haas 96-0284E Service Manual

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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.
Only authorized personnel with the proper training and certication should do many repair procedures.
WARNING: Some mechanical and electrical service procedures can be
extremely dangerous or life-threatening. Know your skill level and abilities.
All information herein is provided as a courtesy for Haas machine owners for reference and illustrative purposes only. Haas Automation cannot be held responsible for repairs you perform. Only those services and repairs that are provided by authorized Haas Factory Outlet distributors are guaranteed.
Only an authorized Haas Factory Outlet distributor should service or repair a Haas machine that is protected by the original factory warranty. Servicing by
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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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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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• 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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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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LINE VOLTAGE ADJUSTMENTS
Please read this section in its entirety before attempting to adjust the line voltage.
Tools Required: Large at tip screwdriver, Digital voltmeter
NOTE: The machine must have air pressure at the air gauge, or a “Low Air Pressure” alarm
will be present on power up.
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.
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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 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
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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:
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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.
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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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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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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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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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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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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- 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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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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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
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
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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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 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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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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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- 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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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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120 TSC OVER TEMP THERMAL SENSOR (Vert) 121 THERMAL SENSOR SIGNAL 122 THERMAL SENSOR RETURN 123 SHIELD
140 230VAC 3PH POWER TO CHIP CONVEYOR MOTOR 141 PHASE A 230VAC 142 PHASE B 230VAC 143 PHASE C 230VAC 144 STARTING WINDING 230VAC 145 STARTING WINDING 230VAC 146 SHIELD DRAIN
140A 230VAC 3PH POWER IN CONDUIT TO CHIP CONVEYOR (Lathe) 141A PHASE A 230VAC 142B PHASE B 230VAC 143B PHASE C 230VAC
160 3PH 230VAC TO CHIP CONVEYOR CONTROLLER 161 PHASE A 230VAC 162 PHASE B 230VAC 163 PHASE C 230VAC 164 SHIELD DRAIN
170 AUTO OFF FUNCTION 171 UNSWITCHED LEG 1 172 SWITCHED LEG 2 173 SHIELD DRAIN
180 COOLANT SPIGOT DETENT SWITCH (Mill) SPARE (Lathe & Horiz) 181 SIGNAL 182 COMMON 183 SHIELD DRAIN
190 UNCLAMP FROM SPINDLE HEAD TO IOASM 191 INPUT 25 192 DIGITAL RETURN 193 SHIELD DRAIN
200 COOLANT SPIGOT MOTOR (12VDC) (Mill) SPARE (Lathe & Horiz) 201 MOTOR + 202 MOTOR -
210 DATA CABLE TO 3” FLOPPY DISK DRIVE
220 SERVO BRAKE 115VAC (Mill) 221 115VAC COMMON 222 115VAC SWITCHED 223 SHIELD DRAIN
230 5’th AXIS BRAKE (Vert & Horiz) TAILSTOCK FORWARD OPTION (Lathe) 231 115VAC COMMON 232 115VAC SWITCHED 233 SHIELD DRAIN
240 PALLETS UP & DOWN INPUTS (Vert & Horiz) BARFEEDER LOAD BAR-BARFEEDER LOAD Q (Lathe) 241 PALLETS UP (Vert & Horiz) END OF BAR (Lathe) 242 PALLETS DOWN (Vert & Horiz) LOADER OK (Lathe) 243 COMMON 244 SHIELD DRAIN
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250 VR SHUT IN / APC DOOR OPEN/ MD NIAGRA COOLANT ON (Vert option) HTC SHUTTLE/MORI MANUAL TOOL RELEASE (Horiz) TAILSTOCK REVERSE OPTION (Lathe) 251 LEG 1 (Mill) 115 VAC (Lathe) 252 LEG 2 (Mill) 115 VAC RETURN (Lathe) 253 SHIELD DRAIN
260 K210 CABLING FOR EC (Mill) SPARE (Lathe) 261 SWITCHED LED 262 UNSWITCHED LEG 263 SHIELD DRAIN
270 K111 CABLING FOR EC (Mill) TAILSTOCK RAPID OPTION (Lathe) 271 UNSWITCHED LEG 1 (Mill) 115 VAC (Lathe) 272 SWITCHED LEG 2 (Mill) 115 VAC RETURN (Lathe) 273 SHIELD DRAIN
280 RED/GREEN STATUS LIGHT WIRING 281 RED LAMP 115VAC 282 GREEN LAMP 115VAC 283 COMMON 115VAC 284 SHIELD DRAIN
290 115VAC TO XFORMER T2 10VAC OUTPUT (Horiz) CABLE OP LIGHT + SPINDLE MOTOR FAN (Lathe) 291 LEG 1 PRIMARY (Horiz) 115 VAC (Lathe) 292 LEG 2 PRIMARY (Horiz) 115 VAC RETURN (Lathe) 293 CENTER TAPPED (GROUND) (Horiz) SHIELD DRAIN (Lathe) 294 LEG 1 SECONDARY (Horiz) 295 LEG 2 SECONDARY (Horiz)
300 115VAC TO SPINDLE MOTOR FAN/OIL PUMP/OILER 301 LEG 1 115VAC PROTECTED 302 LEG 2 115VAC PROTECTED 303 SHIELD DRAIN
310 APC #2 DOOR OPEN (Vert) PC PALLET CW/CCW (Horiz) AUTO DOOR CLUTCH - PARTS CATCHER (Lathe)
330 230V 3PH FROM CB6 TO K2 (LATHE HYDRAULICS) 331 PHASE 1 230VAC 332 PHASE 2 230VAC 333 PHASE 3 230VAC
340 230V 3PH FROM K2 TO HYDRAULIC PUMP (LATHE) 341 PHASE 1 230VAC 342 PHASE 2 230VAC 343 PHASE 3 230VAC
350 SERVO BRAKE RELEASE 115VAC (Mill) 115VAC HYD PUMP ENABLE (Lathe) 351 LEG 1 COMMON (Mill) 115VAC (Lathe) 352 LEG 2 SWITCHED (Mill) 115VAC RETURN (Lathe) 353 SHIELD DRAIN
390 115VAC TO 4’TH AXIS BRAKE (LATHE PART DOOR) 391 LEG 1 COMMON 392 LEG 2 SWITCHED 393 SHIELD DRAIN
410 TOOL CHANGER DOOR/APC CE DOOR OPEN (Mill) TAILSTOCK FOOT SWITCH (Lathe) 411 SIGNAL (Lathe) 412 RETURN (Lathe) 413 SHIELD DRAIN
420 APC #2 PIN CLR #1 / APC #2 PIN CLR #2 / APC #2 PAL #2 HOME / APC #2 PAL #1 HOME (Vert) MORI ARM IN/OUT - SMTC ARM CW/CCW (Horiz)
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430 APC PALLET CLAMP MD PAL UP (Mill) APL LIGHT/BF EXTENDED PUSH (Lathe)
440 AUTO DOOR OPEN (Vert) SMTC CAGE DOOR OPEN - MORI ARM OUT (Horiz) DOOR OPEN (Lathe)
450 APC #2 CE DOOR OPEN (Vert) MORI ARM CW/CCW (Horiz) STEADY REST FOOT SWITCH (Lathe)
460 APC #2 DOOR CLOSED - APC #2 DOOR OPEN (Vert) MORI SLIDE 1/2 WAY - MORI SLIDE LEFT (Horiz) APL ROTOR MARK - APL ROTOR HOME (Lathe)
470 SMTC MOTOR STOP (Vert) SMTC SHUTTLE MARK (Horiz)
490 ALL BRUSHLESS AXIS SERVO MOTOR DRIVE POWER CABLE 491 A PHASE 492 B PHASE 493 C PHASE 494 GROUND
490A A AXIS MOTOR POWER (Vert) 320VDC FROM SPINDLE DRIVE TO AMPLIFIERS (Horiz & Lathe) 490B B AXIS MOTOR POWER (Vert) 320VDC FROM AMPLIFIER TO SERVO POWER SUPPLY (Horiz & Lathe) 490X X AXIS MOTOR POWER 490Y Y AXIS MOTOR POWER 490Z Z AXIS MOTOR POWER
491A HIGH VOLT P1/+ RED (Horiz & Lathe) 492A HIGH VOLT N/- BLACK (Horiz & Lathe) 493A SHIELD DRAIN 491B HIGH VOLT + RED (Horiz & Lathe) 492B HIGH VOLT - BLACK (Horiz & Lathe)
500 OVERTEMP SENSOR FROM SPINDLE MOTOR 501 OVERTEMP WIRE 1 502 OVERTEMP WIRE 2 503 SHIELD DRAIN
510 RELAY CARD 1 DRIVE CABLE - 16 WIRE RIBBON
520 RELAY CARD 2 DRIVE CABLE - 16 WIRE RIBBON
530 RELAY CARD 3 DRIVE CABLE - 16 WIRE RIBBON
540 RELAY CARD 4 DRIVE CABLE - 16 WIRE RIBBON
550 INPUTS CARD CABLE (MOCON P10) 34 WIRE RIBBON
570 LOW VOLTAGE BRUSHLESS AMPLIFIER POWER CABLE ASSEMBLY (Horiz & Lathe) 571 +12VDC #22 572 COMMON 573 - 12VDC #22
610 X AXIS HAAS AMPLIFIER CABLE TO MOTOR CONTROLLER BOARD 610-1 +A CHANNEL 610-2 ANALOG GROUND 610-3 +B CHANNEL 610-4 ANALOG GROUND 610-5 ENABLE 610-6 LOGIC GROUND 610-7 FAULT 610-8 LOGIC GROUND 610-9 NOT USED 610-10 SHIELD/ANALOG GROUND
620 Y AXIS HAAS AMPLIFIER CABLE TO MOTOR CONTROLLER BOARD (SAME AS 610-1 THRU 610-10) (Mill)
630 Z AXIS HAAS AMPLIFIER CABLE TO MOTOR CONTROLLER BOARD (SAME AS 610-1 THRU 610-10)
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640 A AXIS HAAS AMPLIFIER CABLE TO MOTOR CONTROLLER BOARD (SAME AS 610-1 THRU 610-10) (Lathe)
640A A AXIS HAAS AMPLIFIER CABLE TO MOTOR CONTROLLER BOARD (SAME AS 610-1 THRU 610-10) (Mill)
640B B AXIS HAAS AMPLIFIER CABLE TO MOTOR CONTROLLER BOARD (SAME AS 610-1 THRU 610-10) (Mill)
640C C AXIS HAAS VECTOR CURRENT COMMAND CABLE TO MOTOR CONTROLLER BD. (SAME AS 610-1 THRU 610-10) (Vert)
640C HAAS VECTOR DRIVE CURRENT COMMAND CABLE (Horiz & Lathe) 640C-1 A PHASE 640C-2 B PHASE 640C-3 ENABLE 640C-4 FAULT 640C-5 320VDC VOLTAGE MONITOR 640C-6 A PHASE RETURN 640C-7 B PHASE RETURN 640C-8 DIGITAL GROUND 640C-9 FAULT RETURN 640C-10 ANALOG GROUND
650 THREE PHASE POWER TO SPINDLE MOTOR 651 LEG 1 OF 230VAC 652 LEG 2 653 LEG 3 654 SHIELD DRAIN
650A THREE PHASE POWER TO SPINDLE MOTOR 651A LEG 1 OF 230VAC 652A LEG 2 653A LEG 3 654A SHIELD DRAIN
650B THREE PHASE POWER TO SPINDLE MOTOR 651B LEG 1 OF 230VAC 652B LEG 2 653B LEG 3 654B SHIELD DRAIN
660 X-AXIS ENCODER CABLE 660-1 LOGIC RETURN (D GROUND) 660-2 ENCODER A CHANNEL 660-3 ENCODER B CHANNEL 660-4 +5 VDC 660-5 ENCODER Z CHANNEL (OR C) 660-6 HOME/LIMIT SW 660-7 OVERHEAT SWITCH 660-8 ENCODER A* 660-9 ENCODER B* 660-10 ENCODER Z* (OR C*) 660-11 X HALL A (NOT USED) 660-12 X HALL B (NOT USED) 660-13 X HALL C (NOT USED) 660-14 X HALL D (NOT USED) 660-15 SHIELD DRAIN 660-16 (NOT USED)
670 Y-AXIS ENCODER CABLE (SAME AS 660-1 THRU 660-16) (Mill)
680 Z-AXIS ENCODER CABLE (SAME AS 660-1 THRU 660-16)
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690 A-AXIS ENCODER CABLE (SAME AS 660-1 THRU 660-16) (Vert & Lathe)
690A A-AXIS ENCODER CABLE (SAME AS 660-1 THRU 660-16) (Horiz)
690B B-AXIS ENCODER CABLE (SAME AS 660-1 THRU 660-16) (Mill)
690C C-AXIS ENCODER CABLE (SAME AS 660-1 THRU 660-16) (Mill)
700 KEYBOARD CABLE - 34 WIRE RIBBON WITH IDC (FROM VIDEO P4 TO KBIF P1)
710 APC #1 PALLET READY 1 / APC #1 PALLET READY 2 (Vert) P-COOL/BF COLLET OPEN - BF COLLET CLOSE (Horiz) APL GRIP 1,2 (Lathe 711 FORWARD COMMAND (Vert) 712 REVERSE COMMAND (Vert) 713 RESET COMMAND (Vert) 714 COMMON (Vert) 715 SHIELD DRAIN
720 ANALOG SIGNAL FROM MOCON TO SPINDLE DRIVE TO LOAD METER (BRUSH SYSTEMS) 721 0 TO +10 VOLTS SPEED COMMAND (SPINDLE DRIVE CN1-1) 722 SPEED COMMAND REFERENCE (A GROUND) (CN1-17) 723 SHIELD DRAIN
730 POWER METER FROM SPINDLE DRIVE TO KBIF (Vert) (BRUSH SYSTEMS) 731 METER + 732 METER ­733 SHIELD DRAIN
730A POWER METER FROM KBIF TO METER (Vert) (BRUSH SYSTEMS) 733 METER + AFTER TRIM POT 734 METER - AFTER TRIM POT 734 METER - AFTER TRIM POT
730B ANALOG SIGNAL FROM SPINDLE DRIVE LOAD MONITOR (Vert) (BRUSH SYSTEMS) 731 SIGNAL 0.5V 732 GROUND
740 POWER ON/OFF CABLE TO FRONT PANEL 741 POWER ON SWITCH LEG 1 (24 VAC) 742 POWER ON SWITCH LEG 2 #24 N.O. 743 POWER OFF SWITCH LEG 1 (24 VAC) 744 POWER OFF SWITCH LEG 2 #24 N.C. 745 SHIELD DRAIN
750 JOG-CRANK DATA CABLE (REM JOG SIDE CONNECTION) 750-1 LOGIC RETURN (D GROUND) 0VDC 750-2 ENCODER A CHANNEL 750-3 ENCODER B CHANNEL 750-4 +5 VDC 750-5 NC (Vert) JUMPER TO 750-1 (0 VDC) (Horiz & Lathe) 750-6 X-AXIS 750-7 Y-AXIS 750-8 N/C (Vert) ENCODER A* CHANNEL (Horiz & Lathe) 750-9 N/C (Vert) ENCODER B* CHANNEL (Horiz & Lathe) 750-10 N/C (Vert) JUMPER TO 750-4 (+5 VDC) (Horiz & Lathe) 750-11 Z-AXIS 750-12 A-AXIS 750-13 X 10 750-14 X 1 750-15 SHIELD DRAIN 750-16 N/C (Vert) NOT USED (Horiz & Lathe)
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750A JOG HANDLE DATA CABLE (Horiz & Lathe) 751A +5 VDC 752A 0 VDC 753A ENCODER A CHANNEL 754A ENCODER B CHANNEL 755A SHIELD DRAIN
750B JOG HANDLE DATA CABLE (Horiz) 750B-1 +5 VDC JOG HANDLE 750B-2 0VDC 750B-3 JOG HANDLE A CHANNEL 750B-4 JOG HANDLE A* CHANNEL 750B-5 JOG HANDLE B CHANNEL 750B-6 JOG HANDLE B* CHANNEL
760 MONITOR VIDEO DATA CABLE (FROM VIDEO P3 TO CRT)
770 EMERGENCY STOP INPUT CABLE 771 SIGNAL (INPUT 8) 772 RETURN (D GROUND) (65) 773 SHIELD DRAIN
770A SECOND E-STOP INPUT / COUNTERBALANCE (Horiz) / BARFEEDER OPTION (Lathe) 771A SIGNAL 772A RETURN (D GROUND) 773A SHIELD DRAIN
770B THIRD E-STOP INPUT FOR APC (REMOTE CONTROL PANEL) (Vert)
790 APC PIN CLR #1 / MD OP DOOR OPEN - APC PIN CLR #2 / MD OP DOOR CLOSED (Vert) PALLET CHANGER CW/CCW (Horiz) SPARE INPUTS PROBE HOME OPTION (Lathe) 791 SPARE 1 (Vert & Lathe) PALLET CW (Horiz) 792 SPARE 2 (Vert & Lathe) PALLET CCW (Horiz) 793 COMMON 794 SHIELD DRAIN
800 10VAC TO PALLET READY LAMP (Horiz) 801 UNSWITCHED LEG 1 802 SWITCHED LEG 2 803 SHIELD DRAIN
800A LAMP SWITCH JUMPER (Horiz) 801A JUMPER TO 802A 802A JUMPER TO 801A
810 TOOL CHANGER MOTORS 811 TURRET MOTOR + (IO P30-2 TO P6-J) 812 TURRET MOTOR - (IO P30-1 TO P6-I) 813 SHIELD DRAIN
810A TOOL CHANGER MOTORS 811A SHUTTLE MOTOR + 812A SHUTTLE MOTOR ­813A SHIELD DRAIN
820 TOOL CHANGER STATUS 821 LOGIC RETURN (Vert) TOOL CHANGER IN (Horiz) TURRET UNCLAMPED (Lathe) 822 GENEVA MARK (INPUT 5 TO P6-G) (Vert) TOOL CHANGER OUT (Horiz) TURRET CLAMPED (Lathe) 823 TOOL #1 (INPUT 3 TO P6-E) (Vert) MAIN DRAWBAR UP (Horiz) UNUSED (Lathe) 824 SHUTTLE IN (INPUT 1 TO P6-C) (Vert) MAIN DRAWBAR DOWN (Horiz) PART LOAD (Lathe) 825 SHUTTLE OUT (INPUT 2 TO P6-D) (Vert) COMMON (Horiz & Lathe) 826 SHIELD DRAIN
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830 OVERHEAT THERMOSTAT 831 OVERHEAT SIGNAL (INPUT 14) 832 OVERHEAT RETURN (D GROUND) (65) 833 SHIELD DRAIN
840 CIRCUIT BREAKER FOR 160 VDC (Vert) 841 LEG 1 (TO 81) 842 LEG 2 843 SHIELD DRAIN
850 SERIAL PORT #1 TO SERIAL KEYBOARD INTERFACE CABLE
850A SERIAL PORT #2 INTERFACE CABLE - AUXILIARY PORT TO ROTARY CONTROLLER
860 +12V/+5V/Gnd POWER CABLES (Vert) +5V/+12V/-12V/Gnd FROM MAIN POWER SUPPLY (Horiz & Lathe) 861 +12 VOLTS (Vert) +5 VOLTS (Horiz & Lathe) 862 -12 VOLTS FROM LOW V SUPPLY TO 68020 PCB (Vert) LOGIC POWER RETURN (Horiz & Lathe) 863 +5 VOLTS (Vert) LOGIC POWER RETURN (Horiz & Lathe) 864 -5 VOLTS (Vert) +12 VOLTS (Horiz & Lathe) 865 LOGIC POWER RETURN (D GROUND) (Vert) -12 VOLTS (Horiz & Lathe) 866 POWER GOOD SIGNAL FROM SUPPLY (Vert)
860A 12 VOLT POWER TO IOPCB (Vert & Lathe) 12 VDC POWER TO M CODE RELAY BOARD (Horiz) 861A +12 VOLTS 862A LOGIC POWER RETURN (D GROUND) 863A SHIELD DRAIN
860B +5 POWER TO 3” FLOPPY DRIVE (Vert & Lathe)
860C +5,+12,-12 POWER TO 68030 (Vert & Lathe) 12 VDC POWER TO MONITOR FAN (Horiz) 861A +12 VOLTS 862A LOGIC POWER RETURN (D GROUND) 863A SHIELD DRAIN
870 115VAC TO OILER (Vert & Lathe) 871 115VAC LEG 1 872 115VAC LEG 2 873 SHIELD DRAIN
880A HIGH/LOW GEAR UNCLAMP/LOCK SOLENOID POWER (Vert) 115 VAC TO SPINDLE HEAD SOLENOIDS (Horiz & Lathe) 881A 115 VAC SOLENOID COMMON (IO P12-5) (Vert) WYE-DELTA SWITCH COMMAND (Horiz) SPINDLE LOCK (Lathe 882A HIGH GEAR SOLENOID (IO P12-4) (Vert) TOOL UNCLAMP (Horiz & Lathe) 883A LOW GEAR SOLENOID (IO P12-3) 884A TOOL UNCLAMP SOLENOID (IO P12-2) (Vert) HIGH GEAR (Horiz & Lathe) 885A SPINDLE LOCK SOLENOID (IO P12-1) (Vert) 115 VAC COMMON (Horiz & Lathe) 886A PRE-CHARGE SOLENOID #18 (IO P12-7) (Vert) SHIELD DRAIN (Horiz & Lathe) 887A SHIELD DRAIN (Vert) PRECHARGE (Horiz & Lathe)
880B TRANSMISSION HIGH/LOW GEAR SOLENOIDS FOR LATHE (Vert & Lathe) 881B 115 VAC SOLENOID COMMON (IO P12-5) 882B HIGH GEAR SOLENOID (IO P12-4) 883B LOW GEAR SOLENOID (IO P12-3) 884B SHIELD DRAIN
890 SPINDLE STATUS SWITCHES 891 SIGNAL RETURN (D GROUND) (Vert) HIGH GEAR (Horiz & Lathe) 892 HIGH GEAR (Vert) LOW GEAR (Horiz & Lathe) 893 LOW GEAR (Vert) TOOL UNCLAMPED (Horiz & Lathe) 894 TOOL UNCLAMPED (Vert) TOOL CLAMPED (Horiz & Lathe) 895 TOOL CLAMPED (Vert) SPARE (Horiz) SPINDLE LOCKED (Lathe) 896 SPINDLE LOCKED (Vert) COMMON (Horiz & Lathe) 897 SHIELD DRAIN
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900 LOW COOLANT STATUS (Mill) SPARE (Lathe) 901 LOW COOLANT SIGNAL 902 LOW COOLANT RETURN (D GROUND) 903 SHIELD DRAIN
910 115 VAC CIRCUIT BREAKER TO SOLENOIDS 911 LEG 1 912 LEG 2 913 SHIELD DRAIN
910A 115VAC FROM CB4 ON MAIN POWER DIST. (Mill) SPARE 115 VAC (Lathe) 910B 115VAC TO SERVO FAN 910C 115VAC TO DELTA/WYE COIL (Vert & Lathe) 115VAC TO PURGE SOLENOID (Horiz) 910D 115VAC TO WORK LIGHT (Vert) 115 VAC TO PALLET ALARM (Horiz) 115 VAC TO PART CATCHER (Lathe)
920 REGENERATIVE LOAD RESISTOR FOR SERVO (Vert) 921 LEG 1 922 LEG 2 923 SHIELD DRAIN
930 FUSED 230 VAC FOR COOLANT PUMP 931 LEG 1 932 LEG 2 933 SHIELD DRAIN
940 230 VAC TO COOLANT PUMP 941 LEG 1 (P7-A) 942 LEG 2 (P7-F) 943 SHIELD DRAIN
940A 230 VAC SINGLE PHASE POWER TO THROUGH SPINDLE COOLANT PUMP (Horiz) 941A LEG 1 942A LEG 2 943A SHIELD DRAIN
950 LOW AIR PRESSURE/OIL LUBE SENSOR 951 LOW AIR SIGNAL (INPUT 12) 952 LOW AIR/OIL RETURN (D GROUND) (65) (Vert) LOW OIL LUBE SIGNAL (Horiz & Lathe) 953 LOW OIL PRESSURE SWITCH FOR VERTICAL TRANSMISSION (Vert) COMMON (Horiz & Lathe) 954 SHIELD DRAIN
950A LOW HYDRAULIC PRESSURE SWITCH FOR LATHE 952 LOW HYDRAULIC RETURN (D GROUND) 953 LOW HYD PRESSURE SWITCH FOR VERTICAL TRANSMISSION 954 SHIELD DRAIN
960 LOW LUB/DOOR OPEN SENSORS (Vert) LOW TRANSMISSION OIL LUBE (Horiz) LOW HYD PRESSURE (Lathe) 961 LOW LUB SIGNAL (Vert) LOW TRANSMISSION OIL LUBE SIGNAL (Horiz) LOW HYD PRESSURE (Lathe) 962 LOW LUB RETURN (D GROUND) (65) 963 SHIELD DRAIN
970 LOW VOLTAGE SENSOR (Vert) VECTOR DRIVE OVER-VOLT SENSOR (Horiz & Lathe) 971 LOW VOL SIGNAL (Vert) OVERVOLTAGE SIGNAL (Horiz & Lathe) 972 LOW VOL RETURN (D GROUND) (Vert) OVERVOLTAGE RETURN (Horiz & Lathe) 973 SHIELD DRAIN
980 VOLTAGE MONITOR 981 VOLTAGE MONITOR 0 TO 982 VOLTAGE MON RET 983 SHIELD DRAIN
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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
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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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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
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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
Coldre Coldfi re 2 (CF2)
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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
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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 ——-
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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 ——-
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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)
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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
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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
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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
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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
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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
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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
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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
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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
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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)
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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
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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
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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
Page 65
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.
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Page 66
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
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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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Page 68
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
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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
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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
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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)
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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
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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
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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
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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
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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
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Electrical Service
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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
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Page 78
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
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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
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Page 80
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
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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
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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
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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
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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
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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
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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
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Electrical Service
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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
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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
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Electrical Service
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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
Page 90
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
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Page 91
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
Page 92
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
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Page 93
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
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Electrical Service
96-0284 rev E June 2008
Page 94
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
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Page 95
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
Page 96
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
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Page 97
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
Page 98
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
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Page 99
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
Page 100
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
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