haas SL- 96-8710 Service Manual
Haas Technical Publications
Manual_Archive_Cover_Page Rev A
any other party automatically voids the factory warranty.
June 6, 2013
HAAS SERVICE AND OPERATOR MANUAL ARCHIVE
SL-Series Service Manual 96-8710 RevC English June 2001
• This content is for illustrative purposes.
• Historic machine Service Manuals are posted here to provide information for Haas machine owners.
• Publications are intended for use only with machines built at the time of original publication.
• As machine designs change the content of these publications can become obsolete.
• You should not do mechanical or electrical machine repairs or service procedures unless you are qualied
and knowledgeable about the processes.
• Only authorized personnel with the proper training and certication should do many repair procedures.
WARNING: Some mechanical and electrical service procedures can be
extremely dangerous or life-threatening.
Know your skill level and abilities.
All information herein is provided as a courtesy for Haas machine owners
for reference and illustrative purposes only. Haas Automation cannot be held
responsible for repairs you perform. Only those services and repairs that are
provided by authorized Haas Factory Outlet distributors are guaranteed.
Only an authorized Haas Factory Outlet distributor should service or repair a
Haas machine that is protected by the original factory warranty. Servicing by
June 2001
TROUBLESHOOTING
COMMON ABBREVIATIONS USED IN HAAS MACHINES
AC Alternating Current
AMP Ampere
APC Automatic Pallet Changer
APL Automatic Parts Loader
ASCII American Standard Code for Information Interchange
ATC Automatic Tool Changer
ATC FWD Automatic Tool Change Forward
ATC REV Automatic Tool Changer Reverse
AWG American Wire Gauge
BHCS Button Head Cap Screw
CAD Computer Assisted Design
CAM Computer Assisted Machining
CB Circuit Breaker
CC Cubic Centimeter
CCW Counter Clockwise
CFM Cubic Feet per Minute
CNC Computerized Numeric Control
CNCR SPINDLE Concurrent Spindle with axis motion
CRC Cyclic Redundancy Check Digit
CRT Cathode Ray Tube
CW Clockwise
DB Draw Bar
DC Direct Current
DGNOS Diagnostic
DIR Directory
DNC Direct Numerical Control
DOS Disk Operating System
ENA CNVR Enable Conveyor
EOB End Of Block
EOF End Of File
EPROM Erasable Programmable Read Only Memory
E-Stop Emergency Stop
FHCS Flat Head Cap Screw
FT Foot
FU Fuse
FWD Forward
GA Gauge
HHB Hex Head Bolts
HP Horse Power
HS Horizontal Series Of Machining Centers
ID Inside Diameter
IGBT Isolated Gate Bipolar Transistor
IN Inch
IOPCB Input Output Printed Circuit Board
LAN Local Area Network
LB Pound
LED Light Emitting Diode
LO CLNT Low Coolant
LOW AIR PR Low Air Pressure
LVPS Low Voltage Power Supply
MB Megabyte (1 million)
MCD RLY BRD M-Code Relay Board
MDI Manual Data Input
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MEM Memory
M-FIN M-Code Finished
MM Millimeter
MOCON Motor Control
MOTIF Motor Interface
MSG Message
MSHCP Metric Socket Head Cap Screw
NC Numerical Control
NC Normally Closed
NO Normally Open
OD Outside Diameter
OPER Operator
P Pocket
PARAM Parameter
PCB PrintedCircuit Board
PGM Program
POR Power On Reset
POSIT Positions
PROG Program
PSI Pounds Per Square Inch
PWM Pulse Width Modulation
RAM Random Access Memory
REPT RIG TAP Repeat Rigid Tap
RET Return
REV CNVR Reverse Conveyor
RJH Remote Jog Handle
RPDBDN Rotary Pallet Draw Bar Down
RPDBUP Rotary Pallet Draw Bar Up
RPM Revolutions Per Minute
S Spindle Speed
SDIST Servo Distribution PCB
SFM Surface Feet Per Minute
SHCS Socket Head Cap Screw
SIO Serial Input/Output
SKBIF Serial Key Board Inter Face PCB
SMTC Side Mount Tool Changer
SP Spindle
T Tool Number
TC Tool Changer
TIR Total Indicated Runout
TNC Tool Nose Compensation
TRP Tool Release Piston
TS Tail Stock
TSC Through The Spindle Coolant
VF Vertical Mill (very first)
VF-E Vertical Mill- Extended
VMC Vertical Machining Center
WAN Wide Area Network
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1. TROUBLESHOOTING
This section is intended for use in determining the solution to a known problem. Solutions given are intended to
give the individual servicing the CNC a pattern to follow in, first, determining the problems source and second,
solving the problem.
The troubleshooting tips are organized in this section according to the area of the CNC that may be giving sign
of a problem. (Ex.: Out-of round circles in drilling will be found under the heading General Machine Operation Accuracy).
If the problem you are experiencing cannot be found under the heading you expect, please try several other
possible headings. If the problem is still not found, contact Haas Automation for further details.
BEFORE YOU BEGIN:
USE COMMON SENSE
Many problems are easily overcome by correctly evaluating the situation. All machine operations are composed
of a program, tools, and tooling. You must look at all three before blaming one as the fault area. If a bored hole
is chattering because of an overextended boring bar, dont expect the machine to correct the fault. Dont
suspect machine accuracy if the vise bends the part. Dont claim hole mis-positioning if you dont first centerdrill the hole.
FIND THE PROBLEM FIRST
Many mechanics tear into things before they understand the problem, hoping that it will appear as they go. We
know this from the fact that more than half of all warranty returned parts are in good working order. If the
spindle doesnt turn, remember that the spindle is connected to the gear box, which is connected to the
spindle motor, which is driven by the spindle drive, which is connected to the I/O BOARD, which is driven by
the MOCON, which is driven by the processor. The moral here is dont replace the spindle drive if the belt is
broken. Find the problem first; dont just replace the easiest part to get to.
DONT TINKER WITH THE MACHINE
There are hundreds of parameters, wires, switches, etc., that you can change in this machine. Dont start
randomly changing parts and parameters. Remember, there is a good chance that if you change something,
you will incorrectly install it or break something else in the process. Consider for a moment changing the
processors board. First, you have to download all parameters, remove a dozen connectors, replace the board,
reconnect and reload, and if you make one mistake or bend one tiny pin it WONT WORK. You always need to
consider the risk of accidentally damaging the machine anytime you work on it. It is cheap insurance to
double-check a suspect part before physically changing it. The less work you do on the machine the better.
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1.1 GENERAL MACHINE OPERATION
MACHINE NOT RUNNING
Machine cannot be powered on.
Check input voltage to machine (see "Electrical Service").
Check main circuit breaker at top right of electrical cabinet; switch must be at the on position.
Check overvoltage fuses (see "Electrical Service").
Check wiring to POWER OFF button on front control panel.
Check wiring to AUTO OFF relay to IOPCB.
Check connection between 24V transformer and K1 contactor
Check IOPCB (see "Electrical Service").
Check POWER PCB (see "Electrical Service").
Machine can be powered on, but turns off by itself.
June 2001
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 wiring to POWER OFF button on front control panel.
Check connection between 24V transformer and K1 contactor.
Check IOPCB (see "Electrical Service").
Check Parameter 57 for Power Off at E-STOP.
Check MOTIF or MOCON PCB (see "Electrical Service").
Machine turns on, keyboard beeps, but no CRT display.
Check for power connections to CRT from IOPCB. Check for green POWER LED at front of CRT.
Close doors and Zero Return machine (possible bad monitor).
Check video cable (760) from VIDEO PCB to CRT.
Check for lights on the processor.
Machine turns on, CRT works, but no keyboard keys work.
Check keyboard cable (700B) from VIDEO to KBIF PCB.
Check keypad (see "Electrical Service").
Check KBIF PCB (see "Electrical Service").
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VIBRATION
Vibration is a subjective evaluation with perceptions varying among individuals, making it difficult to determine in
mild cases if there is an actual problem. In obvious cases, it is a matter of determining the source - which is
not easy, since all parts rotate together and sound can be transferred readily. Vibrations also need to be
distinguished from noise such as a bad bearing. We will assume that vibrations would be something that could
be felt by putting your hand on the spindle ring. One crude method of measurement would be to take an
indicator on a magnetic base extended 10 inches between the turret and spindle housing and observe the
reading of the indicator. A reading of more than .001 would indicate excessive vibration. The two common
sources of noise are the spindle and axis drives. Most complaints about vibration, accuracy, and finish can be
attributed to incorrect machining practices such as poor quality or damaged tooling, incorrect speeds or feeds,
or poor fixturing. Before concluding that the machine is not working properly, ensure that good machining
practices are being observed. These symptoms will not occur individually (Ex. A machine with backlash may
vibrate heavily, yielding a bad finish). Put all of the symptoms together to arrive at an accurate picture of the
problem.
Machine vibrates while spindle is on and is not cutting. Sometimes only at specific RPM.
If the spindle alone causes vibration of the machine this is usually caused by the belt/pulley drive system
or the chuck jaws are not centered correctly.
Machine vibrates while jogging the axis with the jog handle.
The HAAS control uses very high gain accelerations curves. This vibration as you jog is simply the
servos quickly trying to follow the handle divisions. If this is a problem, try using a smaller division on
the handle. You will notice the vibration more at individual clicks than when you are turning the handle
faster. This is normal.
The machine vibrates excessively in a cut.
This is a tough one to call because machining practices come into play. Generally speaking, the least
rigid element of a cut is the tool because it is the smallest part. Any cutter will vibrate if pushed beyond
its tensile strength. In order to eliminate the machine as the source of the problem, you need to check
the spindle and the backlash of the axes as described in the following sections. Once machining
practices have been eliminated as the source of vibration, observe the machine in both operation and
cutting air. Move the axes (individually) without the spindle turning and then turn the spindle without
moving the axes. Isolate whether the vibration comes from the spindle head or from an axis.
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ACCURACY
Before you complain of an accuracy problem, please make sure you follow these simple dos and donts:
Ensure that the machine has been sufficiently warmed up before cutting parts. This will eliminate
mispositioning errors caused by thermal growth of the leadscrews (see "Thermal Growth" section).
Dont ever use a wiggler test indicator for linear dimensions. They measure in an arc and have sine/cosine
errors over larger distances.
Dont use magnetic bases as accurate test stops. The high accel/decel of the axis can cause them to
move.
Dont attach test points to the sheet metal of the spindle head.
Dont check for accuracy/repeatability using an indicator with a long extension.
Ensure that test indicators and stops are absolutely rigid and mounted to machined casting surfaces
Check a suspected error with another indicator or method for verification.
Ensure that the indicator is parallel to the axis being checked to avoid tangential reading errors.
Center drill holes before using jobber length drills if accuracy is questioned.
Once machining practices have been eliminated as the source of the problem, determine specifically what
the machine is doing wrong.
June 2001
Diameters are out of round
Check that tooling and machining practices are correct. Bores will be out of round due to tool deflection
much more frequently than due to spindle bearing problems.
Drill
Diameters are incorrect in X-axis
Ensure the tool probe is set up correctly (settings, etc.)
Ensure tool offsets are coorect. Note that the coordinate system (FANUC, YASNAC, HAAS) must be
selected before setting tools.
Ensure Parameter 254, Spindle Center, is set correctly.
Check for thermal growth of the X-axis leadscrew (see Thermal Growth section).
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Center holes are malformed
Ensure tooling is tight.
Ensure Parameter 254, Spindle Center, is set correctly.
Check spindle to turret pocket alignment. It may be out of alignment due to a crash or misadjustment.
Check for thermal growth of the X-axis leadscrew (see Thermal Growth section).
Part faces are conical
Wedge may be out of alignment due to a crash.
Check tooling setup. Turning long, unsupported parts may cause conical part faces.
Check for thermal growth of the leadscrews (see Thermal Growth section).
C
L
Part/Tooling Problem Geometry Problem
C
L
C
L
Bores are tapered
Check that tooling and machining practices are correct. Bores will be tapered if the tooling is inappropriate,
the speeds and feeds are incorrect, or coolant is not getting to the cutting tool when required.
Although it is rare, the spindle may be out of alignment due to a crash
Check that the turret face is parallel with x-axis.
C
L
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Outside diameter (O.D.) is tapered
Check tooling setup. Turning long, unsupported parts can cause a tapered O.D.
Check tailstock setup. Excessive hold pressure on the tailstock can distort parts.
Spindle to Z-axis may be out of alignment (not parallel).
Program around it. Reduce depth of final rough cut and finish pass to reduce part deflection.
June 2001
C
L
Poor Geometry
C
L
Material left after facing a part
Ensure tooling is correct.
Ensure turret is aligned to X-axis travel.
Ensure Parameter 254, Spindle Center, is set correctly.
C
L
C
L
Poor Technique
C
L
Material Left After Facing Part
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FINISH
Machining yields a poor finish
Check the condition of the tooling and the spindle.
Ensure turret is clamped.
Ensure tooling is tight.
Check tooling for chatter or lack of rigidity.
Check the balance of the chuck, part, and fixture.
Check for backlash.
Check turret alignment.
THERMAL GROWTH
A possible source of accuracy and positioning errors is thermal growth of the leadscrews. As the machine
warms up, the leadscrews expand in both linear axes (X and Z), causing accuracy and positioning errors. This
is especially critical in jobs that require high accuracy.
NOTE: Thermal growth will be more noticeable in the X-axis, since errors will be
doubled when cutting a diameter.
Verify Thermal Growth
There are a number of ways to verify the problem. The following procedure will verify thermal growth of the Xaxis reversed-anchored leadscrew in a machine that has not been warmed up:
1. Home the machine. In MDI mode, press POSIT and PAGE DOWN to the OPER page.
2. Jog to an offset location. Select the X-axis and press the ORIGIN key to zero it.
3. Press the OFSET key, then scroll down to G110 (or any unused offset). Cursor to X and press the
PART ZERO SET key. This will set X) at this position.
4. Enter a program that will start at the new zero position, rapid a certain distance in the X direction,
feed the final .25 inches slowly, and then repeat the X movement.
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5. In order to set up the indicator, run the program in SINGLE BLOCK mode, and stop it when X is at
the end of its set travel. Set the magnetic base on the spindle retainer ring or other rigid surface,
with the indicator tip touching the turret in the X-axis, and zero it.
6. Exit SINGLE BLOCK mode, and run the program for a few minutes. Enter SINGLE BLOCK mode
again, stop the program when X is at the beginning of its travel, and take a final reading on the
indicator. If the problem is thermal growth, the indicator will show a difference in the X position.
June 2001
NOTE: Ensure the indicator setup is correct as described in Accuracy section. Error
in setup are common, and often incorrectly appear to be thermal growth.
7. A similar program can be written to test for thermal growth in the Z-axis.
Solutions
Since there are many variables that affect thermal growth, such as the ambient temperature of the shop and
program feed rates, it is difficult to give one solution for all problems.
Thermal growth problems can generally be eliminated by running a warm-up program for approximately 20
minutes before machining parts. The most effective warm-up is to run the current program, at an offset Z
position before the part. This will allow the leadscrews to warm up to the correct temperature and stabilize.
Once the machine is at temperature, the leadscrews won't expand any further, unless they are allowed to cool
down. A warm-up program should be run after each time the machine is left idle.
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1.2 SPINDLE
NOT TURNING
Spindle not turning
If there are any alarms, see Alarms section.
Check that the spindle turns freely when machine is off.
If spindle is still not turning, replace MOCON PCB.
Disconnect the drive belt. If the spindle will not turn, it is seized and must be replaced.
For Brush machines only:
If spindle drive does not light the RUN LED, check forward/reverse commands from IOPCB.
Check that the drawtube piston is not bound against the spindle shaft on the air cylinder style.
Check the wiring of analog speed command from MOTIF PCB to spindle drive (cable 720).
Disconnect the drive belt. If the spindle will not turn, it is seized and must be replaced.
NOTE: Before using the replacement spindle, the cause of the previous failure must
NOISE
Most noise attributed to the spindle actually lie in the motor or drive belt of the machine. Isolate the sources of
noise as follows:
Excessive noise coming from the spindle head area.
be determined.
Remove the left end covers and check the machines drive belt tension.
Run the motor with the drive belt disconnected. If the noise persists, the problem lies with the motor. If it
disappears, go on to the next step.
Check for the correct amount of lubrication to the spindle bearings (1cc per hour) in an air mist lubricated
spindle.
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VECTOR DRIVE
To properly troubleshoot the Vector Drive, use the following questions as a guide:
What alarms are generated?
When does the alarm occur?
Is the Vector Drive top fault light on?
Is there a fault light on any of the servo amplifiers?
Does the alarm reset?
Does the spindle motor turn at all?
Does the spindle turn freely by hand?
Have the C-axis parameters been confirmed?
What is the input voltage to the vector drive unit?
What does the DC Bus voltage measure? (320 VDC to 345 VDC)
Does the DC Bus voltage displayed on the diagnostic page match the measured DC Bus voltage?
All of the questions above must be answered. The DC Bus voltage should be between 320 VDC to 345 VDC
with the machine powered up but not running. If the voltage is not in this range, adjust the taps on the main
line transformer until this voltage range is achieved. There is a possibility the drive is faulty, but low Bus
voltage can also be caused by a shorted REGEN load or a shorted amplifier.
June 2001
If the DC Bus voltage is below 50 VDC and never goes any higher, perform Steps 1-6.
1. With the machine powered up, is the green POWER-ON L.E.D. lit? If not, replace the Vector
Drive unit.
2. Power down the machine. Disconnect the REGEN load (terminals 1 and 2 on the Vector Drive
unit) and measure the resistance from each wire-to-chassis ground (open) and between the wire
leads. The resistance should be 8.6 ohms for machines with 20/15 Vector drives and HT10K mills
equipped with 40/30 drives. All other machines with 40/30 drives should measure 6 ohms. If not,
replace the REGEN load or cabling.
3. Disconnect cable 490 at terminals 2 and 3 of the Vector Drive and from the servo amplifiers. With
a multimeter in the diode mode, place the red meter lead to the +HV terminal and the black meter
lead to the -HV terminal of each amplifier. The meter should read open.
4. Reverse the leads: Place the red meter lead on the -HV terminal and the black lead on the +HV
terminal. The meter should read .7 ohms in both instances. If not, replace the faulty amplifier.
5. Measure the resistance between terminals 1 and 3 of the Vector Drive. The meter should read
greater than 100K ohms. If not, the Vector Drive is faulty.
6. If the green POWER-ON L.E.D. was lit (from Step 2), leave both 490 cables (2 and 3) disconnected from the drive and power up the machine.
a. Does the DC Bus voltage come up? If not, the Vector Drive is faulty.
b. Measure the voltage between terminals 1 and 3. The voltage should be 300
VDC or more. If not, the Vector Drive is faulty.
If both a and b check out okay, there is a problem with either the amplifiers or the REGEN load.
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TROUBLESHOOTING
If the fault occurs upon acceleration -or- the spindle accelerates slowly -or- the spindle
makes noise, do the following:
7. Disconnect the output cables to the spindle motor. Turn on the machine and press <RESET>. Do
not command the spindle to turn. With a volt meter, measure the DC voltage between each output
phase (terminals 9, 10, and 11) to the 320V RTN (terminal 3). The meter should read 165 VDC in
each case, else one phase is faulty.
8. Measure the resistance across the motor wires from phase to phase and from each phase to
chassis. The meter should read .1 ohms phase-to-phase and open phase-to-chassis.
If the fault occurs upon deceleration or acceleration just as the spindle reaches its specified speed, or if an overvoltage alarm (119) occurred, do the following:
9. Disconnect the REGEN load resistors (terminals 1 and 2) and measure the resistance from each
wire lead-to-chassis ground and between the wire leads. The meter should read open lead-toground, and 6 ohms between the leads for machines with 40/30 Vector drives and 8.6 ohms
between the leads on machines with 20/15 Vector drives and HT10K mills.
10. Measure the resistance from terminal 1 to terminal 3. If the resistance is less than 100K, the drive
is faulty.
11. With the REGEN load left disconnected, power-up the machine and command a spindle speed of
700 RPM (300 RPM for lathes in high gear). Press <RESET> while monitoring the DC voltage
between terminal 1 and terminal 3. The voltage should read 330 VDC and then drop to less than
50 VDC momentarily. If not, that drive is faulty. If the voltage at RESET was okay and the alarm
was resettable, the REGEN load should be replaced even if the resistance appears to be
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TROUBLESHOOTING
1.3 TRANSMISSION (SL 30 AND 40)
The transmission cannot be serviced in the field and must be replaced as a unit. Never remove the motor from
the transmission, as this will damage the transmission and void the warranty.
NOISE
Excessive or unusual noise coming from transmission.
Operate the machine in both high and low gears. Monitor for noise in both gear positions, and determine if the
noise varies with the motor or output shaft speed.
If the noise only occurs in one gear throughout the entire RPM range of that gear position, the problem lies
with the transmission, and it must be replaced.
If the noise occurs in both gear positions, disconnect the drive belts (see Transmission section, Mechani-
cal Service) and repeat the previous step. If the noise persists, the transmission is damaged and must be
replaced.
Disconnect the drive belts (see Transmission section, Mechanical Service) and run the machine in high
gear. Command a change of direction and listen for a banging noise in the transmission as the machine
slows down to zero RPM and speeds back up in reverse. If the noise occurs, the motor has failed and the
transmission must be replaced.
June 2001
GEARS WILL NOT CHANGE
Machine will not execute a gear change.
Check the voltage to the gear shifter motor. The voltage between pins 2 and 3 should be approximately
+28V when high gear is commanded and -28V when low gear is commanded. If these voltages are correct,
the gear shifter motor has failed and the transmission must be replaced. If these voltages are incorrect, the
cabling or transmission power supply is at fault.
INCORRECT GEAR SELECTED OR SENSED
Spindle speed is not consistent with selected gear.
Monitor the discrete inputs and outputs SP HIG and SP LOW on the diagnostics display while command-
ing high and low gear. The output SP HIG should be 1 when high gear is selected, and SP LOW should be
1 when low gear is selected. The inputs SP HIG and SP LOW should be 0 when that gear is engaged, and
should both be 1 when the transmission is between gears. These inputs should never read 0 at the same
time.
If any of these inputs/outputs are incorrect, either the gear change limit switches or the wiring to the I/O PCB is
at fault. The limit switches are located inside the transmission, and cannot be replaced.
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TROUBLESHOOTING
1.4 SERVO MOTORS / LEADSCREWS
NOT OPERATIN G
All problems that are caused by servo motor failures should also register an alarm. Check the alarm history to
determine the cause of the problem before any action is taken.
Servo motor is not functioning.
Check the power cable from rear electrical cabinet to ensure connection is tight.
Encoder is faulty or contaminated (Alarms 139-142, 153-156, 165-168, 182-185). Replace motor
assembly on brushless machines
Open circuit in motor (Alarms 139-142, 153-156, 182-185). Replace motor assembly ("Axis Motor
Removal / Installation").
Motor has overheated, resulting in damage to the interior components (Alarms 135-138, 176).
Replace motor assembly ("Axis Motor Removal/Installation").
Wiring is broken, shorted, or missing shield (Alarms 153-156, 175, 182-185).
Motor has overheated; no damage to the interior components. OVERHEAT alarm has been
triggered. After thorough check of motor (DO NOT DISASSEMBLE!), take necessary steps to
eliminate the problem and alarm to resume operation. If motor is still inoperable, replace motor
assembly ("Axis Motor Removal/Installation").
Check for broken or loose coupling between the servo motor and the lead screw. Replace or repair
the coupling ("Axis Motor Removal/Installation")
Check for a damaged lead screw, and replace if necessary ("Lead Screw Removal and Installation"
section).
NOTE: If a lead screw fails, it is most often due to a failed bearing sleeve. When
NOISE
Lead screw noise is usually caused by a lack of lubrication and is usually accompanied by heating. Other
causes are misalignment, bearing sleeve damage, or ball nut damage. Check the alarm history of the machine
and look for axis overcurrent and following error alarms.
NOTE: Do not replace lead screws or bearing sleeves without due consideration; they
replacing the lead screw in an older machine, always replace the bearing
sleeve with the current angular contact bearing sleeve ("Bearing Sleeve
Removal and Installation" section).
are extremely durable and reliable. Verify that customer complaints are not due
to tooling, programming, or fixturing problems.
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TROUBLESHOOTING
Servo motor noise.
Disconnect the servo motor from the lead screw and rotate by hand. If the noise persists, replace
the motor assembly ("Axis Motor Removal/Installation" section).
If motor noise is caused by motor bearings, replace motor.
Lead screw noise.
Ensure oil is getting to the lead screw through the lubrication system. Look for a plugged metering
valve.
Check for damage to the bearing sleeve.
June 2001
NOTE: The current angular contact design sleeve has a fixed pre-load; it cannot be
adjusted.
Run the axis back and forth. The motor will get very hot if the bearing sleeve is damaged. If so, turn
the axis by hand and feel for roughness in the lead screw. Loosen the clamp nuts at both ends of
the lead screw. If the symptom disappears, replace the bearing sleeve. Be certain to check for
damage to the lead screw shaft where the bearing sleeve is mounted. If the noise persists, the lead
screw is damaged and must be replaced. When replacing the lead screw in an older machine,
always replace the bearing sleeve with the current angular contact design bearing sleeve.
Misalignment in the lead screw itself will tend to cause the lead screw to tighten up and make
excessive noise at both ends of the travel. The ballnut may get hot. Misalignment radially at the
yoke where the lead screw ball nut mounts is indicated by heating up of the ball nut on the lead
screw, and noise and tightness throughout the travel of the lead screw. Misalignment at the yoke
where the ball nut mounts is indicated by noise and tightness at both ends of the travel of the lead
screw. The ball nut may get hot.
NOTE: Customer complaints of Lead Screw noise may not indicate a bad screw.
Screws from different manufacturers produce varying levels of noise. Often
machines are built with two or more different brands of screws in the same
machine. If complaints are generated about one axis screw in comparison to
another, it is possible that the screws are simply sourced from different
manufacturers.
16
ACCURACY / BACKLAS H
Accuracy complaints are usually related to tooling, programming, or fixturing problems. Eliminate these
possibilities before working on the machine.
Poor Z-axis accuracy.
Check for a loose encoder on the servo motor. Also, ensure the key in the motor or the lead screw is in
place and the coupling is tight (Brush motors only).
Check parameters for that axis.
Check for backlash in the lead screw as outlined below.
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TROUBLESHOOTING
Initial Preparation-
Turn the lathe ON. ZERO RET the machine and move the carriage to the approximate center of its travel in the
Z-axis. Move the turret to the approximate center of the X-axis travel.
X-Axis:
1. Place a dial indicator and base on the spindle retaining ring with the tip of the indicator positioned
on the outside diameter of the turret, as shown in Fig. 1.4-1
Fig. 1.4-1 Dial indicator in position to check X-axis.
2. Set dial indicator and the Distance to go display in HANDLE JOG mode to zero as follows:
Zero the dial indicator.
Press the MDI button on the control panel.
Press the HANDLE JOG button on the control panel.
The Distance to go display on the lower right hand corner should read: X=0 Z=0
3. Set the rate of travel to .001 on the control panel and jog the machine .010 in the positive (+) X
direction. Jog back to zero (0) on the display. The dial indicator should read zero (0) ± .0001.
4. Repeat step 3 in the negative (-) direction.
TOTAL DEVIATION BETWEEN THE DIAL INDICATOR AND THE CONTROL PANEL DISPLAY
SHOULD NOT EXCEED .0002.
An alternate method for checking backlash is to place the dial indicator as shown in Fig. 4-1 and manually
push on the turret in both directions. The dial indicator should return to zero after releasing the turret.
NOTE: The servos must be on to check backlash by this method.
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TROUBLESHOOTING
Z-Axis:
1. Place a dial indicator and base on the spindle retaining ring with the indicator tip positioned on the
face of the turret as shown in Fig. 1.4-2.
June 2001
Fig. 1.4-2 Dial indicator in position to check Z-axis
2. Set dial indicator and the Distance to go display in the HANDLE JOG mode to zero as follows:
Zero the dial indicator.
Press the MDI button on the control panel.
Press the HANDLE JOG button on the control panel. The Distance to go: display on the lower
right hand corner should read: X=0, Z=0
3. Set the rate of travel to .001 on the control panel and jog the machine .010 in the positive (+) Z
direction. Jog back to zero (0) on the display. The dial indicator should read (0) ± .001.
4. Repeat Step 3 in the negative (-) direction.
TOTAL DEVIATION BETWEEN THE DIAL INDICATOR AND THE CONTROL PANEL DISPLAY
SHOULD NOT EXCEED .0002.
An alternate method for checking backlash is to place the dial indicator as shown in Fig. 4-2 and manually
push on the turret in both directions. The dial indicator should return to zero after releasing the turret.
NOTE: The servos must be on to check backlash by this method.
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96-8710 rev C
June 2001
TROUBLESHOOTING
VIBRATION
Excessive servo motor vibration.
Check all Parameters of the suspected axis against the Parameters as shipped with the machine. If
there are any differences, correct those and determine how the Parameters were changed.
A bad motor can cause vibration if there is an open or short in the motor. A short would normally
cause a GROUND FAULT or OVERCURRENT alarm; check the ALARMS. An ohmmeter applied to the
motor leads should show between 1 and 3 ohms between leads, and over 1 megohm from leads to
chassis. If the motor is open or shorted, replace.
OVERHEATING
Servo motor overheating.
If a motor OVERHEAT alarm occurs (ALARMS 135-138), check the Parameters for an incorrect
setting. Axis flags in Parameters 1, 15, or 29 can invert the overheat switch (OVER TEMP NC).
If the motor is actually getting hot to the touch, there is excessive load on the motor. Check the users
application for excessive load or high duty cycle. Check the lead screw for binding ("Accuracy/
Backlash" section). If the motor is binding by itself, replace in accordance with "Axis Motor Removal/
Installation".
SERVO ERROR
Servo Error Too Large alarms occur on one or more axes sporadically.
Check motor wiring for shorts.
Driver card may need replacement.
Servo motor may need replacement.
Check for binding in motion of lead screw.
LEAD SCREWS - VISUAL INSPECTION
The three main causes of Lead Screw failure are:
Loss of Lubrication
Contamination
Machine Crash
Wear of the Nut balls and the screw threads is generally not an issue under proper operating conditions.
Each type of suspect cause will leave telltale signs on the Lead Screw itself.
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TROUBLESHOOTING
Loss of Lubrication:
The lubrication system of the machine provides a layer of oil for the Lead Screw components to operate on,
eliminating metal-to-metal contact. Should a problem with the lubrication system develop, that failure will
accelerate all wear issues.
1. Dry metal-to-metal contact following lube breakdown will create intense heat at the contact points.
The Nut balls will weld to the Nut races due to the heat and pressure of the preload. When
movement of the Lead Screw continues, the welds will be broken, ripping off particles of both the
balls and the races. This loss of diameter will reduce the preload, reducing machine accuracy.
Lead Screws with this type of wear, but no screw surface marring, can be repaired by the factory.
2. A second cause of wear of the Lead Screws is material fatigue. Material fatigue typically occurs at
the end of the Lead Screw service life. Signs of material fatigue include black, contaminated
coolant, pitting of the screw surface, loss of preload, and metal flakes on the Lead Screw.
Lead Screws suffering from material fatigue are not repairable and are considered scrap.
Contamination:
Contamination of the lubrication and/or coolant systems of the machine will produce problems with the Lead
Screws.
June 2001
Check the condition of the lube on the Lead Screw threads.
1. If the lube is wet and clean, this indicates a properly functioning lube system.
2. If the lube is thick and dark, but free of metal chips, the lube itself is old and must be changed out.
The entire system should be cleaned of the old lube.
3. If the lube is wet and black, the lube system has been contaminated by metal particles. Inspect
the Lead Screws for wear.
Contamination of the lube and/or coolant systems can be caused by a wearing Lead Screw, or by metal chips
entering the systems through open or loose way covers. Check all way covers and seals for excessive clearances.
Machine Crash:
A hard machine crash can cause a Lead Screw to lock up. The static overload created during a machine crash
can break apart the Nut balls, denting the thread surfaces. Turning the Nut by hand will result in an obvious
grinding feeling and/or sound.
1. Check the screw for straightness.
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2. Look for ball dents at the ends of the screw length. These indents will be a sure sign of a hard
machine crash. The inertia of the table is transferred, due to the sudden stop, directly to the balls
inside the Nut, creating impressions on the screw surface.
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TROUBLESHOOTING
CLEANING
In most cases, a thorough cleaning of the suspect Lead Screw will resolve bad screw issues, including noise
complaints.
1. Manually jog the Nut to one end of the screw.
2. Visually inspect the screw threads. Look for metal flakes, dark or thick lube, or contaminated
coolant: See Visual Inspection - Contamination above.
3. Use alcohol, or other approved cleaning agents, to wash the screw.
CAUTION! Do not use detergents, degreasers, or solvents to clean Lead Screws
or their components. Do not use water-based cleaners to avoid rust.
4. Jog the Nut to the other end of its travel. If metal flakes are now present on the screw threads, you
may have wear issues.
5. Re-lubricate screw threads before returning the machine to service.
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TROUBLESHOOTING
1.5 TURRET CLAM P / UNLCAMP
ALARM 113 and 114
1) Check the tool changer solenoid.
A) Does the solenoid appear to be activating.?
I) If no, check power to the solenoid during a tool change. If there is voltage replace the solenoid.
II) If yes, go on.
B) Are the exhaust mufflers dirty?
I) If yes, remove the muffler and do a tool change. If the alarm goes away then replace the muffler
II) If no, proceed to the next step.
C) Is there water in the airlines?
I) If yes, insure that the air is now dry and replace the solenoid.
II) If no, proceed to the next step.
2) Check air pressure.
A) Is the main regulator set to a minimum 85 psi?
B) Does the air pressure drop more than 10 psi during a tool change?
I) If no, go to the next check.
II) If yes, the lathe has an insufficient volume of air. Must have a supply of 100 psi at 4 sfm at the
regulator. A small diameter air supply hose, hose length, and fitting size may restrict the volume
of air going to the machine.
June 2001
3) Remove the top toolchanger cover. Confirm that the air cylinder is fully clamping (114 alarm) or fully
unclamping (113 alarm).
A) If yes, go to the next check,.
B) If no, try to push the air cylinder into position.
I) If the air cylinder will not fully clamp or unclamp disconnect the air cylinder from the cam lever
and retry. If the air cylinder still does not fully clamp or unclamp, replace the air cylinder.
II) If the air cylinder fully clamps and unclamps then:
1) Cam balls fell out of time with each other. This would be more common on the original
style cams. This design does not have a cage. Fully clamping the air cylinder by hand
should position the 3 balls correctly.
2) If this problem persists then the cams might be damaged. Replace with part numbers
93-8138 cam upgrade kit. This is a cam assembly with the cage. It is compatible with
all lathes.
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TROUBLESHOOTING
4) Clamp switch or unclamp switch is failing or is out of adjustment. (Reed style or telemecanique switches).
A) Switch identification and adjustment.
I) Reed style switches- these types of clamp/unclamp switches are mounted on the air cylinder to
detect the clamp and unclamp position of the turret. The air cylinder has a magnetic piston,
which activates the switch when the magnetic piston is under it. This style detects the move ment of the piston, not the turret shaft.
1) Adjust the switch by first confirming that the air cylinder is fully clamped. While observ ing the diagnostic data for the control, slide the switch in one direction until the bit
changes from a 1 to a 0. Mark the position with a pen then do the same while sliding
the switch in the other direction. Position the switch between the two markings and
tighten the clamp.
2) If the alarm still persists then the switch might be failing. Change the clamp switch with
the unclamp switch at the air cylinder and at the lube panel. If the problem goes away
or changes to an unclamp alarm then replace the switch.
II) Telemecanique clamp/unclamp switches at the rear of the turret shaft- these
types of switches detect the position of the turret shaft during a tool change,
these switches are installed on the same bracket which supports the turret
home switch, also called the a-axis home switch.
The amount of shaft movement or turret pop out is very important with this style
of switch. The switches are a direct indication of the position of the shaft. If the
turret in/out travel is not adjusted correctly or the switch bracket is holding the
switches too far apart then alarms during a tool change will occur.
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TROUBLESHOOTING
1.6 HYDRAULIC SYSTEM
HYDRAULIC PRESSURE
Low hydraulic pressure alarm (143).
Check for any leaks.
Check that the oil level is above the black line.
Check that the oil pressure is within 50-500 psi. If the hydraulic unit needs to be replaced, see Hydraulic
Unit Removal/Installation section.
Check that the temperature is less than 150 degrees. If the hydraulic unit needs to be replaced, see Hydrau-
lic Unit Removal/Installation section.
Phasing changes cause the hydraulic unit to change directions resulting in alarm 134.
Make sure the filter has been replaced within the last 6 months.
If pressure drops below 40 PSI during activation of chuck or tailstock, an alarm will occur.
June 2001
HYDRAULIC CHUCK
Chuck wont clamp/unclamp.
Check for alarm condition.
Check display for Low Hydraulic Pressure alarm (134).
Check that the oil pressure gauge is within 50-500 psi.
Use a voltage meter to check the solenoid circuit breaker. Replace solenoid valve if faulty.
NOISE IN HYDRAULIC POWER UNIT
Hydraulic power unit noise
NOTE: Noise in hydraulic unit should decrease a few minutes after start up
Check for leaks in hose.
Check that the oil level is above the black line.
Check for loose pieces/hardware.
Check for debris in motor/cooling fins.
Remove, clean, and reinstall adjustment valves.
24
HYDRAULIC TAILSTOCK
Tailstock pulsates as it moves
Check operating pressure (Minimum operating pressure is 120 psi.).
Check for leaks at hydraulic cylinder.
Check for leaks at hose fittings.
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June 2001
TROUBLESHOOTING
1.7 ELECTRICAL TROUBLE SHOOTING
CAUTION! Before working on any electrical components, power off the machine
ELECTRICAL ALARMS
and wait approximately 10 minutes. This will allow the highvoltage
power on the brushless amplifiers to be discharged.
Axis Drive Fault Alarm
Blown amplifier - indicated by a light at bottom of amplifier when power is on. Replace amplifier.
Amplifier or MOCON is noise sensitive. If this is the case, the alarm can be cleared and the axis
will run normally for a while.
To check an amplifier, switch the motor leads and control cables between the amplifier and the one
next to it. If the same problem occurs with the other axis, the amplifier must be replaced. If the
problem stays on the same axis, It is 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, which is very rare.
Amplifier faulting out for valid reason, such as overtemp, overvoltage, or +/-12 volt undervoltage
condition. This usually results from running a servo intensive program, or unadjusted 12 volt power
supply. Adjust voltage to correct specifications or replace the power supply.
Overvoltage could occur if regen load is not coming on, but this does not usually happen. The
problem could also be the axis motor itself, with leads either shorted to each other or to ground,
which is very rare.
Axis Overload
The fuse function built into the MOCON has been overloaded, due to a lot of motor accel/decels, or
hitting a hard stop with the axis. This safety function protects the amplifier and motor, so find the
cause and correct it. If the current program is the cause, change the program. If the axis hits a
hard stop, the travel limits may be set wrong.
Phasing Error
The MOCON did not receive the proper phasing information from the motors. DO NOT RESET the
machine if this alarm occurs. Power the machine down and back up. If the problem persists, it is
probably a broken wire or faulty MOCON connectors. This problem could also be related to the
Low Voltage Power Supply. Check to see if the LVPS is functioning properly.
Servo Error Too Large
This alarms occurs when the difference between the commanded axis position and the actual
position becomes larger than the maximum that is set in the parameter.
This condition occurs when the amplifier is blown, is not receiving the commands, or the 320 volt
power source is dead. If the MOCON is not sending the correct commands to the amplifier, it is
probably due to a broken wire, or a PHASING ERROR that was generated.
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TROUBLESHOOTING
Axis Z Fault or Z Channel Missing
During a self-test, the number of encoder counts was found to be incorrect. This is usually caused
by a noisy environment, and not a bad encoder. Check all shields and grounds on the encoder
cables and the motor leads that come into the amplifiers. An alarm for one axis can be caused by
a bad grounding on the motor leads of another axis.
Axis Cable Fault
During a self-test, the encoder cable signals were found to be invalid. This alarm is usually caused
by a bad cable, or a bad connection on the motor encoder connectors. Check the cable for any
breaks, and the encoder connectors at the motor controller board. Machine noise can also 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.
June 2001
Alarm 157, "MOCON Watchdog Fault"
The self-test of the MOCON has failed. Replace the MOCON.
Alarm 354 - Aux Axis Disconnected
When this alarm is generated, do not press RESET. Turn Setting 7 OFF. Enter DEBUG mode, then view the
Alarms/Messages page. On the Messages page, a code will appear similar to WO1. The list of codes and
their descriptions appears below:
WO1 Power was just turned on or failed. Check the ribbon cables from the Aux Axis PCB to the proces-
sor for correct routing. Check for communication problems between the processor and the Aux
Axis PCB.
WO2 Servo following error too large. Check the encoder for contamination or dirt. Check for an intermit-
tent connection at both ends of the motor cable.
WO3 Emergency Stop. The E-STOP button was pressed, or an E-STOP condition occurred.
WO4 High load. Check for binding in the tool changer gearbox and motor. Rotate the carousel by hand
and feel for any binding. Make sure the tool holders are the correct weight.
26
WO5 Remote RS-232 commanded off. Check the ribbon cable and the voltage to the Aux Axis PCB.
Check for 115VAC (minimum) to the Aux Axis PCB from the main transformer. Check the fuse
holder and the fuse that is protecting this circuit.
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June 2001
TROUBLESHOOTING
WO6 Air or limit switch or motor overheat. Check that the motor is not hot. Check for any binding in the
motor. Check for overweight tooling.
WO7 Z channel fault. Either the encoder or the cable is bad. Change the encoder first, as it is easier to
change than the cable. If the problem persists, change the cable.
WO8 Over-current limit, stalled or PCB fault. Check for binding in the tool changer gearbox. Make sure
the belt is not too tight. Ohm out the motor cable, checking pins G to F (should be open), G to H
(should be open), and F to H (should read between 2.5 and 5 ohms). Check all the connections on
the Aux Axis PCB and motor cable.
WO9 Encode ES. Z channel is missing. Bad encoder or cable. See WO7.
WOA High voltage. Check the incoming voltage to the Aux Axis PCB. Incoming voltage must be 115
VAC. See WO5.
WOB Cable fault. Check the cable from the motor to the Aux Axis PCB. Check for loose connections at
each end.
PROCESSOR STA CK DIAGNOSTIC
(DISCONNECT CABLES FROM A NORMAL OPERATING SYSTEM)
Remove low voltage cable from the Video & Keyboard PCB
Processors LED's are normal.
Runs fine and the CRT is Normal.
No keypad beep.
Remove the Data & or Address buss from the Video & Keyboard PCB
Processors LED's Normal - then Run goes out.
Remove the Data & or Address buss from the Micro Processor PCB
Processors LED's - CRT and Run are out.
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TROUBLESHOOTING
KEYBOARD DIAGNOSTIC
June 2001
NOTE: Refer to the "Cable Locations" section of this manual for a drawing of the
Keyboard Interface PCB.
28
NOTE: This Keyboard Grid is for machines with a Keyboard Interface only. This
Keyboard Grid is not for machines with a Serial Keyboard Interface.
The following is an example of how to troubleshoot the keypad:
NOTE: Keypad Diodes 1-24 correspond to chart numbers 1-24.
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June 2001
TROUBLESHOOTING
Example
1. Pressing the RESET button will cause diodes 1 and 17 to conduct.
With the POWER OFF read across diode 1.
A typical reading is between .400-.700 ohms, note your reading.
2. Press and hold the RESET button. If the diode is conducting, the reading should drop about .03 ohms.
(If your reading was .486 and it dropped to .460, for a difference of .026; the diode is
good).
The same will hold true for diode 17 in this example. If the reading stays the same or there
is no change, the diode is not conducting. Pull P2 and read between pins 1 and 17.
Press and hold <RESET>. The meter should read a short (0 ohms) if not the keypad is
bad.
ETHERNET
Error 53 The computer name specified in the network path cannot be located
This error usually happens when NET USE C: \\SERVER\HAAS/PERSISTENT: NO /YES is entered during the
setup phase.
To fix this error first verify the following:
1. A 10 Base-T network is present.
2. The network cable is coming from a hub (not the server).
3. The server name that you specified in yo
2. u NET USE command is correct.
4. Your network is running IPX/SPX protocol.
If all of the above is correct and communications between the Haas CNC and the network are not established,
there may be compatibility issues between an older Novell network and an NT 4.0 server. If the NWLink IPX/
SPX Compatible Transport on the NT server is set to auto detect the protocols frame, the NT server may be
detecting the Novell server first and setting the NWLink IPX/SPX Compatible Transport frame protocol to 802.3
The NWLink IPX/SPX Compatible Transport required for the mills to connect to an NT server is 802.2. Since
these two frame protocols are different the mill would never connect to the desired NT server. To remedy this
check the following:
1. On the Ethernet boot disk, edit the protocol.ini file in the NETI directory.
2. Find the line FRAME=ETHERNET_802.2 and change it to FRAME=ETHERNET_802.3
3. Save the file
4. Insert the boot disk back into the CNC and cycle the power.
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