B

P2A

P72

P9

P82

REMUNCL

A/B

1040/A

M21

ESTOP-D/E

770C/D

P81

1050A

DOOR-B

SQUIRT
LOOIL

190

Q22

5'THBRAKE

P31

K33

M21

CR12

540

P63

P74
P66

P67

P68

P69

P76

DOORLOK

5'THBRK

Q21

230

M22

P61

FROMMOCON

Q33

Q32

550

M26

M27

220

1160

TSCPURGE

HTCSHUT

PRE-CHG

Q20

P32

310

PALRDY

HTCSHUT

K34

M22

CR13

SPIGCCW

250

TB1

P62

SPIGCW

GREEN

RED

M23

K35

M23

CR14

J9

(INPUTMUX

DISABLE)

SPARE

AIRBLAST

BEEPER

PALCW/CCW

AIRDOOR

OILSQUIRT

P33

C66

Q23

TSCPURGE

K36

M24

CR15

540A

TOMCD RLY

P70

530

Q18

270

NC COM

CR33

M24

P60

TB2

860A

NO

M25

NSK

P77

K2

T1

C59

*

M26

AIRBLAST

BEEPER

PALCW

PALCCW

AIRDOOR

OILEXTEND

P35A

260

PALRDY

P79

P80

CR10

K18

200

SPIGOT

P35P34P36

AXISBRAKE

K17

PROBE

P78

+25V

CR34

CR5

AGND

CR11

140A

CHIPCEN/REV

P37

P57

K1

C69

TP4

Z9

CR25

R51

CHIPC REV

CR24 CR23 CR21 CR22 CR20

C9

Z6

K37

M25

P75

CR9

Z10

CR1

U73

L1

Q44

Q30

Q31

Q28

Q29

Q27

Q46

Q7

Q17

280

BEACON

R3

K9

K10

CR2 CR3 CR4 CR6

C70

CR35

I/OPCB-U 3-AUGUST-05

IOPCB-UCCA

CHIPCOC ADJUST

R122

Z8

CR16

R127

140

CHIPCONVEYOR

P38

P58

CR7

K38

P64

P65

CHIPCEN

P59

APCMTR

TCMOTORS

810

Q39

R4

Q40

R145

D10

R66

CR8

R52

R146

R310

REMVTO ISOL115

J2

CR19 CR17 CR18

K11

K12

R311

R7

R44

520

TCIN
TCOUT
TCCW
TCCCW
HIGHGEAR
LOWGEAR
UNCLAMP
DELTA-WYE

SERVOBRK
PALUP
SPARE1
SPARE2

510

4THBRK
COOLANT
AUTOOFF
SPINFAN

TSC COOL

MILL
LATHE

J1

C15

Q3

K32

C14

Q4

160

230VAC3PH

R42

R5

D1

D18

D17

D21

D20

C46

Q19

P54

880B

Q13

Q14

P53

Q15

P53A

Q16

Q5

Q41

P47

Q42

Q2

Q10

P50

Q11

P48

Q45

Q36

Q6

Q43

Q8

Q9

Q12

Q1

D19

115V3PH

P56

90

D22

GBI/F

SPHD SOLENOIDS

P55

880C

350

880A

DELTA-WYE

SPARE

P52

710

PALUP

430

P51

SERVOBRK-A/B

350A

P49

4'THBRAKE

P46

390

TSCENABLE

TSCO/T

130

120

P73

COOLO/T

170

P42

AUTOOFF

K7

TSCCOOL

940A

P45

COOL/TSC230 IN

930

P44

COOLANT

940

P43

SPINFAN

300A

P41

LUBOIL PUMP

300

P40

P39

PLUG # CABLE #  TO  LOCATION PLUG #

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

54

Electrical Service

96-0284 rev E June 2008

PLUG # CABLE #  TO  LOCATION PLUG #

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

96-0284 rev E June 2008

Electrical Service

55

PLUG # CABLE #  TO  LOCATION PLUG #

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

56

Electrical Service

96-0284 rev E June 2008

PLUG # CABLE #  TO  LOCATION PLUG #

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

ISCRETE OUTPUTS

D

+12V

Typical Discrete Input Circuit

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

MACRO CABLE HORIZONTAL VERTICAL LATHE

1000 820 P2/3 TC In (C) TC In (C) TT Unlock
SMTC Arm Mark (O) SMTC Pkt Dwn TL TC Home
EC-400 (O) SMTC Pkt Dwn

1001 820 P2/3 TC Out (C) TC Out (C) TT Lock
SMTC Shuttle Out (O) SMTC Pkt Up TL TC Mark
EC-400 (O) SMTC Pkt Up

1002 820 P3 PC DB Down (C) Tool #1 *C-axis Disengage
EC-400 (O) SMTC Tool #1 (O) SMTC Tool #1

1003 900 P4 Lo TSC Press Lo TSC Press Spare
EC-400 Lo TSC Press

1004 820 P3 PC Collet Down (C) TC Mark *C-axis Engage
EC-400 SMTC TC Mark (C) SMTC TC Mark

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

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

96-0284 rev E June 2008

Electrical Service

57

MACRO CABLE HORIZONTAL VERTICAL LATHE

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

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

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

GR Plasma Confi rm

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

1011 950 P12 Low Air Low Air Low Air

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

1013 830 P14 Overheat Overheat Overheat

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

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

1016 890 P15 Spare 3rd DB Pos Sw Spare
EC-400 3rd DB Pos Sw

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

1018 780 P16 Contactor On Contactor On Spare

1019 780 P16 Cntr Balance Cntr Balance Spare

1020 950 P12 Gearbox Low Oil Gearbox Low Oil Low Hydraulic

1021 410 P17 Air Door Sw GR Air Curtain APC (O) *TS Foot Sw
EC-400 TC Door Open CE Door Open (O) *Sub Spin Chck Ftsw
Old EC-300 Tool Door Open

1022 790 P18 PC Pallet CW (C) APC Pin Clr #1 (O) *Probe Home
EC-400 PP Pallet Lift (O) MD Op Door Open

1023 790 P18 PC Pallet CCW (C) APC Pin Clr #2
EC-400 PP Pallet Lower (O) MD Op Door Closed

1024 190 P19/20 PC Op Station Locked/ Rem Uncl (O) Chuck Uncl Foot Sw
Frnt Door
BF End of Bar

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

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

1027 240 P21 PC Pallet Down (C) APC Pal #1 Home BF Load Q
BF Load Q (C) Old MD Pal Down
EC-1600 Clamp Press

1028 Grnd Fault Grnd Fault Grnd Fault

1029 1070 P22/77 Skip Skip Skip

1030 200 P35 Possible P-Cool Spigot (C) BF End of Bar
EC-400 Spigot

1031 140B P1 Chip Conveyor Chip Conveyor Chip Conveyor

1032 420 P23 Mori Notch Pin In/ (C) APC #2 Pin Clr #1 Pocket Down
SMTC Arm In
EC-400 Pallet Clamped

58

Electrical Service

96-0284 rev E June 2008

MACRO CABLE HORIZONTAL VERTICAL LATHE

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

SMTC Arm Out

EC-400 Pallet Unclamped

1034 420 P23 Mori Tool 1/SMTC Arm CCW (C) APC #2 Pal #2 Home Tool One
EC-400 Pallet Clamp Error

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

1036 440 P24 Mori Arm In/SMTC Cage (O) Auto Door Open (O) Auto Door Open
Door Open
EC-400 SMTC Cage
Door Open

1037 440 P24 Mori Arm Out APL Load Station Door Open

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

1039 450 P25 Mori Arm CW Spare for Foot Sw

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

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

1042 470 P27 Mori Swing Spin/SMTC SMTC Motor Stop Motor Stop
Shuttle Mark
EC-400 SMTC Motor Stop

1043 470 P27 Mori Swing Mag/SMTC SMTC Origin Origin
Slide at Chain
EC-400 SMTC Origin

1044 470 P27 Mori Cage Door Open/ SMTC Cl/Uncl Cl/Uncl
SMTC Slide at Standby
EC-400 SMTC Cl/Uncl

1045 470 P27 Mori Slide Right/SMTC
Slide at Spindle
EC-400 Tool Transer

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

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

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

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

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

96-0284 rev E June 2008

Electrical Service

59

DISCRETE OUTPUTS

MOCON PCB

0VDC

+12VDC

Typical 115/230V Output Circuit (Kxx)

115/230V

V

H

N

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

MACRO RELAY CABLE HORIZONTAL VERTICAL LATHE (SL) VOLTAGE

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

1101 K2 430 P51/75 TC Door Open (EC) APC Pal Clamp APL Light 115V
PC Pallet Up (HS) Old MD Pal Up BF Extd Push
New MD Pal Unclamp
GR Air Curtain
NSK Spin Fwd

V

SOLENOID/PUMP

LE 1

I/O PCB

K

1102 K3 710 P52/75 PC Pallet Up (EC) APC#1 Pallet Ready 1 APL Grip 1 115V
P-Cool (HS) NSK Spin Rev
BF Collet Open (HS)

1103 K4 710 P52 PC Pallet Down (EC) APC#1 Pallet Ready 2 APL Grip 2 115V
BF Collet Close (HS) Robot Fix Uncl

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

1105 K6 940 P43 Coolant Coolant Coolant 230V

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

1107 K8 300 P40/41 Sp Fan Sp Fan Sp Fan 115V
Oil pump Oil pump Oil pump
Luber Luber Luber

1108 K9 810 P58/59 SMTC ATC Fwd (EC) TC In APL Rotator CW 170VDC*
Tool Xfer Fwd (EC) SMTC ATC Fwd BF load Q paired w/
PC Main DB Fwd (HS) APC Chn Drv Fwd 8-pos TC Rotate K10
BF Load Q (HS)

1109 K10 810 P58/59 SMTC ATC Rev (EC) TC Out APL Rotator CCW 170VDC*
Tool Xfer Rev (EC) SMTC ATC Rev BF Load Bar paired w/
PC Main DB Rev (HS) APC Chn Drv Rev 8-pos TC Rotate K9
BF Load Bar (HS)

60

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96-0284 rev E June 2008

MACRO RELAY CABLE HORIZONTAL VERTICAL LATHE (SL) VOLTAGE

1110 K11 810 P59 SMTC Crsl CW (EC) TC CW Auto Door Mtr Open 170VDC*
TC In (HS) SMTC Crsl CW paired w/
K12

1111 K12 810 P59 SMTC Crsl CCW (EC) TC CCW Auto Door Mtr Close 170VDC*

TC Out (HS) SMTC Crsl CCW paired w/
K11

1112 K13 880A P54/55 High Gear (EC) High Gear High Gear 115V
4 High Gear (HS)

1113 K14 880A P54/55 Low Gear (EC) Low Gear Low Gear 115V
4 Low Gear (HS)

1114 K15 880A P55 Tool Unclamp Tool Unclamp Chuck Unclamp 115V

1115 K16 880A P53 Delta-Wye Switch Delta-Wye Switch Delta-Wye Switch 115V
P53A/P55 Laser Hi Press Assist

1116 K17 200 P35 Spigot CW (EC) Spigot CW TL TC CW +12VDC*
P-Cool (HS)

1117 K18 200 P35 Spigot CCW (EC) Spigot CCW TL TC CCW +12VDC*
P-Cool (HS)

1118 K19 260 P34 Pallet Ready Light APC Pal Ready +12VDC*

1119 K20 270 P33 TSC Purge TSC Purge T/S rapid 115V
OM live tool #2

1120 K21 880A P55 Precharge Precharge TT Out 115V
Laser Low Press Assist TL TC up

1121 K22 250 P32 PP Pallet Lift (EC) VR Shut In T/S Rev 115V
HTC Shuttle (HS) APC Door Open OM live tool #3
Mori Manual Tool Rls (HS) Old MD Niagra Clnt On

1122 K23 230 P31 5th Axis Brake 5th Axis Brake T/S Fwd 115V
OM live tool #1

1123 K24 1040 P29/30 Door Interlock CE Door Lock CE Door Lock 115V

1124 K25 310 P68 PC Pallet Clamp (EC) APC#2 Door Open Auto Door Clutch 115V
PC Pallet CW (HS)

1125 K26 310 P68 PC Air Blast DES Vac Enable Parts Catcher 115V
Proto Flood Coolant GR Plasma Head Down
PC Pallet CCW (HS)

1126 K27 220 P69 SMTC Pkt U/D Sol (EC) VR shut out C-Axis Engage 115V
Air Door (HS) VB clamshell
SMTC Pkt U/D Sol
Laser Vac Enable

1127 K28 940A P45 TSC Clnt TSC Clnt P73 HP coolant 230V

1128 K29 280 P36 Spindle Lube Spindle Lube Spindle Lube 115V

1129 K30 280 P36 Worklight Worklight Worklight 115V

1130 K31 140 P37/38 ChipC En ChipC En ChipC En 230V*
paired w/
K32

96-0284 rev E June 2008

Electrical Service

61

MACRO RELAY CABLE HORIZONTAL VERTICAL LATHE (SL) VOLTAGE

1131 K32 140 P37/38 ChipC Rev ChipC Rev ChipC Rev 230V*
paired w/
K31

1132 K33 M21 TB1 M-Fin M-Fin M-Fin Relay
Shower Coolant (EC) GR Plasma Start Contact*
Mori Notch Pin Out (HS) HIT Index

1133 K34 M22 TB1/P77 Probe Probe Probe Relay
Laser Aim Beam On Contact*

1134 K35 M23 TB1/P77 Probe (EC) Laser Shut Open Spin Probe Enable Relay
Mori Mag CW (HS) Spin Probe Enable` Contact*

1135 K36 M24 TB1 Flood Coolant (EC) HIT Go Home Probe Arm Up Relay
Mori Mag CCW (HS) Contact*

1136 K37 M25 TB2/P76 Oil Squirter (MOM) Oil Squirter (MOM) Probe Arm Down Relay
Oil Squirter (MOM) Contact*

1137 K38 810A P58/74 PC Main DB En (HS) APC Chn Drv Pwr En 8-pos TC Rotate 160VDC*

1138 K39 M27 P66 Air Jet Blast (EC) Gantry Oil Air Blast 115V
PC Air Blast (HS) Air Blast ML BF push
Air Closer Enable
Chuck Clamp

1139 K40 M28 P67 PC Beeper APC Beeper, Airblast Sub Spin Chuck 115V
Old EC300 Tool Door
New MD Airblast

62

Electrical Service

96-0284 rev E June 2008

SERIAL KEYBOARD INTERFACE PCB WITH HANDLE JOG (34-4241B)

SPKRBEEP

The Serial Keyboard Interface PCB (SKBIF) provides:

• connection between the operator keypad and the main processor

• differential receiver for video data

• power for the backlight of the LCD

• connection between the jog handle (remote jog handle) and the main processor

• various machine-dependent functions.

The SKBIF is backward-compatible for all previous mill, lathe and simulator hardware and software versions.

NOTE: The video data connectors are only used by machines with a 15” monitor. Machines

Connector Descriptions

P1 This connector supports an RS-232 ribbon cable that sends and receives data from the Main Processor.
P2 This connector is used for the operator keypad interface. It receives keyboard data, which it sends to

the SKBIF micro-controller (U8), where the data is processed and sent out over the RS-232 line to the
Main Processor.

96-0284 rev E June 2008

with a 10” monitor have a separate differential card in the LCD panel connected

directly to the main processor.

Electrical Service

63

P3 This connector is wired directly to the Cycle Start and Feed Hold buttons on the operator pendant front

panel. The signals are sent to the SKBIF micro-controller (U8), where the data is processed and
sent out over the RS-232 line to the Main Processor.

P4 This connector is used on machines with an an analog Load Meter and is wired directly to the Load

Meter on the operator pendant front panel. The signals are sent to the SKBIF micro-controller (U8),
where the data is processed and sent out over the RS-232 line to the Main Processor.

P5 This connector is wired directly to the Beeper on the operator pendant front panel. The Main Processor

sends On/Off commands to the Beeper, while the ‘beeps’ associated with each key stroke are
controlled by wiring between P5 and the SKBIF micro-controller (U8).

P6 This connector is wired directly to the Cycle Start and Feed Hold buttons on a Remote Jog Handle or

an auxiliary front panel. It handles Part Ready and Pallet Rotate signals as well as mill Pallet 6 schedul-
ing. 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.

P6A This connector is wired directly to an auxiliary front panel (such as a Tool Changer panel). It handles

Cycle Start, Feed Hold, Part Ready and Pallet Rotate signals as well as mill Pallet 6 scheduling. The
signals are sent to the SKBIF micro-controller (U8), where the data is processed and sent out over the
RS-232 line to the Main Processor.

P7 This connector is used by mills utilizing a pallet changer. Pallet 1 and 2 scheduling signals are sent to `

the SKBIF micro-controller (U8), where the data is processed and sent out over the RS-232 line to the
Main Processor.

P8 This connector is used by mills utilizing a pallet changer. Pallet 3 and 4 scheduling and vertical mill MD

Load Table Rotation signals are sent to the SKBIF micro-controller (U8), where the data is processed
and sent out over the RS-232 line to the Main Processor.

P9 This connector is wired to the Enhanced Remote Jog Handle. RJH(E) signals are sent to the SKBIF

micro-controller (U8), where the data is processed and sent out over the RS-232 line to the Main
Processor.

P10 This connector is wired to the beacon on the operator pendant. Thin pendant signals are sent in over

the RS-232 line from the Main Processor to the SKBIF micro-controller (U8), which turns the beacon on
and off. A regular operator pendant has the beacon connected directly to the I/O Board, which turns the

beacon on and off.

P11 This connector is not currently used.
P12 This connector is not currently used.
J1 This connector is wired to the Jog Handle on the operator pendant front panel. Jog Handle signals are

sent to the SKBIF micro-controller (U8), where the data is processed and sent out over the RS-232 line
to the Main Processor. If a cable is present on J3, jog handle signals are sent to the MOCON from J3.

J2 This connector is wired to the Remote Jog Handle. RJH signals may be sent to the SKBIF micro-

controller (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.

64

Electrical Service

96-0284 rev E June 2008

J5 This connector is not currently used.
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 micro-control-
ler (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 assem-

blies. This connector is not used for thin pendants, or if cabling is present on J20 and J22.

J13 This connector provides power to a high voltage power supply in the LCD panel to supply backlighting

to the LCD.

J14 This connector is used to program the SKBIF micro-controller.
J15 This connector is used to program PAL chip U12.
J16 This connector receives video data from the Main Processor by way of J6. The video data exits the

SKBIF from J16 and is sent directly to the LCD panel.

J17 This connector is wired to the E-Stop button on the operator pendant front panel and to J20. The E-

STOP signal enters at J17 and exits at J20, where it is sent to the I/O Board and Power Supply card.

J18 This connector supports an RS-232 RJ-11 style phone cable that sends and receives data from the

Main Processor.

J19 This connector is not used at this time. A jumper is in place across the two pins.
J20 This connector receives +12V DC to power the SKBIF, Power On, Power Off and E-Stop signals.
J22 This connector is wired to the Power On and Power Off buttons on the operator pendant front panel and

to J20. The Power On and Off signals are received by J22 and sent to J20.

SW1 This switch determines how the beeper is being driven. The switch is set to ‘BEEP’ for a front panel

that contains a buzzer. The switch is set to ‘SPKR’ for a front panel that contains a speaker.

SW2 The COLOR switch is set based upon what LCD assembly is used. SHARP LCD assemblies require

the switch to be placed to the left (toward COLOR). LG LCD assemblies require the switch to be
placed to the right (away from COLOR). The STROBE switch should always be placed to the left
(toward STROBE).

96-0284 rev E June 2008

Electrical Service

65

VIDEO & KEYBOARD PCB W/ETHERNET & USB DRIVE

U66

BT1

C106

C148

S1

15" 10"

C109

C24

RUN

U66A

U57

S2

U60

C34

C102

C47

RS-232
PORT 1

RS-232
PORT 2

+

C206

C113

C30

U37

U35

C78

U36

U34

C76

J3

C77

U21

MON

J14

C138

J1

C41C39

ADDRESS BUS

E-NET (RJ-45 Jack)

U1

U2

U3

U4

U5

U6

U7

U8

CF2

(34-4410)

C44

U46

J9

J2

C45

C282

U10

U11

U12

U13

U14

U15

U16

U17

DATABUS

U51

C27

RUN

D6

C48

PGM

D5

VIDEO

D1

MSG

D2

SIO

D3

POR

D4

STAT

D7

+5V

D9

J4

J5

J8

U29

850 - to
SKBIF

To
15" LCD
Video
Monitor

Power

C281

C283

U74

J10

U80

J8

J13

J6

C25

J12

U5

J3

RP1

(1)

(DOC

J8

(BATTERY)

USB

(33-0211B)

J13

D3

PC 104 CCA

HARD

J11

J10

J4

(ICOP CCA)

U18

U23

J1

ADDRESS

Z1

U19

U29

RP4

RP4

B10

U24

DRIVE

J14

KYBRD

U21

PC 104

(34-3406)

U25

DATA

J5

C34

C35

J7

J2

U30
U31
U32

P1

Video/Floppy CCA

Left side end view of

LCD ENET/HD OPT (32-3406/7)

Power

USB Cable to Pendant

PLUG # CABLE # SIGNAL NAME TO  LOCATION PLUG #

P 1 8 6 0 L O W V O L T A G E P O W E R S U P P LY P C B — —

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 ____

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96-0284 rev E June 2008

MOCON PCB

P24

P10

P34

P26

P27 P28

P11

P13

P18

P20

P6

P7

P8

P9

P21P17 P22

P12

P14

P16

P33

P32

P5

P4

P35

P3

P30

P31

P19

JU2

INSTALLJUMPER
FOR MOCON 2

U43

P2

P15

P1

PLUG # CABLE # SIGNAL NAME  TO  LOCATION PLUG #

P1 ——- DATA BUSS VIDEO PCB ——­ MICRO PROC. PCB ——-

P2 610 X DRIVE SIGNAL X SERVO DRIVE AMP. P
P3 620 Y DRIVE SIGNAL Y SERVO DRIVE AMP. P
P4 630 Z DRIVE SIGNAL Z SERVO DRIVE AMP. P
P5 640 A DRIVE SIGNAL A SERVO DRIVE AMP. P
P32 640B B DRIVE SIGNAL B SERVO DRIVE AMP. P
P6 660 X ENCODER INPUT X ENCODER ——-

96-0284 rev E June 2008

Electrical Service

67

PLUG # CABLE # SIGNAL NAME  TO  LOCATION PLUG #

P7 670 Y ENCODER INPUT Y ENCODER ——­P8 680 Z ENCODER INPUT Z ENCODER ——­P9 690 A ENCODER INPUT A ENCODER ——­P30 690B B ENCODER INPUT B ENCODER ——-

P10 550 MOTIF INPUTS/I/O OUTPUTS I/O PCB P4
P11 510 I/O RELAYS 1-8 I/O I/O PCB P1
P12 520 I/O RELAYS 9-16 I/O PCB P2
P13 530 I/O RELAYS 17-24 I/O PCB P51
P14 540 I/O RELAYS 25-32 I/O PCB P3
P15 860 LOW VOLTAGE POWER SUPPLY PCB ——­P16 720 SP. LOAD METER LOAD METER ——­P17 640C VOLTAGE MONITOR VECTOR DRIVE J3
P18 750 JOG ENCODER INPUT JOG HANDLE ——­P19 ADDRESS BUSS VIDEO PCB ——-

MICRO PROC. PCB ——­P20 1000 SP. ENCODER INPUT SPINDLE ENCODER ——­P21 X-AXIS TEMP SENSOR
P22 730B SP. DRIVE LOAD SPINDLE DRIVE ——­P24 990 HOME SENSORS X, Y & Z LIMIT ——­P26 Y-AXIS TEMP SENSOR
P27 Z-AXIS TEMP SENSOR
P28 SPARE
P31 690C C ENCODER INPUT SPINDLE MOTOR

(lathe- 2nd spindle encoder)

Plug numbers and descriptions are on the next page

P33 640C VCTR DR CUR. CMD. VECTOR DRIVE J3
P34 SPARE
P35 PWM OUTPUT (LASER)

RS-232 P

ORT #1 PCB

GND

P3

PIN 1

P1

34-4090

P2

PLUG # CABLE #  TO  LOCATION PLUG #

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

68

Electrical Service

96-0284 rev E June 2008

WYE-DELTA SWITCH ASSEMBLIES

TO

SPINDLE

MOTOR

650A

1

CA7

-37

2

Black
White

Red

A2

L3

5

L2

21

NC

32

1

A1

3L1

CA7

A1

L1

3

A2

L2

5

L3

21

NC

32

DELTA WYE

To P53

I/O PCB

-37

22

NC

31

4

T1

T2

T3

6

2

4

T1

6

T2

T3

22

NC

650B

31

To Haas

Vector Drive

M CODE RELAY BOARD

OUTPUT

M28

NO COM NC NO COM NC

121110987654321 121110987654321

K8

LED8

P3

U7

U2 U4 U1

U3

LED9

U6 U5

32-3085B

M CODE RELAY BOARD

U10

JP4 JP8
JP3 JP7
JP2 JP6
JP1 JP5

U11

12 VOLT DC

540/P6

OUTPUT

U9

P2

M21M25 M22M26 M23M27 M24

K1

LED1

540/P1

INPUT

Addressing Jumpers

96-0284 rev E June 2008

Electrical Service

69

PLUG # CABLE # SIGNAL NAME  TO  LOCATION PLUG #

P1 540 MOCON INPUT I/O PCB P62
P2 860A 12V DC TO M-CODE PCBA PSUP P31
P3 540A I/O PCB OUTPUT
P4 M21 M-FUNCTION
M22 PROBE OPTION
M24 spare
P5 M25 spare
M26 spare
M27 spare
P6 540B M CODE OUTPUT 2nd MCD P1

YDRAULIC PCB

H

TB3 P4 P3

C1

K5

OFF

T1

K1K2

K6

P5

P9

CB1

TB2

K4

NE1

K3

FU1

P1P2 P6

PLUG # CABLE #  TO  LOCATION PLUG #

P1 880B I/O PCB P12
P2 90 POWER PCB P8
P3 410 GEARBOX
P4 350 I/O PCB (Hyd pump en) P54
P5 350A AXIS BRAKE Servo Motor
P6 350 115V SERVO BRAKE
P9 350A AXIS BRAKE Servo Motor
TB2 340 HYDRAULIC MTR
TB3 70 MAIN TRANSFORMER (VECTOR DRIVE UNIT)

70

Electrical Service

96-0284 rev E June 2008

TSC MOTOR DRIVE/HIGH PRESSURE COOLANT PCB

P4 P1

78

79

TSC MTR DRV CCA

LINE 1:

77

230V AC IN

OFF

LINE 2:

LINE 3:

R4 Q3

HS2

HS3

230V AC

MTR OUTPUT

R3

P3

OVR TMP

C4

C3

LE1

R9

U3

Q2

R10

C1

R6

R7

R2

R5

R8

P2

MOTOR EN

R11

R1

U2

U1

CB1

HS1

Q1

C2

PLUG # CABLE # LOCATION PLUG #

P1 33-0941E 3ph coolant pump socket Pump Socket
P2 33-1944 Coolant Enable I/O PCB P73
P3 33-0941E OVR TMD Pump Socket
P4 33-0987 230V IN Out transformer TB2

HAAS VECTOR DRIVE UNIT

TO I/O PCB

P58 & P12

TO MOCON

C 640C

P17

Delta-Wye

Contactors

(Horiz & Vert)

U

X

VW ZY

REGEN

RESISTOR

SPINDLE

MOTOR

X
Y

Z

M

G

E

TO I/O PCB P18

Over Voltage

Power to

Servo Amps

DC Bus

+

-

Haas Vector Drive

J3

J1

1234567891011

+ - ABC ABC

R

+ - RSTGGUVW

96-0284 rev E June 2008

R

230 VAC

UVW

78 79

S

(Horiz)

T

PCBA

HOPT-A

Electrical Service

71

QUAD APC ( 32-3078A) PCB

K1

C21

CR7

10A

5A

AGND

TCL

TP2
TP1

J1

C28

Q7

FU2

R25

K2

R26

K3

K4

R27

T1

P2
P1

Q3 Q4

FU1

P3A

P3

Q6Q5

Q1

Q2

P4

P5

P6A

P6

PLUG # CABLE # LOCATION PLUG #

P1 33-1516 I/O PCB P62
P3 33-6038A Air Door
P4 33-0191 From Power Card
6A 33-6038A Pallet Chain Motor

RENISHAW TOOL PRESETTER (LATHE)

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

I/O or M-Code
Relay Board
If Equipped

I/O
Skip

OMI

WORK

PROBE

Note:
To test probe use M53 in MDI
Verify that the yellow lead blinks and
the green LED turns on

P22

BY R

Y
W
B
Shield

DG

LG

GREY

WHT

M22M22

BR

YEL

LTP

BR

Shield

OMM 1

OMM 2

CONTROL O/P

POWER IN

Rtrn

24V

N/C C N/O

1 SIGNAL Y

2 SIGNAL GY
3 START W
4 0V GN

5 10V BN

6 0V GN
7 SIGNAL Y

8 SIGNAL GY

9 START W

10

ERROR

11

12

LOW
BATT

13

14

SEE
NOTE 2

15

16 +24V

17 0V

18 GND/SCN

M23

I/O or M-Code
Relay Board
If Equipped

Renishaw

Box

O/P

CONTROL

JUMPER

Power Card
P3

Dual Probe
LTP and Work Probe - Lathe

M52 LTP ON
M62 LTP OFF
M53 PROBE ON
M63 PROBEOFF

Note:
To test probe use M53 in MDI
Verify that the yellow lead blinks and
the green LED turns on

This toggles the skip bit shown on the
Diagnostics page, when the probe is deflected

19 SIG.STRENGTH
20 AUDIO EXT.
21 +

M/C START
1ms - 150 ms

22 ­23 +

SEE
NOTE 2

24 -

Notes:

1. Set SW2 as shown

AUTO START

234

1

ABCD

MC STARTIN 21 & 22

2. Set SW3 as shown

BUZZER OFF

234

1

ABCD

BUZZER ON

O/P O/P

14 & 15 23 & 24

STATUS STATUS

N/O N/O

3. Other switch configurations
as defined in user handbook

ERROR

ERROR

72

Electrical Service

96-0284 rev E June 2008

OPERATOR PENDANT

RS-232 INTERFACE

ESTOP, ON/OFF 12V PWR

PENDANT SUPPORTARM

BEEPER

LIGHT

SWITCH

TO

CONTROL CABINET

LCD

BACKLIGHT

VIDEO DATA

12V DC

VIDEO DATA

12V DC

USB DRIVE

REMOTE JOG HANDLE

CYCLE START
FEED HOLD

P9 J8

J16

SKBIF

J13

J18

J6

J20

P5

J4

J9

TOOL CHANGER

AUTO/MAN

CW

CCW

ENHANCED

(OPTION)

AUX

FPANEL

P6

J10

START/

FEED

HOLD

HOOK

SWITCH

P3

J1

P2

J17

J22

CYCLE START

FEED HOLD

+5VDC
0 VDC
A ENC
B ENC

24 PIN FLEX CABLE

JOG HANDLE

HAAS

2ND HOME

MEMORY KEY LOCK (OPTION)

EMERGENCY

STOP

POWER

ON

POWER

OFF

USER'S AUX F-PANEL

PALLETROTATE

PARTREADY

EMERGENCY

STOP

+

-

CE DOOR
(EUROPE)

(OPTION)

FRONT PANEL

KEYPAD

96-0284 rev E June 2008

Electrical Service

73

HORIZONTAL MACHINE CONTROL CABINET WIRING DIAGRAM

CABLE
90A
90B
740
760
770
850
1050

CABLE
490B

690B

CABLE
490X
660

CABLE
490Z
680
350A

CABLE
490B
690B
230

NAME
115VAC to LCD LVPS
115VAC to Work Light Switch
Power On/Off
Video Data
Emergency Stop
SKBIF
Door Switch Wiring

NAME
Super Speed Tool Changer
Motor Power
Super Speed Tool Changer
Encoder

NAME
X-Axis Motor Power
X Encoder, X Home Limit Switch

NAME
Z-Axis Motor Power
Z Encoder, Z Home Limit Switch
24VDC Servo Brake Release

NAME
B-Axis Motor Power
B Encoder, B Home 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
230VAC3PH to TSC Coolant Pump
TSC Over Temp

CABLE
300
960

CABLE
140

CABLE
940

CABLE
420

450
770B
810
880B

NAME
115VAC to Oiler
Low Lube

NAME
230VAC3PH Power to
Chip Conveyor Motor

NAME
230VACto Coolant Pump

NAME
APC #2 CLR #1 & #2/APC #2
PAL#2 & #1 Home
APC #2 CE Door Open
Emergency Stop Input
APC Motor
Transmission High/Low Gear
Solenoids

LUBE

PANEL

CONVEYOR

SPARE

FRONT PANEL/

PALLET CHANGER

TOOL CHANGER

REMOTE BOX/
FRONT PANEL

CHIP

SIGNAL

MFIN/

CLG

COOLANT

CABLE
100
730B

CABLE
240

410
710

770B
790
810A
M28

CABLE
250
310
430
460
480

NAME
M-FIN
SP Drive Load (Coolant Level
Gauge Sensor)

NAME
APC PALHome/MD PALUp­APC PAL1 Home PALDown
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

74

Electrical Service

96-0284 rev E June 2008

VERTICAL MACHINE CONTROL CABINET WIRING DIAGRAM

CABLE
90A
90B
280
720
740
750
770
1050

CABLE
490B

690B

CABLE
490X
660

CABLE
490Z
680
350A

CABLE
490B
690B
230

CABLE
300
960
990

CABLE
140

CABLE
940

CABLE
420

450
770B
810
880B

NAME
115VAC to LCD LVPS
115VAC to Work Light Switch
Red/Green Status Light
Analog Speed Command to Spindle
Power On/Off
Jog-Crank Data 'RJH'
Emergency Stop
Door Switch Wiring

NAME
Super Speed Tool Changer
Motor Power
Super Speed Tool Changer
Encoder

NAME
X-Axis Motor Power
X Encoder, X Home Limit Switch

NAME
Z-Axis Motor Power
Z Encoder, Z Home Limit Switch
24VDC Servo Brake Release

NAME
B-Axis Motor Power
B Encoder, B Home Limit Switch
5'th Axis Brake

NAME
115VAC to Oiler
Low Lube
X/Y/Z Home Sensors

NAME
230VAC3PH Power to
Chip Conveyor Motor

NAME
230VACto Coolant Pump

NAME
APC #2 CLR #1 & #2/APC #2
PAL#2 & #1 Home
APC #2 CE Door Open
Emergency Stop Input
APC Motor
Transmission High/Low Gear
Solenoids

CONTROL

CABINET

FRONT

PANEL

SPARE-1/

SUPER
SPEED

TOOL

CHANGER

X

AXIS

Z

AXIS

5TH AXIS

LIMIT

SWITCHES

CHIP

CONVEYOR

COOLANT

SPARE-4/

QAPC-L

FAST

TOOL

CHANGER

Y

AXIS

A

AXIS

TOOL

CHANGER

TSC

MFIN/

CLG

SPARE-3/

QAPC-R

SPARE-5/

APC DR/

RECVR

CABLE
490X
660

CABLE
490Y
670

CABLE
490A
690
390

CABLE
810
810A
820

CABLE
940A
130

CABLE
100
730B

CABLE
240

410
710

770B
790
810A
M28

CABLE
250
310
430
460
480

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
230VAC3PH to TSC Coolant Pump
TSC Over Temp

NAME
M-FIN
SP Drive Load (Coolant Level
Gauge Sensor)

NAME
APC PALHome/MD PALUp­APC PAL1 Home PALDown
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

96-0284 rev E June 2008

Electrical Service

75

LATHE CONTROL CABINET WIRING DIAGRAM

CABLE
90A
90B
740
760
770
850
1050

CABLE
490B

690B

CABLE
490X
660

CABLE
490Z
680
350A

CABLE
490C
690C
230

NAME
115VAC to LCD LVPS
115VAC to Work Light Switch
Power On/Off
Video Data
Emergency Stop
SKBIF
Door Switch Wiring

NAME
Super Speed Tool Changer
Motor Power
Super Speed Tool Changer
Encoder

NAME
X-Axis Motor Power
X Encoder, X Home Limit Switch

NAME
Z-Axis Motor Power
Z Encoder, Z Home Limit Switch
24VDC Servo Brake Release

NAME
C-Axis Motor Power
C Encoder, B Home Limit Switch
5'th Axis Brake

CONTROL

CABINET

SPINDLE

FRONT

PANEL

SPINDLE

BARFEEDER

AXIS

TURRET

X

AXIS

Z

AXIS

TAILSTOCK

C AXIS

HEAD

SUB

LIVE

TOOLING

TSC

CABLE
190

300A
880A
890

950

CABLE
490
660

CABLE
490
670

CABLE
490
690
390

CABLE
810
810A
820

CABLE
940A
130

NAME
Unclamp from Spindle Head to
I/O PCB
115VAC to Spindle Motor Fan/Oil
Pump/Oiler
High/Low Gear Unclamp/Lock
Solenoid Power
Spindle Status Switches
Low Air Pressure Sensor

NAME
Axis Motor Power
Encoder, Home Limit Switch

NAME
A-Axis Motor Power
A Encoder, Y-Home Limit Switch

NAME
Axis Motor Power
Encoder,A-Home Limit Switch
4'th Axis Brake

NAME
Tool Changer Turret Motor
Tool Changer Shuttle Motor
Tool Changer Status

NAME
230VAC3PH to TSC Coolant Pump
TSC Over Temp

CABLE
300
960

CABLE
140

CABLE
940

NAME
115VAC to Oiler
Low Lube

NAME
230VAC3PH Power to
Chip Conveyor Motor

NAME
230VACto Coolant Pump

LIMIT

SWITCHES

CHIP

CONVEYOR

COOLANT

MFIN/

CLG

HPU

CABLE
100
730B

CABLE
770B

NAME
M-FIN
SP Drive Load (Coolant Level
Gauge Sensor)

NAME
Emergency Stop Input

76

Electrical Service

96-0284 rev E June 2008

CABLES

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

12.0 IN

71-73 33-0952A
OVR VLTPROTC

12345

PSUP P25

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

48.0 IN

73-L6
K1-3

72-L5
K1-2

71-L4
K1-1

77
XFMR TB2

78
XFMR TB2

79
XFMR TB2

2.0 IN

RED

WHT

BLK

77-79 33-0078A
230V OUT
XFMR TB2

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

RED

WHT

13

BLK

2.0 IN

96-0284 rev E June 2008

Electrical Service

77

CABLE 90, 115V 3PH POWER SUPPLY - I/O PCB (33-0095A)

28.0 IN

1.5 IN 1.5 IN

2: RED

90, 33-0095A
115V3PH
I/O PCB P56

90, 33-0095A
115V3PH
PSUP P19

3: WHT

12

1: BLK

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

3: RED

4

2: WHT

3

1: BLK

12

78

Electrical Service

96-0284 rev E June 2008

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

LENGTH

2.00 IN
<LINE 1>

115VLCD LVPS
LCD LVPSTB1

RED

BLK

1

<LINE 1>
115VLCD LVPS
<LINE 3>

3: GRN

213

2: BLK

1: RED

GRN

2.00 IN

ASSY. #
33-8250

33-8251
33-8252
33-8253
33-8254
33-8255
33-8256
33-8257
33-8258
33-8259
33-8248

MACHINE
VF 0-2, VB-1

MINI MILL
ML
SL-40
VF 6-11
VF 3-5, SL-20/30
HS (ALL)
SL-40LB
TRM
VS-3
OM-1/OL-1

LENGTH

12.00 FT

12.00 FT

9.50 FT

21.00 FT

18.17 FT

14.50 FT

7.85 FT

23.00 FT

10.00 FT

21.50 FT

6.00 FT

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

22.0 IN

90B, 33-0219A
LVPS115V
PSUP P2

5: RED

90B, 33-0219A
LVPS115V
LVPSPCB J1

<LINE 1>
90A, <ASSY#>

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

2: BLK

2.00 IN

<LINE 3>
PSUP P11

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

12

3: BLK

1

96-0284 rev E June 2008

Electrical Service

1: RED

79

CABLE 90B FAN CORD - VECTOR DRIVE 2HD (33-1024A)

UPPER

FANFAN

5.75 IN

CABLE 90B WORK LIGHT (33-2330)

90B, <ASSY. #>

3:WHT

WORK LIGHT
LAMP PLUG

1

2

2:GRN

1:BLK

ASSY. # MACHINE
33-2331A

33-2330A
33-1330A
33-1331A
33-1337
33-1338

OL-1
OM-1
SL-20/30/40
SL-40LB
GT-10
SL-30L/LB

LOWER

LENGTH

90B, <ASSY. #>
WORK LIGHT
FR PNL LAMP SW

LENGTH

7.0 FT

8.5 FT

10.4 FT

12.7 FT

20.0 FT

32.0 FT

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

29.0 IN

SW P2
115V

WHT

SW P5
115V

BLK

12

5.00 IN
GRN

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

2: BLK

1

1: RED

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

TP/20AWG

4.0 FT

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

2: BLK

1: RED

23

1

80

Electrical Service

96-0284 rev E June 2008

CABLE 90C, 115V TRANSFORMER POWER SUPPLY - 8’ (33-6408)

8.0 FT

1

2

3

1: RED

2: BLK

90C, 33-6408
115VAC
PSUP P17

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

LENGTH

3

4

3: RED

4: BLK

LENGTH

LABELA

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

LABELA TEXT

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

1
2

ASSY#

90C, 33-6408
115VAC
TRANS P2/P4

LABEL B

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

1

RED
BLK

213

2: BLK

1: RED

LABEL B TEXT

33-8310C
33-8311C

33-8312
33-8315

96-0284 rev E June 2008

8.00 FT

10.00 FT

8.00 FT

23.00 FT

SP FAN PWR

SP FAN PWR

HPU FAN PWR

SP FAN PWR

Electrical Service

SP FAN

SP FAN

HPU FAN

SP FAN

SP FAN PWR

SP FAN PWR

HPU FAN PWR

SP FAN PWR

PSUP P14
PSUP P14
PSUP P16

PSUP P14

81

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

50.0 IN

2.0 IN

RED

94
XFMR

WHT

95
XFMR

BLK

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

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

2.0 IN
RED

BLK

WHT

14

GRN/YEL

96
XFMR

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

10.0 INCH

BLK <GND>

RED <SIG>

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

1

ASSY. #
33-0100A

33-0301
33-0101

1: RED

2: BLK

L-1

17.0 INCH

17.0 INCH

69.0 INCH

LENGTH

2.25 FT

2.25 FT

6.60 FT

22.0 IN

LENGTH

4: RED

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

MCD PCB M21
MCD PCB M21

L-1

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

BLK

RED

N/O
P4-3

COM
P4-2

RED
BLK

82

Electrical Service

96-0284 rev E June 2008

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

140A 33-0149
CHIPC ENA/REV

BLK
WHT
YEL

<REV>
<ENA>
<COM>

CHIPC PCB P4

140A 33-0149
CHIP ENA/REV

<COM>
<REV>

YEL
BLK

HOPT PCB P5

WHT<ENA>

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

RED

WHT

BLK

SHIELD

1

140A 33-0164A
CHIPC EN/REV
IOPCB P37/37A

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

SHIELD

160, 33-0160D
CHIPC 230V
PSUP P21

4
2 1

BLK

3

RED

WHT

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

140A 33-0164A
CHIPC EN/REV
CHIPC P2/3/4

160, 33-0160D
CHIPC 230V
IOPCB P39

SHIELD

RED

WHT

BLK

1

3

4

2

1

YEL

<COM>

WHT

<ENA>

BLK

<REV>

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

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

WIRE SIDE OF
CONNECTOR

96-0284 rev E June 2008

RED
BLK

RED
BLK

BLK
RED

170 <ASSY#>
AUTO/OFF
PSUP P23

Electrical Service

RED

BLK

RED
BLK

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

2: RED
1: BLK

4

21

3

83

CABLE 190, TOOL RELEASE (33-0190C)

LENGTH

TOP VIEW

SIDE VIEW

ASSY. #
33-0190C

33-3190C
33-4190
33-5190A
33-6190C
33-7190C
33-8190A
33-8290A
33-8291
33-9190
33-9191

190, <ASSY #>
REM UNCLAMP
REM UNCL SW

RED

BLK

MACHINE
VF 0-2

VB-1
ML
VR-11B
VF 6-11
VF 3-5
VS-3
GR-510/512
GR-712
HS-3/3R
OL-1

CABLE 190, TOOL RELEASE (33-1900)

<LINE 3>
P19

P19
P19
P19
P19
P19
P19
P19
P19
P19
P49

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

LENGTH (IN)

176.00 IN

444.00 IN

60.00 IN

282.00 IN

264.00 IN

201.00 IN

372.00 IN

564.00 IN

588.00 IN

294.00 IN

126.00 IN

RED
BLK

LENGTH (FT)

14.67 FT

37.00 FT

5.00 FT

23.50 FT

22.00 FT

16.75 FT

31.00 FT

47.00 FT

49.00 FT

24.50 FT

10.50 FT

1

<LOGIC RETURN>

SHIELD DRAIN

TOLERANCE

3.50 IN

±

1.5% OF LENGTH

±

IN

2.00

±

1.5% OF LENGTH

±

1.5% OF LENGTH

±

3.50 IN

±

1.5% OF LENGTH

±

1.5% OF LENGTH

±

1.5% OF LENGTH

±

1.5% OF LENGTH

±

3.00 IN

±

TOP VIEW

SIDE VIEW

190, <ASSY #>
REM UNCLAMP
REM UNCL SW

RED

BLK

ASSY. #
33-1900

33-1901
33-1902
33-1903

MACHINE
VF 5/50T

VF 6-11/50T
VS-1/3
EC-1600

LENGTH

LENGTH

13.00 FT

19.70 FT

31.00 FT

23.00 FT

190, <ASSY #>
REM UNCLAMP
I/O PCB P19

TOLERANCE

3.00 IN±

±

3.50 IN

±

1.5% OF LENGTH

±

1.5% OF LENGTH

RED
BLK

1

<LOGIC RETURN>

SHIELD DRAIN

84

Electrical Service

96-0284 rev E June 2008

190/240/260/710/770A FRONT ENCLOSURE SIGNAL RECEPTACLE (32-6660B)

SW P2
115V

95
SW P5

SHIELD

BLK

1

SHIELD

BLK

1

9: SHIELD

5: GRN
1: RED

8: BLK

4: WHT

RED

2 COND TP 22AWG

BLK

FRNT PNL
WORK LITE
FRNT PNL SW

190, 32-6660B
FRONT DOOR
I/O PCB P19

RED

260, 32-6660B
PALREADY LITE
I/O PCB P34

RED

AUX FP
PALRDY SW
SKBIF J11

4 COND 24AWG

1

2

1

BACK SIDE OF CONNECTOR

2

STANDARDRECEPTACLE
SOCKET CONTACTS
(SIDE VIEW)

240, 32-6660B
PALUP/DWN SW
I/O PCB P21

SHIELD

1

WHT
BLK

5

A: RED <PALDOWN>

B: WHT <PALUP>

D: SHIELD
E: RED <PALALARM>
F: BLK <PALALRM RTN>
H: SHIELD
J: GRN <CW ROTATION>
K: WHT <CCW ROTATION>

RED

M: RED <PALRDY LITE>

P: BLK <LS DOOR RTN>

R: RED <LS DOOR CLOSE>

770A, 32-6660B
2ND E-STOP

C

D

E

V

F

GL

I/O PCB P6

BAS

R

T

b

P

U

a

e

c

N

Z

d

M

W

Y

X

HK

J

1: RED
2: BLK

M28, 32-6660B
PALLETALARM
I/O PCB P67

RED

BLK

6

3

T: RED <2ND E-STOP>
U: BLK <RETURN>
V: BLK <GND>
W: WHT <PAL UP>
X: BLK <PALRDY SW RTN>
Y: RED <PAL RDY SW>
Z: BLK <PALRDY LITE RTN>

4

21

SHIELD

710, 32-6660B
PALUP/DWN SOL
I/O PCB P52

GRN/YEL <CHASSIS GND>

BLK

RED

64

3

21

WHT

a: RED <WORKLITE>
b: BLK <WORKLITE>
d: RED <PALDWN>
e: BLK <PALDOWN RTN>

CABLE 200, PROGRAMMABLE COOLANT (33-0202)

MACHINE
GR510/512

VF 0-5
VF 6-11
VB-3
VR-11B
EC-300
EC-1600
VS-3

BLK

ORN

3

4

12

WHT

RED

ASSY. #
33-0201

33-0202
33-0203
33-0204
33-0205
33-0206
33-0208
33-8200

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

LENGTH

50.00 FT

13.50 FT

20.50 FT

38.00 FT

22.00 FT

15.00 FT

24.00 FT

29.00 FT

TOLERANCE

1.5% OF LENGTH

±

3.50 IN

±

1.5% OF LENGTH

±

1.5% OF LENGTH

±

1.5% OF LENGTH

±

3.50 IN

±

1.5% OF LENGTH

±

1.5% OF LENGTH

±

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

1
RED

BLK

ORN

WHT
SHIELD

96-0284 rev E June 2008

Electrical Service

85

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

1

SHLD DRN

6.0 IN 22AWG

3: BLK <DRAIN>

1

FRONT VIEW

OF SOCKET

CENTER

KEY

<VIDEO PCB END>

VIDEO J11

RED

STRIP

210, ASSY #
FL DR DATA
VIDEO PCB J12

2.0 IN 2.0 IN

210, ASSY #
FL DR DATA
FRNT PNL FLD

RED

STRIP

<FLOPPY DRIVE END>

1

BACK VIEW

OF SOCKET

LENGTH

ASSY. #
33-0210A

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

MACHINE
VF0-2, VB-1

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

CABLE 230, TAILSTOCK CONTROL - FORWARD (33-1988)

15.0 FT.

230 33-1988
FORWARD (TS)
SOLENIOD

Back view

LENGTH

12.00 FT

1.50 FT

19.00 FT

15.00 FT

6.00 FT

9.00 FT

TOLERANCE

3.00 IN
.50 IN

0±±

3.50 IN

±

3.50 IN

±

2.00 IN

±

2.00 IN

±

230 33-1988
FORWARD (TS)
I/O PCB P31

6

4

1 BRN
2 BLU

231

3 GRN

86

Electrical Service

96-0284 rev E June 2008

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

11.50FT
PALUP

3: BLK

43

240, 33-0113
PALUP/DWN SW
PALCHNGR

1: RED

PALDWN

PALUP

PALDWN

GND

SHLD

1

2: RED
3: WHT
4: BLK

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

2: WHT

CABLE 240/260/430/770A/790 AUX. FRONT PANEL SIGNAL RECEPTACLE (32-6670)

GRN

SW P2
115V

95
SW P5

BLK
[LS DOOR RTN]

RED
BLK

SHLD

4
1

RED [LS DOOR CLOS]

BLK [PAL RDY LITE RTN]

SHLD

1

RED [PAL RDY LITE]

260 32-6670
PALREADY LITE
I/O PCB P34

1

BACK SIDE
OF CONNECTOR

2

9: SHIELD

5: GRN

1: RED

8: BLK

4: WHT

1

2

32-6670
WORK LITE
FRNT PNL SW

790, 32-6670
FRONT DOOR
I/O PCB P18

AUX FRNT PNL
PALRDY SW
SKBIF J11

Standard Receptacle
Socket Contacts
Side View

A

S

B

R

C

T

b

P

D

U

a

e

c

E

N

V

Z

d

F

M

W

Y

X

GL

H

K

J

32-6670
LIFT PROTECT SOL
PSUP P15

430, 32-6670
PALUNCLMP SOL
I/O PCB P51

770A 32-6670
2ND E-STOP
I/O PCB P6

240, 32-6670
PALUNCLMP SW
I/O PCB P21

SHIELD

G: GRN/YEL [GND]

M28 32-6670
AIRBLAST SOL
I/O PCB P67

RED [LIFT PROTECT SOL]
BLK [RTN]

1

BLK [PAL UNCLMP
SOL RTN]

RED [PAL UNCLMP SOL]

RED [2ND E-STOP]

BLK [RTN]

RED [+12V]

SHIELD

RED [AIR
BLAST SOL]

SHIELD

BLK [SOL RTN]

WHT [PAL UNCLMP SW]
BLK [RTN]

1

JUMPER

1

3 IN

A: GRN [WORKLITE GND]
B: SHIELD

D: RED [2ND E-STOP]
E: BLK [RTN]
K: GRN [CW ROTATION]
L: WHT [CCW ROTATION]
M: RED [PALRDY LITE]

N: BLK [PALRDY LITE RTN]

P: BLK [LS DOOR RTN]
R: RED [LS DOOR CLOSE]
T: BLK [LIFT PROTECT RTN]
Y: BLK [PALRDY SW RTN]
W: SHIELD

X: SHLD

Z: RED [PAL RDY SW]

a: RED [WORKLITE]
b: BLK [WORKLITE]
d: SHIELD

e: RED [LIFT PROTECT SOL]

2

3" BLK

4: BLK

43

2

96-0284 rev E June 2008

Electrical Service

87

CABLE 240/260/430/770A/790 AUX. FRONT PANEL SIGNAL CABLE (32-6665A)

F: BLK [PAL UNCLMP SW]

c: WHT/BLK [PAL UNCLMP SW RTN]

A: BRN [WRK LITE GND]

R: RED [FRNT DR SW]

A

B

C

T

D

U

c

E

V

d

F

W

X

G

H

J

C

D

E

F

G

S

R

b

P

a

e

N

Z

M

Y

L

K

b: BLK [WRK LITE RTN]

A

B

S

T

b

a

U

e

c

V

Z

d

Y

W

X

H

K

J

P: WHT/RED [FRNT DR SW RTN]

e: WHT/BRN [LIFT PROTECT SOL]

R

P

a: RED [WORK LITE]

N

M

L

W: SHIELD

1 TP #18 AWG

DETAILB

AUX FRONT PANEL SIGNAL CABLE

8.0 IN

U: BLU [PAL UNCLMP SOL RTN]

C: ORG [PAL UNCLMP SOL]

A

B

S

C

T

b

D

U

e

c

E

V

d

F

Y

W

X

G

H

K

J

T:BRN [LIFT PROTECT SOL RTN]

R

P

a

N

Z

M

L

H: WHT [AIR BLAST SOL]

N: BLK [PAL RDY LITE RTN]

M: RED [PAL RDY LITE]

J: GRN [AIR BLAST SOL RTN]

X: SHIELD

3 TP #20 AWG

DETAILA

2: BLK [WRK LITE RTN]

1: RED [WORK LITE]

1: RED 6" JUMPER

7 COND #24 AWG

DETAILC

1: WHT/BLK [PAL UNCLMP SW RTN]

3: BRN [WRK LITE GND]

2

3

1

3: BRN 6" JUMPER

2

3

1

2: BLK 6" JUMPER

2: WHT/BRN [LIFT PROTECT SOL]

1: BRN [LIFT PROTECT SOL RTN]

2: WHT [AIR BLAST SOL]

1: GRN [AIR BLAST SOL RTN]

2: ORG [PAL UNCLMP SOL]

1: BLU [PAL UNCLMP RTN]

10: RED [PAL RDY LITE]

3: BLK [PAL UNCLMP SW]

2: RED [FRNT DR SW]

1: WHT/RED [FRNT DR SW RTN]

3: BRN [WRK LITE GND]

WORK

LITE

WORK

LITE

1

1

1

5: BLK [PAL RDY LITE RTN]

4

3

1 2

PALUNCLMP

FRNT DR

SW

2: WHT/BRN

[LIFT PROTECT

SOL]

LIFT PROTECT

SOL

AIR BLAST

SOL

PALUNCLMP

SOL

SW

88

E: WHT [2ND ESTOP RTN]

D: BLU [2ND ESTOP]

A

B

S

C

T

b

D

a

U

e

c

E

V

Z

d

F

Y

W

X

G

H

K

J

R

P

N

M

L

Z: RED [PAL RDY SW]

L: GRN [CCW ROT]

Y: BLK [PAL RDY SW RTN]

Y: BRN [ROT RTN]
K: ORG [CW ROT]

d: SHIELD

7 COND #24 AWG

DETAILD

Electrical Service

9: BLU [2ND E-STOP]

8: GRN [CCW ROT]

7: ORG [CW ROT]

6: RED [PAL RDY SW]

1: BLK [PAL RDY SW RTN]

2: BRN [ROT RTN]

4: WHT [2ND ESTOP RTN]

AUX

FRNT PNL

96-0284 rev E June 2008

CABLE 240/260/430/770A/790 AUX. FRONT PANEL SIGNAL RECEPTACLE (32-6667B)

GRN

115V

95
SW P5

BLK
[LS DOOR RTN]

SHLD

4
1

RED [LS DOOR CLOS]

BLK

RED
BLK

32-6667B
WORK LITE
FRNT PNL SW

790, 32-6667B
FRONT DOOR
I/O PCB P18

[PALRDY LITE RTN]

SHLD

1

RED [PAL RDY LITE]

1

BACK SIDE OF CONNECTOR

2

9: SHIELD

5: GRN

1: RED

8: BLK

4: WHT

AUX FRNT PNL
PALRDY SW
SKBIF J11

1
2

STANDARDRECEPTACLE
SOCKET CONTACTS
SIDE VIEW

260 32-6667B
PALREADY LITE
I/O PCB P34

A: GRN [WORKLITE GND]

32-6667B
LIFT PROTECT SOL
PSUP P15

430, 32-6667B
PALUNCLMP SOL
I/O PCB P51

770A 32-6667B
2ND E-STOP
I/O PCB P6

A

B

S

C

R

T

b

P

D

U

a

e

c

E

N

V

Z

d

M

F

W

Y

X

GL

HK

J

240, 32-6667B
PALUNCLMP SW
I/O PCB P21

RED [LIFT PROTECT SOL]
BLK [RTN]

1

BLK [PAL UNCLMP SOL RTN]

SHIELD

RED [PAL UNCLMP SOL]

12

RED [2ND E-STOP]

BLK [RTN]

RED[+12V

1

SHIELD

]

1

WHT[PALUNCLMP SW

5

BLK [RTN]

G: GRN/YEL [GND]

M28 32-6667B
AIRBLAST SOL
I/O PCB P67

RED [AIR BLAST SOL]

SHIELD

6

4

3

2

1

BLK [SOL RTN]

B: SHIELD
C: RED
D: RED [2ND E-STOP]
E: BLK [RTN]
K: GRN [CW ROTATION]
L: WHT [CCW ROTATION]
M: RED [PALRDY LITE]

N: BLK [PALRDY LITE RTN]
P: BLK [LS DOOR RTN]
R: RED [LS DOOR CLOSE]
T: BLK [ LIFT PROTECT RTN]
W: SHIELD
Y: BLK [PALRDY SW RTN]
Z: RED [PAL RDY SW]

]

a: RED [WORKLITE]
b: BLK [WORKLITE]
c: BLK
d: SHIELD
e: RED [LIFT PROTECT SOL]

CABLE 250, TAILSTOCK CONTROL - REVERSE (33-1989)

15.00 FT.

250 33-1989

REVERSE (TS)
SOLENOID

Back view

250 33-1989

REVERSE (TS)
I/O PCB P32

3 GRN

34

12

1 BRN
2 BLU

96-0284 rev E June 2008

Electrical Service

89

CABLE 250 MORI T/C RECEPTACLE OUTPUTS (33-8155A)

BLK (PIN 4)

BLK (PIN 6)

BLK (PIN 7)

BLK (PIN 5)

GRN/YEL

BLK (PIN 14)

8

14

20

BLK

BLK (PIN 15)

BLK (PIN 8)

BLK (PIN 16)

BLK (PIN 9)

RED (PIN 13)

BLK (PIN 3)

BLK (PIN 1)

15

REAR
VIEW

1

4

28

GRN

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

33-8155A

115VSOLENOIDS

SMTC PCB P3

54 IN

REAR VIEW
OF CONNECTOR

250 TOOL
RELEASE
I/O PCB P32

CHASSIS
GROUND

15

16 14

7

6

8

REAR
VIEW

GRN

BLK

PIN OUT OF CONNECTOR
1 MAG CW/Y01A
2 M22 (SPARE)
3 MAG NOTCH OUT/Y01C
4 SWING SP/Y017
5 CHANGE MAG/Y016
6 SLIDE RIGHT/Y015
7 CHANGE LEFT/Y014
8 ARM CCW/Y013
9 MAG CCW/Y01B
10 M25 (SPARE)

12

13 1112910

5

3

4

11115V SW LINE (SPARE)
12 CHASSIS GROUND (SPARE)
13 115V COMMON
14 ARM IN/Y010
15 ARM OUT/Y011
16 ARM CW/Y012

4

3

21

RDY
LAMP

RED
RDY

LAMP

BLK

260 33-8105
READY LAMP
AUX F-PNL

CABLE 270, TAILSTOCK CONTROL - RAPID (33-1987)

13.5 FT.

270/880A 33-1987
RAPID (TS)
TT / SOL

260 33-8105
READY LAMP
I/O PCB P34

270/880A 33-1987
RAPID (TS)
I/O P33/HPU SOL

123

1 3

RED
BLK
DRAIN

1 BRN
2 BLU
3 GRN

90

Electrical Service

96-0284 rev E June 2008

CABLE 280, HAAS BEACON (33-1035A)

2

RED

3
1

WHT

BLK

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

ASSY. # MACHINE
33-1035A

33-1036A
33-1037C
33-1039C
33-8160B

VF0-5, SL20/30
VF6-11
SL-40
VB1/3, HS-3
VS-3

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

300, <ASSY #>
LUB OIL PUMP
LUBE RACK

32

1

1:RED

2:BLK

300
LUBE
PUMP

1: RED

2: BLK

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

<LINE 3>
IOPCB P36

IOPCB P36
IOPCB P36
IOPCB P36
BASE CAPPER

ASSY. # MACHINE
33-1333

33-1343
33-1353
33-1363A

VF0-11
SL-10/30/40
SL-20
SL-40L

LENGTH

17.75 FT

21.75 FT

22.00 FT

13.50 FT

22.00 FT

SHLD

BLK

WHT

TOLERANCE

3.50 IN±

3.50 IN

±

3.50 IN

±

3.50 IN

±

3.50 IN

±

300, <ASSY #>
LUB OIL PUMP
IOPCB P40

LENGTH

2.75 FT

10.50 FT

7.50 FT

13.50 FT

432 1

RED

SHIELD

BLK

RED

3 2

1

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

300A, <ASSY #>
GBOX OIL PUMP

RED

BLK

OIL PUMP CON

ASSY. # CONTROL
33-8168

33-8169
33-8175A

BOTTOM
TOP
BOTTOM

LENGTH

7.00 FT

13.00 FT

16.00 FT

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

SHLD

312

BLK

RED

96-0284 rev E June 2008

Electrical Service

91

CABLE 310, DOOR OPEN (33-2300)

ASSY. # MACHINE
32-2300

32-2301
32-2302
32-2303
32-2304
32-2305
32-2306
32-2307
32-2308
32-2309
32-2310
32-2313
32-2314
32-2316
32-2320

LATHES
MM, SMM
SL-10, ML
SL-40
SL-20, TL-15
SL-30
APC, APCQ
APC, APCQ
APCQ
APCQ
MDC-1
EC-400
TL-1/2/3
EC-400/500/400PP
EC-630

LENGTH

CABLE 350/350A, AXIS BRAKE (33-0904B)

LENGTH

18 IN
12 IN
39 IN
54 IN
75 IN

84 IN
150 IN
150 IN
186 IN
186 IN

21 IN

21 IN

84 IN
150 IN
204 IN

2: BRN <SIG>

1: BLU <GND>

TABLE

<LINE1>
<LINE2>
<LINE3>

RED
BLK

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

AXIS BRAKE
HYD PMP EN
1AXIS BRAKE

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

1

2: RED

3: BLK

350 33-0907
Z-AXIS BRK
TRANS PCB P1

BRAKE PCB P6
TRANS PCB P4
BRAKE PCB P6

18.0 IN

<LINE1>
<LINE2>
<LINE4>

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

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

25.00"

23.00"

27.00"

2: BLK

1: RED

23

123

1 RED
2 BLK

1

92

Electrical Service

96-0284 rev E June 2008

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

A1 COIL

BLK

350A33-0352B
115HYD CNTCR
CONTACTRCOIL

A2 COIL

RED

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

23

3: BLK

4

1: SHLD

1

2: RED

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

ASSY. #

MACHINE

6

40"

LENGTH

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

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

LENGTH

<LINE 2>

BLK

2: BLK

1: RED

23

RED

1

1

33-8511
33-8512

HS-3R
VTC

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

410 <ASSY #>

RED

3

1

4

2

BLK

TC DOOR LS
TC DOOR L/SWITCH

ASSY. #
33-9825A

33-9821A
33-9829
33-9830
33-9831

MACHINE
HS-1 (ALL)

HS-2/3
EC-300
GR-408
GR-510/512/
710/712

LENGTH

LENGTH

15.00 FT

5.50 FT

20.75 FT

28.00 FT

48.00 FT

9.50 FT

11.00FT

115V4TH BRAKE
115VSP BRAKE

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

TOLERANCE

3.00 IN
.00 IN

2±±

3.50 IN

±

4.00 IN

±

5.00 IN

±

1

RED
BLK

DRAIN

96-0284 rev E June 2008

Electrical Service

93

CABLE 420/440/450/460/470/770B MORI T/C RECEPTACLE INPUTS (33-8150C)

MAG CCW

MAG CW

MAN

TL RLS FS

GND

SHIELD

1

ORG
BRN

WHT/BLK

6

CHANGE SLIDE

HALF WAY(X006)

CHANGE SLIDE

LEFT (X004)

RED
YEL

SHIELD

1

YEL

WHT

BLK

33-8150B

INPUTS

SKBIF J9

DRAIN

460

I/O PCB P26

1

RED
BLK

BLK

RED

WHT/BLK

BRN

YEL

ORG

15

YEL

WHT

770B

I/O PCB P7

3RD E-STOP

420

RED

BLK

RED

BLK

1

4

9

21

26

BLK

RED

BLK

RED

3

BLK

8

RED

14

BLK

20

RED

BLK

25

BLK

RED

28

RED

BLK

I/O PCB P23

I/O PCB P24

I/O PCB P25

ASSY#

33-8150C

440

450

I/O PCB P27

470

1

RED MAG NOTCH PIN IN (X00E)
BLK MAN TOOL RELEASE (X00B)
RED 1ST.POT(X00C)
BLK POT COUNT (X00D)

1

RED ARM IN (X000)
BLK ARM OUT (X001)

1

RED ARM ROTATE CCW (X003)
BLK ARM ROTATE CW (X002)

1

RED +12DC
BLK CNG SWG TO SPNDL (X009)
RED CNG SWG TO MAG (X008)
BLK CAGE DOOR SW

RED CNG SLIDE RIGHT (X005)

BLK LOGIC GROUND

CABLE 420/430/470/810 SIDE-MOUNT TOOL CHANGER AMPHENOL CABLE ASSEMBLY (33-0822)

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

KEY

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

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

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

A

B

M

L

N

C

P

T

K

J

H

D

S

E

R

G

F

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

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

1

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

5

8

324

1

1
234 56

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

SHIELD

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

21

94

Electrical Service

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

96-0284 rev E June 2008

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

LABELA LABEL BLENGTH

See Table

<(LINE 1>

RELAYCABLE

<(LINE 3>

PIN 1

ASSY. #
33-0515

33-0525
33-0535
33-0545

CABLE 510

PIN 1/2 SERVO POWER ON/RTN
PIN 3/4 PALLETUP/RTN
PIN 5/6 SPAREA/RTN
PIN 7/8 SPARE B/RTN
PIN 9/10 4THAXIS BRAKE/RTN
PIN 11/12 COOLANT ON/RTN
PIN 13/14 AUTO POWER OFF/RTN
PIN 15/16 SPINDLE COOLING (VF-0)

RED EDGE

LABELA & B

<LINE 1>

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

SPINDLE LUBE
SPINDLE FAN
GEAR BOX OIL PUMP
WAY LUBE PUMP/RTN

LABEL B
<LINE 2>

RELAYCABLE
RELAYCABLE
RELAYCABLE
PRE I/O-S P3

16COND/28AWG

LABELA
<LINE 3>

MOCON P11
MOCON P12
MOCON P13
MOCON P14

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

RED EDGE

LABEL B
<LINE 3>

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

CABLE 520

PIN 1/2 TOOL SHUTTLE IN/RTN
PIN 3/4 TOOL SHUTTLE OUT/RTN
PIN 5/6 TOOLTURRET CW/RTN
PIN 7/8 TOOLTURRET CCW/RTN
PIN 9/10 HIGH GEAR SHIFT/RTN
PIN 11/12 LOW GEAR SHIFT/RTN
PIN 13/14 TOOL UNCLAMP/RTN
PIN 15/16 SPINDLE LOCK/RTN

CABLE 530

PIN 1/2 SPIGOT FORWARD/RTN
PIN 3/4 SPIGOT REVERSE/RTN
PIN 5/6 SPAREA/RTN
PIN 7/8 SPARE B/RTN
PIN 9/10 PRECHARGE/RTN
PIN 11/12 SPARE C (HTC SHUTTLE)/RTN
PIN 13/14 5TH AXIS BRAKE/RTN
PIN 15/16 DOOR LOCK (EUROPE)/RTN

PIN 1

LENGTH

46.0 IN
46

.0 IN

46

.0 IN

38

.0 IN

96-0284 rev E June 2008

Electrical Service

95

CABLE 540/540A/850 I/O PCB TO MCD CONTROLS (33-1515G)

FACE UP FACE DOWN

PIN 1

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

<LINE 1A>

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

<LINE 1B>

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

RED STRIPE

LENGTH

<LINE 2>

MCD CONTROLS
SMTC DRIVER
CSM SERIAL KBD
MCD CONTROLS

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

<LINE 3A>

MCD PCB P1
SMTC DRVR P1
SKBIF P1
MCD PCB P1

PIN 1

<LINE 3B>
I/O PCB P62

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

LENGTH

2.00 FT

1.75 FT

2.50 FT

3.20 FT

96

Electrical Service

96-0284 rev E June 2008

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

550, ASSY #

PIN 1 PIN 1

INPUT # SIGNAL

00 SHUTTLE IN (SMTC PKT DOWN)
01 SHUTTLE OUT (SMTC PKT UP)
02 TOOL#1 MARKER (SMTC TOOL #1)
03 LOW TSC COOLANT

04 GENEVAMARK (SMTC TC MARK)
05 IN HIGH GEAR
06 IN LOW GEAR
07 EMERGENCY STOP
08 DOOR OPEN
09 M CODE FINISH (GR PLASMA CONFIRM)
10 LOW VOLTAGE
11 LOW AIR PRESSURE

12 LOW WAY LUBE OIL
13 OVERHEATSERVO REGEN
14 DRAW BAR OPEN
15 DRAW BAR CLOSED
16 SPARE(3RD DB POS SW)
17 SPINDLE DRIVE FAULT
18 SPINDLE STOPPED
19 SPINDLE AT SPEED
20 LOW GEARBOX/SPINDLE OIL

21 SPARE1
22 SPARE2A
23 SPARE2B

24 REMOTE TOOL UNCLAMP
25 LO PHASE

INPUTS CABLE
MOCON PCB P10

(LASER LOW ASSIST GAS PRESSURE)

(LASER LOW PURGE AIR PRESSURE)

(VB LOW CHILL PRESSURE)
(VB CLAMSHELL DOOR OPEN)
(APC PIN CLR MD OPEN)

46.0"

INPUT # SIGNAL

26 SPARE3A

(APC PAL#2 HOME, OLD MD PAL UP,

NEW MD PALUNCLAMP)

27

28 GROUND FAULT
29 SKIP
30 SPIGOT
31 CHIP CONVEYOR OVERCURRENT

32
33 SPARE4B (APC #2 PIN CLR #2)
34 SPARE4C (APC #2 PAL #2 HOME)
35 SPARE4D (APC #2 PAL #1 HOME)
36 SPARE6A (AUTODOOR)
37 SPARE6B
38 SPARE7A (APC #2 CE DOOR OPEN)
39 SPARE7B
40 SPARE8A (APC #2 DOOR CLOSED)
41 SPARE8B (APC #2 DOOR OPEN)
42 SPARE9A (SMTC MTR STP)
43 SPARE9B (SMTC ORIGIN)
44 SPARE9C (SMTC CL/UNCL)
45 SPARE9D (SMTC CL/UNCL)
46 SPARE10A (APC DOOR CLOSED)
47 SPARE10B (APC DOOR OPEN)
48 SPARE10C (APC PAL CLAMPED)
49 SPARE10D (APC PAL IN POSITION)

SPARE3B
(APC PAL#1 HOME, OLD MD PAL DOWN,

EC-1600 CLAMP)

SENSE CIRUIT
SPARE4A (APC #2 PIN CLR #1)

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

96-0284 rev E June 2008

Electrical Service

97

CABLE 610 (620, 630), AXIS CURRENT COMMAND (33-0610E)

MOCON END

WHT/BLU <FAULT>

WHT/BLK <ENABLE>

WHT/RED <+B>

WHT/GRN <+A>

1

SHIELD <ANALOG GND>

BLU <LOGIC GND>

BLK <LOGIC GND>

RED <ANALOG GND>

GRN <ANALOG GND>

2

2 1

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

2

1

WHT/BRN <A>

WHT/ORG <B>
WHT/BLK <ENBL>

WHT/YEL <FLT P>

WHT/RED <320VA>

2

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

RED <A GND>

1

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

MOCON-AMP

1

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

33-0610E

2

AMP END

1

2

2 1

1

WHT/BRN <A>

WHT/ORG <B>

WHT/BLK <ENBL>

WHT/YEL <FLT P>

2

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

YEL <FLT>

DRAIN

WHT/RED <320VA>

RED <A GND>

MOCON

PCB P17

BLU

BLK
RED
GRN

WHT/BLU
WHT/BLK
WHT/RED
WHT/GRN

1

98

Electrical Service

96-0284 rev E June 2008

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

15.0 IN

BLK

13.0 IN

FEED HOLD
N/O SW 3

YEL

2.5 IN

FEED HOLD

BLK

CYCL STRT
N/O SW 4

RED

CYCL STRT
N/O SW 3

N/O SW 4

2.5 IN

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

FWD
I/O PCB P51

2

1

WHT
ORG

REV
I/O PCB P52

64

2 13
RED

BLK

SHLD

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

TP/22AWG

TP/22AWG

710 33-8154
FWD/REV
NSK 120V RLY

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

NSK RLY
K3-1

RED

NSK RLY
K3-5

BLK

NSK RLY
K2-5

ORG

NSK RLY
K2-1

WHT

BLK
YEL
BLK
RED

1

96-0284 rev E June 2008

Electrical Service

99