haas VF- 96-8100 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

VF-Series Service Manual 96-8100 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 qualied
and knowledgeable about the processes.

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

WARNING: Some mechanical and electrical service procedures can be

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

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

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

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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TROUBLESHOOTING

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

June 2001

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TROUBLESHOOTING

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 problems 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, dont expect the machine to correct the fault. Dont
suspect machine accuracy if the vise bends the part. Dont claim hole mis-positioning if you dont 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 doesnt 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 dont replace the spindle drive if the belt is
broken. Find the problem first; dont just replace the easiest part to get to.

DONT TINKER WITH THE MACHINE

There are hundreds of parameters, wires, switches, etc., that you can change in this machine. Dont 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
processors 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 WONT 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").

Constant E-Stop Condition (will not reset)

 Check Hydraulic counterbalance pressure, low pressure switches and cabling.

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TROUBLESHOOTING

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. Because the VF Series uses a gear head, it will be noisier than a
direct drive or belt system. 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 covers. One crude method of measurement would be to take an indicator on a
magnetic base extended 10 inches between the table 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 jogging the axis with the hand wheel.

 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. Isolate
the source of vibration per "Spindle", "Servo Motors/Leadscrews", and "Gearbox and Spindle Motor"
sections.

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TROUBLESHOOTING

ACCURACY

Before you complain of an accuracy problem, please make sure you follow these simple dos and donts:

 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).

 Do not use a wiggler test indicator for linear dimensions. They measure in an arc and have sine/cosine

errors over larger distances.

 Do not use magnetic bases as accurate test stops. The high accel/decel of the axis can cause them to

move.

 Do not attach magnetic base to the sheet metal of the spindle head or table.
 Do not mount the magnetic base on the spindle dogs.
 Do not 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

(e.g. spindle head casting, spindle nose, or the table).

 Do not rapid to position when checking accuracy. The indicator may get bumped and give an inaccurate

reading. For best results, feed to position at 5-10 inches per minute.

 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

Machine will not interpolate a round hole.

 Check that the machine is level (see "Installation" section).
 Check for backlash ("Servo Motors/Leadscrews" section).

Bored holes do not go straight through the workpiece.

 Check that the machine is level (see "Installation" section).
 Check for squareness in the Z axis.

Machine bores holes out-of-round.

 Check that the machine is level (see "Installation" section).
 Check the sweep of the machine (see "Spindle Sweep Adjustment" section).

Bored holes are out of round or out of position.

 Check for thermal growth of the leadscrew (see "Thermal Growth" section).
 The spindle is not parallel to the Z axis. Check the spindle sweep to the table and the squareness

of the Z axis with a cylinder square. If available use a spindle master bar and indicate the spindle
to the Z axis.

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TROUBLESHOOTING

Machine mis-positions holes.

 Check for thermal growth of the leadscrew (see "Thermal Growth" section).
 Check that the machine is level (see "Installation" section).
 Check for backlash (see "Servo Motors/Leadscrews" section).
 Check the squareness of the X axis to the Y axis.

Machine leaves large steps when using a shell mill.

 Check that the machine is level (see "Installation" section).
 Check the sweep of the machine (see "Spindle Sweep Adjustment" section).
 Cutter diameter too large for depth of cut.

Boring depth inaccurate

 Check for thermal growth of the leadscrew (see "Thermal Growth" section).
 Check the hydraulic counterbalance system. Check for:

 abnormal noises from counterbalance system,
 oil leaks (esp. at fittings and at filter at top of cylinder),
 bound cylinder.

FINISH

Machining yields a poor finish.

 Check for gearbox vibration.
 Check for backlash ("Accuracy/Backlash" section)
 Check the condition of the tooling and the spindle.
 Check spindle
 Check the condition of the servo motors.
 Check that the is machine level.

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TROUBLESHOOTING

THERMAL GROWTH

A possible source of accuracy and positioning errors is thermal growth of the leadscrew. As the machine
warms up, the leadscrews expand in all three linear axes, causing accuracy and positioning errors, or inaccu­rate boring depths. This is especially critical in jobs that require high accuracy, machining multiple parts in one
setup, or machining one part with multiple setups.

June 2001

NOTE: On machines equipped with linear scales, thermal growth will not affect

NOTE: The leadscrew will always expand away from the motor end.

machine positioning or accuracy. However, it is still recommended that the
machine be warmed up before cutting parts.

VERIFY THERMAL GROWTH

There are a number of ways to verify the problem. The following procedure will verify thermal growth of the X­axis 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 on the table (example: X-15.0" Y-8.0" ). Select the X axis and press the

ORIGIN key to zero it. Select the Y axis and zero it.

3. Press the OFSET key, then scroll down to G110 (or any unused offset). Cursor to X and press
PART ZERO SET twice. This will set X0, Y0 at this position.

4. Enter the following program. It will start at the new zero position, rapid 10 inches in the X direc­tion, feed the final .25 inches at 10 inches/min., and then repeat the X movement.

G00 G90 G110 X0 Y0;
X10.0;
G01 X10.25 F10. ;
M99;

5. In order to set up the indicator, run the program in SINGLE BLOCK mode, and stop it when X is at

10.25". Set the magnetic base on the table, with the indicator tip touching the spindle housing 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 10.25", and take a final reading on the indicator. If the
problem is thermal growth, the indicator will show a difference in the X position.

NOTE: Ensure the indicator setup is correct as described in "Accuracy" section.

Errors 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 Y and Z axes, if necessary.

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TROUBLESHOOTING

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 above the part or table, with the spindle "cutting air". 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're allowed to cool down. A warm-up program should be run after each time the machine is
left idle.

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TROUBLESHOOTING

1.2 SPINDLE

NOT TURNING

Spindle not turning.

 If there are any alarms, refer to "Alarms" section.

 Check that the spindle turns freely when machine is off.

 If motor turns but spindle does not, see "Belt Assembly" and "Spindle Motor & Transmission" sections.

 Command spindle to turn at 1800 RPM and check spindle drive display. If display blinks bb, check

spindle orientation switch ("Spindle Orientation" section). If spindle drive does not light the RUN LED,
check forward/reverse commands from IOPCB ("Electrical Service").

June 2001

 Check the wiring of analog speed command from MOTIF PCB to spindle drive (cable 720).

 If spindle is still not turning, replace MOCON PCB ("Electrical Service").

 If spindle is still not turning, replace spindle drive ("Electrical Service").

 Check for rotation of the gearbox (if applicable) or the motor (VF-0). If the motor or gearbox operates,

check the drive belt ("Belt Assembly" section).

 Disconnect the drive belt. If the spindle will not turn, it is seized and must be replaced ("Spindle

Assembly" section).

NOTE: Before using the replacement spindle, the cause of the previous failure must

be determined.

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TROUBLESHOOTING

NOISE

Most noises attributed to the spindle actually lie in the motor/gearbox or drive belt of the machine. Isolate the
sources of noise as follows:

Excessive noise coming from the spindle head area.

On VF-1 through 6 models, first determine if the noise is related to the RPM of the motor or the RPM
of the spindle. For example: If the noise appears at 2000 RPM in high gear, listen for a similar noise
at 500 RPM in low gear. If the same noise persists, the problem lies with the gearbox. If the noise
disappears, the problem could be either the gearbox or the spindle, and further testing is necessary.

NOTE: The gear ratio is 1:1.25 in high gear, and 3.2:1 in low gear.

 Remove the head covers and check the machines drive belt tension ("Tension Adjustment" section).

If the noise persists, turn the drive belt over on the pulleys. If the noise is significantly different, the
belt is at fault. Replace the belt ("Belt Assembly" section).
If the noise does not change, remove the belt and go on to the next step.

 Check the pulleys for excessive runout (more than 0.003" axial or radial).

 Run the motor (VF-0) or the gearbox (VF-1, VF-2, VF-3) with the drive belt disconnected. If the noise

persists, the problem lies with the gearbox/motor. If it disappears, go on to the next step.

 Check for the correct amount of lubrication to the spindle bearings (0.5-1.0 cc every two hours) in an air

mist-lubricated spindle.

If the spindle is not getting lubrication, correct the problem per the lube and air diagram at the
back of this manual and replace the spindle ("Spindle Assembly" section).
If the spindle is getting lubrication, replace the spindle ("Spindle Assembly" section).

Note: Haas Automation does not honor warranty requests for gearbox or spindles

without vibration analyzer signatures.

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TROUBLESHOOTING

OVERHEATING

When investigating complaints of overheating, a temperature probe must be used to accurately check the
temperature at the top of the spindle taper. The temperature displayed in Diagnostics is not relevant. A machine
that runs at high RPM continuously will have a much warmer spindle than a machine that runs at a lower RPM.
New spindles tend to run much warmer than spindles that have already been run-in. In order to run a valid test
on a new spindle, ensure that it is properly run-in.

To run-in a spindle, run the following program (it will take approximately 6 hours):

N100 S300 M03 G04 P900. N700 S6000 M03
G04 P900. M05 G04 P900.
M05 G04 P900. M05
G04 P900. G04 P900. G04 P900.
N200 S1000 M03 N500 S4000 M03 G04 P900.
G04 P900. G04 P900. N800 S7500 M03
M05 M05 G04 P900.
G04 P900. G04 P900. M05
N300 S2000 M03 G04 P900. G04 P900.
G04 P900. N600 S5000 M03 G04 P900.
M05 G04 P900. M99
G04 P900. M05
G04 P900. G04 P900.
N400 S3000 M03 G04 P900.

June 2001

NOTE: This program will step the spindle speed from 300 RPM up to 7500 RPM at

regular intervals of time, stop the spindle and allow it to cool to room
temperature, then restart it so the temperature can be monitored.

ALTERNATE SPINDLE RUN-IN PROGRAM

Run program #O02021 with the air pressure to the spindle set to 30 psi. (for all spindles). Program time is
approximately 2 hours. If possible run the program overnight by changing M30 to M99 so it can repeat. Adjust
spindle speed override depending on maximum spindle speed of machine: Set override 50% for 5,000 RPM
machines; Set at 100% for 7,500 and 10,000 RPM machines; Set at 150% for 15,000 RPM machines.

N100
S750M3
G04 P600.;
S2500M3;
G04 P600.;
S5000M3;
G04 P900.;
N200
M97 P1000 L15
M97 P2000 L15
M30;
N1000
S7500M3;
G04 P30.;
S500 M3;
G04 P150.;
M99;

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TROUBLESHOOTING

N2000
S10000M3;
G04 P30.;
S500M3;
G04 P150.;
M99;
%

 If at any time during this procedure the spindle temperature rises above 150 degrees (120 degrees

for 50 Taper), start the procedure over from the beginning and follow the steps below.

NOTE: Once run-in program is complete reset the air pressure back to 17psi. (20psi.

If the spindle fails this test for any reason, check the following:

for 15K spindles, 25psi. Mini-Mill) prior to checking spindle temperature.

 Check for correct amount of lubrication.

NOTE: Over lubrication is a common source of overheating. Check the oil flow

carefully.

 Check the drive belt tension. Belts that are too tight will cause heating of the top bearing in the

spindle housing.

 Ensure that the correct oil is being used (refer to "Maintenance Schedule").

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TROUBLESHOOTING

STALLING / LOW TORQUE

Generally, complaints of stalling or low torque relate to incorrect tooling or machining practices. A spindle that
is tending to seize will yield a poor finish machining, run very hot and very loud. Investigate machining prob­lems before concluding the problem exists with the spindle or spindle drive.

SPINDLE DRIVE

Low line voltage may prevent the spindle from accelerating properly. If the spindle takes a long time to acceler­ate, slows down or stays at a speed below the commanded speed with the load meter at full load, the spindle
drive and motor are overloaded. High load, low voltage, or too fast accel/decel can cause this problem.

If the spindle is accelerated and decelerated frequently, the regenerative load resistor on top of the control may
heat up. If this resistor heats beyond 1000C, a thermostat will generate an overheat alarm.

If the regen load resistors are not connected or open, this could then result in an overvoltage alarm. The
overvoltage occurs because the regenerative energy being absorbed from the motor while decelerating is turned
into voltage by the spindle drive. If this problem occurs, the possible fixes are to slow the decel rate or reduce
the frequency of spindle speed changes.

June 2001

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.

If the DC Bus voltage is below 50 VDC and never goes any higher, perform Steps 1-6.

14

1. With the machine powered up, is the green POWER-ON L.E.D. lit? If not, replace the Vector
Drive unit.

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TROUBLESHOOTING

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.

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 okay.

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15

TROUBLESHOOTING

ORIENTATION

Spindle loses correct orientation.

Non Vector Drive

 Check the orientation ring for tightness. Ensure the shaft on which the ring mounts is clean and is

free of grease and oil.

 Check the orientation ring for cracks near the bolt holes or near the balancing holes.

If there are cracks, replace the ring.

 Check the shot pin on the gearbox for binding, damage, and proper operation. Replace it if it is

damaged.

Vector Drive

 Check alarm history. Look for Spindle Z Fault, or Spindle Reference Missing alarms. If these

alarms exist, there may be a defective spindle encoder, or a broken ground or shield connection.

 Check parameters.
 Check for a mechanical slip at the contact points of all components between the spindle and the

spindle encoder.

June 2001

TOOLS STICKING IN TAPER

Tool sticking in the taper causes ATC to be pulled up; accompanied by a popping noise as
the tool holder pops out of the spindle taper.

NOTE: This problem may occur after loading a cold tool into a hot spindle (a

NOTE: In a proper working system the spindle will pop slightly during a tool change.

 Check the condition of the tooling, verifying the taper on the tooling is ground and not turned. Look

for damage to the taper caused by chips in the taper or rough handling. If the tooling is suspected,
try to duplicate the symptoms with known-to-be-good tooling.

 Check the condition of the spindle taper. Look for damage caused by chips or damaged tooling.

Also, look for damage such as deep gouges in the spindle taper caused by tool crashing.

 Duplicate the cutting conditions under which the deflection occurs, but do not execute an

automatic tool change. Try instead to release the tool using the tool release button on the front of
the spindle head. If sticking is observed, the deflection is not caused by improper ATC
adjustment, but is a problem in the spindle head on the machine.

 Ensure the spindle is not running too hot (140° or above).

result of thermal expansion of the tool holder inside the spindle taper). It
may also occur due to heavy milling, milling with long tooling, or cuts with
heavy vibration. This also is the result of thermal expansion.

If sticking only occurs during these situations, check your application to
ensure proper machining techniques are being used; check the feeds and
speeds for the tools and material being used. If a tool is pulled out of the
extractors due to a tool stuck in the taper then the unclamp switch is not
adjusted correctly or the switch could be bad.

This popping does not create flex in the carousel or the need to remove the tool
with a mallet.

16

96-8100 rev C

June 2001

TROUBLESHOOTING

 Check air supply. Max air pressure drop of 10psi. during a tool change is allowed.
 Check drawbar height adjustment.
 Does the tool tip to the spindle gauge line exceed 3.5?
 Are the correct pull studs being used?

Tool Holder / Spindle Fretting

Is fretting present on the tool holder or spindle?

Fretting is the result of sideways movement of a tool holder in the spindle. Fretting can leave a wave pattern on
the mating surfaces and will affect the fit and finish of both the tool holder and the spindle.

 If light fretting is present, check the application to ensure proper machining techniques are being

used; check the feeds and speeds for the tools and material being used.

 Light fretting and rust may be cleaned from the tool holder with a fine scotchbrite hand pad and

solvent. If scotchbrite is used, clean the tool holder and spindle taper thoroughly after use with an
alcohol pad. Apply a thin coat of light oil to the taper of the tool holder. Grease the pull stud.

96-8100 rev C

17

TROUBLESHOOTING

1.3 SERVO MOTORS / LEADSCREWS

NOT OPERATING

All problems that are caused by servo motor failures should also register an alarm. Check the alarm history to
determine the problems cause 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, replace the encoder on brush 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).
 Dust in the motor from brushes has shorted out the motor (VF-E only) (Alarms 153-156, 175, 182-

185). Replace motor assembly ("Axis Motor Removal/Installation").

 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).

June 2001

18

NOTE: If a lead screw fails, it is most often due to a failed bearing sleeve. When

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).

96-8100 rev C

June 2001

TROUBLESHOOTING

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

are extremely durable and reliable. Verify that customer complaints are not due
to tooling, programming, or fixturing problems.

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).

 Noise is caused by motor brushes (VF-E only). Remove and inspect brushes. Blow out brush dust

and inspect the armature.

Lead screw noise.

 Ensure oil is getting to the lead screw through the lubrication system (See Air and Oil Diagrams).

Look for a plugged metering valve.

 Check for damage to the bearing sleeve.

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 through out 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.

96-8100 rev C

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.

19

TROUBLESHOOTING

ACCURACY / BACKLASH

Accuracy complaints are usually related to tooling, programming, or fixturing problems. Eliminate these
possibilities before working on the machine.

Poor mill table-positioning accuracy.

 Check for backlash in the lead screw as outlined below:

 Check parameters for that axis

 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 machines only).

INITIAL PREPARATION -

Turn the VMC ON. ZERO RET the machine and move the mill table to the approximate center of its travel in the
X and Y directions. Move the spindle head to approximate center of the Z-axis travel, also.

June 2001

CHECKING X-AXIS:

1. Set up a dial indicator and base on the mill table as shown in Fig. 1-1.

20

Figure 1-1. Dial indicator in position to check X-axis.

96-8100 rev C

June 2001

TROUBLESHOOTING

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 Y=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. 1-1 and manually
push on the mill table in both directions. The dial indicator should return to zero after releasing the table.

NOTE: The servos must be on to check backlash by this method.

CHECKING Y-AXIS:

1. Set up a dial indicator and base on the mill table as shown in Fig. 1-2.

96-8100 rev C

Figure 1-2. Dial indicator in position to check Y-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 Y=0 Z=0.

21

TROUBLESHOOTING

3. Set the rate of travel to .001 on the control panel and jog the machine .010 in the positive (+) Y
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. 1-2 and manually
push on the mill table in both directions. The dial indicator should return to zero after releasing the table.

NOTE: The servos must be on to check backlash by this method.

CHECKING Z-AXIS:

1. Set up a dial indicator and base on the mill table as shown in Fig. 1-3.

2. Manually push up and down on the spindle head while listening for a clunk. Also, watch for any
rapid change in the dial indicator. Either of these indicate possible backlash.

June 2001

NOTE: Servos must be on to check for backlash in the Z-axis.

NOTE: Do not mistake deflection for backlash in the system.

22

Figure 1-3 Dial indicator in position to check Z-axis.

96-8100 rev C

June 2001

TROUBLESHOOTING

If backlash is found in the system, check for the following possible causes:

 Loose SHCS attaching the ball nut to the nut housing. Tighten the SHCS as described in

Mechanical Service.

 Loose SHCS attaching the nut housing to the mill table, spindle head, or saddle, depending on the

axis. Tighten the SHCS as described in Mechanical Service.

 Loose clamp nut on the bearing sleeve. Tighten the SHCS on the clamp nut.
 Loose motor coupling. Tighten as described in Mechanical Service.
 Broken or loose flex plates on the motor coupling.

NOTE: The coupling cannot be serviced in the field and must be replaced as a unit

if it is found to be defective.

 Loose SHCS attaching the bearing sleeve to the motor housing. Tighten as described in "Lead

Screw Removal and Installation".

 Defective thrust bearings in the bearing sleeve. Replace the bearing sleeve as outlined in "Bearing

Sleeve Removal and Installation".

 Loose SHCS attaching the axis motor to the motor housing. If the SHCS are found to be loose,

inspect the motor for damage and if none is found, tighten as described in "Axis Motor Removal/
Installation". If damage is found, replace the motor.

 Incorrect backlash compensation number in the parameter in the machine. Check Parameters 13,

27, and 41.

 Worn lead screw.

VIBRATION

Excessive servo motor vibration.

 Swap the suspected bad servo motor with a known good driver and check to see if there is a driver

problem. If needed, replace the DRIVER PCB ("Electrical Service" section).

 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.

96-8100 rev C

23

TROUBLESHOOTING

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 users

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".

FOLLOWING ERRORS

FOLLOWING ERROR (Brush Machines only) or SERVO ERROR TOO LARGE alarms 103­106, 187 occur on one or more axes sporadically.

 Check DC bus voltage on diagnostics page #2 (brush machines only). Verify this voltage on the drive

cards in the control panel. If it is at the low side of the recommended voltages, change the transformer
tap to the next lower voltage group as explained in the Installation Manual.

 Check motor wiring for a short.
 Check driver card ("Electrical Service").
 Check servo motor ("Axis Motor Removal/Installation").
 Check encoder (brush machines only)

June 2001

DRIVE FAULT / OVERCURRENT

Z-axis motor overcurrent.

 Alarm not cleared
 Low counterbalance pressure
 Check Z axis parameters
 Check the lead screw for binding
 Check motor and cable for shorts
 Check amplifier (drive card on a VF-E)

VF-6 with Z axis brake only

 Brake power fuse blown
 Brake power transformer blown
 Brake power rectifier blown
 Cabling pinched
 Brake failed

24

96-8100 rev C

June 2001

TROUBLESHOOTING

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 a non-issue under proper operating conditions.

Each type of suspect cause will leave telltale signs on the Lead Screw itself.

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.

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.

96-8100 rev C

25

TROUBLESHOOTING

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.

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.

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.

June 2001

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.

26

96-8100 rev C

June 2001

TROUBLESHOOTING

1.4 AUTOMATIC TOOL CHANGER

DEFLECTION

Deflection is usually caused by ATC misalignment, and sometimes caused by damaged or poor quality tooling,
a damaged spindle taper, or a damaged drawbar or poor air supply. Before beginning any troubleshooting,
observe the direction of the ATC deflection.

During a tool change, ATC appears to be pushed down.

 Check to see if pull studs on the tool holder are correct and tight.
 Check the adjustment of the Z offset ("Setting Parameter 64").

NOTE: If the offset is incorrect a tool changer crash can occur and a thorough

inspection of the ATC will be necessary.

 Check the adjustment of the Z offset. Check parameters 71, 72, and 143 against the values that

are in the documentation sent with the machine.

 Ensure the tool holders are held firmly in place by the extractor forks.
 Ensure the balls on the drawbar move freely in the holes in the drawbar when the tool release

button is pressed. If they do not move freely, the ATC will be pushed down about 1/4" before the
tool holder is seated in the taper, resulting in damage to the roller bolts on the ATC shuttle.
Replace the drawbar.

 Check Drawbar height adjustment.
 If TSC, check for excessive coolant tip wear.

Tool holder sticking in the spindle taper causes the ATC to be pulled up as the spindle
head is travelling the distance specified in parameter 71; accompanied by a popping noise
as the tool holder pops out of the spindle taper.

NOTE: This problem may occur after loading a cold tool into a hot spindle (a result

of thermal expansion of the tool holder inside the spindle taper. It may also
occur in cuts with heavy vibration. This also is the result of thermal expansion.
If sticking only occurs during these situations, check your application to ensure
proper machining techniques are being used. If tool is pulled out of extractors
due to a tool being stuck in the taper then the unclamp switch is not adjusted
correctly or the switch could be bad.

96-8100 rev C

 Check the condition of the customers tooling, verifying the taper on the tool holder is ground and

not turned. Look for damage to the taper caused by chips in the taper or rough handling. If the
tooling is suspected, try to duplicate the symptoms with different tooling.

 Check the condition of the spindle taper. Look for damage caused by chips or damaged tooling.

Also, look for damage such as deep gouges in the spindle taper caused by tool crashing. See
"Spindle Assembly" section for spindle cartridge replacement.

27

TROUBLESHOOTING

 Duplicate the cutting conditions under which the deflection occurs, but do not execute an auto-

matic tool change. Try instead to release the tool using the tool release button on the front of the
spindle head. If sticking is observed, the deflection is not caused by improper ATC adjustment, but
is a problem in the spindle or tool release piston. See the "Spindle Assembly" section in Mechani­cal Service for spindle cartridge replacement.

 Check air supply pressure it should be 85 psi (min). An air pressure drop of no more than 10 psi

during tool release is acceptable. An air pressure drop greater than 10 psi is caused by a supply
line restriction or an undersize supply line. Use of quick couplers (1/4") can cause restriction.
Directly connecting the air hose to a barb fitting can help.

During a tool change, ATC appears to be pulled up; no popping noises.

 Check the adjustment of the Z offset ("Setting Parameter 64" section).

June 2001

NOTE: If the offset is incorrect, a tool changer crash can occurred, and a thorough

inspection of the ATC will be necessary.

 Ensure the roller bolts on the shuttle of the ATC are tight against the V-guides on the ATC holding

arm. If the lower right roller bolt is loose against the V-guide, the upper right bolt is probably bent.
See the following section ("ATC Crashing") or "Roller Bolt Replacement", for roller bolt replace­ment.

NOTE: Bent roller bolts are a symptom of another problem with the ATC. Repair the

bent roller bolt and then isolate the ATC problem.

 Check Parameter 71 against the values that are in the documentation sent with the machine.
 Ensure the balls on the drawbar move freely in the holes in the drawbar when the tool release

button is pressed. If they do not move freely, the ATC will be pushed down about ¼ before the tool
holder is seated in the taper, resulting in damage to the roller bolts on the ATC shuttle. Replace
drawbar.

Tool holders twist against extractor fork during a tool change.

 Check the alignment of the ATC in the X and Y axes ("Automatic Tool Changer Alignment" section).

28

Tool holders spin at all pockets of the ATC when the ATC shuttle retracts.

 ATC is misaligned in the Y axis. Realign ATC ("Automatic Tool Changer Alignment" section).

NOTE: Observe the direction the tool holder rotates, as this will be the direction in

which the Y axis of the ATC needs to be moved.

96-8100 rev C

June 2001

TROUBLESHOOTING

Tool holders spin only at certain pockets of the ATC when the ATC shuttle retracts.

 Check all the extractor forks to ensure they are centered in the pocket of the ATC. Also, see

above. See "Extractor Fork Replacement" section, if necessary.

NOTE: If the ATC shows the problem as described here, each extractor fork must be

CRASHING

The most common ATC crashes are outlined as follows:

checked and centered to eliminate the possibility of the ATC being aligned
against an incorrectly-centered fork.

Shuttle crashes into spindle when a tool change is commanded (tool holder is in the pocket
facing the spindle head).

 Rotate the carousel to an empty pocket. Refer to the Programming and Operation manual for

correct operation.

NOTE: This crash is fairly common and is a result of operator error. If the ATC is

stopped in the middle of tool change cycle, the operator must command the
ATC to an empty pocket before the machine will operate correctly. Repeated
crashes of this type can damage the I/O board, the slip clutch, and the shuttle
motor in the ATC.

During a tool change spindle crashes into top of the tool holder after a turret rotation.

When the spindle head moves down over the top of the tool holder during a tool change, the pull stud will bind
inside the drawbar bore of the spindle, forcing the ATC down, breaking the carousel. Bending the upper right
roller bolt on the ATC shuttle or completely breaking it off is also possible. Tool holder is not held correctly in
the extractor fork, possibly held only in one side of the extractor and at an odd angle.

96-8100 rev C

 Check all of the extractor forks on the ATC.

During a tool change spindle crashes into top of the tool holder after a turret rotation.

The balls in the drawbar do not move freely, causing the ATC to be forced down far enough to break the carou­sel. Bending the upper right roller bolt on the ATC shuttle or completely breaking it off is also possible.

 Ensure the balls on the drawbar move freely in the holes in the drawbar when the tool release

button is pressed. If this failure occurs, check all of the extractor forks on the ATC for damage and
repair the spindle drawbar.

 Check drawbar height and set according to the appropriate section, if necessary.

ATC properly deposits a tool holder in the spindle, but the tools are dropped onto the
machine table when the shuttle retracts.

 Inspect the balls and the Belleville springs in the drawbar. See appropriate section and replace

drawbar.

29

TROUBLESHOOTING

The part or fixture on the mill table crashes into long tooling or into the ATC itself when
machining.

 Either reposition the tools to remove the interference, or program the carousel to rotate long tooling

out of the way of the part (USE THIS ONLY AS A LAST RESORT). CAUTION! If the carousel has to
be programmed to rotate long tools clear of the part, the correct carousel position must be
programmed back in before a tool change can be executed.

June 2001

NOTE: If these crashes occur, thoroughly inspect the ATC for damage. Pay close

attention to the extractor forks, the sliding covers on the ATC carousel, and the
roller bolts on the ATC shuttle. See appropriate section for extractor fork
replacement.

30

96-8100 rev C

June 2001

TROUBLESHOOTING

SIDE MOUNT TOOL CHANGER RECOVERY FLOW CHART

96-8100 rev C

31

TROUBLESHOOTING

BREAKAGE

Breakage of the ATC is caused by either very hard and repeated crashes or excessive TSC coolant tip wear.

ATC shuttle is broken off of the holding plate.

 Carefully inspect the bosses on the shuttle casting (where the roller bolts mount) for damage to the

threads or cracks. If any of the bosses are cracked, replace the casting. Realign the tool changer
after repairing the machine.

ATC extractor forks are damaged after breakage.

 Check the condition of the mounting holes in the carousel. If the threads are damaged, they must

be repaired or the carousel replaced. See appropriate section for extractor fork replacement.

NOISY OPERATION

To isolate noise(s) in the ATC, carefully observe the ATC in operation and look for the following:

June 2001

ATC makes noise as the shuttle moves.

 Check the adjustment of the roller bolts on the ATC ("Roller Bolt Replacement" section). Loose

roller bolts can cause the ATC to make a clunking noise when the shuttle is commanded to move.
Tight roller bolts can cause the shuttle motor to labor excessively, possibly damaging the motor or
the I/O board. In this case, the shuttle may also move too slowly.

 Check for damage to the trap door on the ATC cover. See appropriate section for trap door

replacement.

 Check for missing plastic riders on the ATC shutter. See "ATC Trap Door Replacement" for shutter

replacement.

 Ensure the guide pin mounted to the holding plate is not bent and does not scrape the ATC cover

during movement. See "ATC Trap Door Replacement" for guide pin replacement.

 Listen for damage to the gear train in the shuttle motor. If the motor is found to be the source of

the noise, replace the motor ("Shuttle Motor Removal" section). DO NOT try to repair the motor or
to further isolate the noise in the motor.

 Check to ensure the Geneva driver on the turret motor is tight and properly adjusted ("Shuttle

Motor Removal" section). If the Geneva driver is found to be loose, check for damage to the
Geneva star. Any roughness in the slots will require that it be replaced ("Geneva Star Replace
ment" section).

 Check the adjustment of the Geneva driver in relation to the Geneva star ("Geneva Star Replace

ment" section). If the adjustment is too loose, the carousel will vibrate heavily and make a loud
clanking noise during carousel rotation. If the adjustment is too tight, the turret motor will labor
excessively and the carousel may appear to move erratically.

32

NOTE: If the turret motor adjustment is tight for extended periods, the turret motor,

Geneva star, and the I/O board may be damaged. If the adjustment of the
Geneva star appears tight at some pockets and loose at others, the problem
lies with the Geneva star. Check the concentricity of the star relative to the
bearing housing on the carousel assembly. If the concentricity of the star is
proven to within specification and the problem still persists, the Geneva star
must be replaced ("Geneva Star Replacement" section).

96-8100 rev C

June 2001

TROUBLESHOOTING

 Ensure the screws holding the turret motor to the mounting plate are tight ("Turret Motor Removal"

section).

 Ensure the screws attaching the motor mounting plate to the shuttle casting are tight.
 Check for excessive noise in the gear train of the turret motor. See appropriate section for turret

motor replacement.

NOTE: If the motor is found to be the source of noise, replace the motor assembly

SPINDLE ORIENTATION

A switch is used to sense when the pin drops in to lock the spindle. When the pin drops the switch opens,
indicating orientation is complete. The normally-closed side of this switch is wired to the spindle drive and
commands it into the COAST STOP condition. This is done to make sure that the spindle motor is not pow­ered when the pin is locking the spindle. If, during a tool change, the dogs on the spindle shaft do not align with
the keys on the ATC carousel, the spindle orientation may be at fault.

The orientation of the spindle is as follows:

1. If the spindle is turning, it is commanded to stop,

2. Pause until spindle is stopped,

3. Spindle orientation speed is commanded forward,

4. Pause until spindle is at orientation speed,

(motor, mounting plate, and Geneva driver). DO NOT attempt to repair the
motor or to further isolate the problem in the motor.

96-8100 rev C

5. Command spindle lock air solenoid active,

6. Pause until spindle locked status is active and stable,

7. If not locked after time-out time, alarm and stop.

ATC out of orientation with the spindle. Incorrect spindle orientation will cause the ATC
to crash as the shuttle moves. Alarm 113 will be generated.

 Check the orientation of the spindle.

ATC will not run.

 In all cases where the tool changer will not run, an alarm is generated to indicate either a shuttle

in/out problem or a turret rotation problem. These alarms will occur either on an attempt to change
tools (ATC FWD) or ZERO RETURN the machine (AUTO ALL AXES). Use the appropriate alarm to
select one of the following problems:

33

TROUBLESHOOTING

ATC shuttle will not move; shuttle is getting power (Command a tool change and check for
power being applied to the shuttle motor).

 Disconnect the slip clutch arm from the ATC shuttle and ensure the shuttle can move freely. If not,

appropriate section for shuttle adjustment.

 Command a tool change with the shuttle disconnected.

 If the shuttle cycles, check the slip clutch on the ATC. See "Shuttle Installation" section for slip
clutch replacement.

June 2001

NOTE: The slip clutch should move the shuttle with a fair amount of force, but not so

 If the ATC shuttle does not cycle, the motor has failed and must be replaced. Turn the motor by
hand and feel for binding in the gear train in the motor.

NOTE: The motor uses a large amount of gear reduction and should be hard to turn

much that the shuttle cannot be made to slip when holding it back by hand. If
the slip clutch is frozen, replace it. It cannot be rebuilt in the field.

by hand.

ATC shuttle will not move; shuttle is not getting power.

 Command a tool change check for power being applied to the shuttle motor.
 Check that the TC IN/TC OUT LED on the I/O PCB is illuminated when a tool change takes place.

 If the LED lights, check the fuse FU5 on the POWER PCB or FU1 on the I/O PCB. Otherwise,
check the I/O PCB ("Electrical Service").
 If the LED does not light, check cables I/O-P1-510 and I/O-P2-520.

 Check ATC shuttle relay

ATC turret will not rotate; turret motor is getting power.

 Command a tool change check for power being applied to the turret motor.
 If power is applied but the output shaft on the motor does not turn, check for binding between the

turret motor assembly and the Geneva star ("Automatic Tool Changer" section). Check for damage
to the Geneva star or the Geneva driver. Check for a broken turret motor ("Turret Motor Removal"
section).

34

NOTE: Do not attempt to repair the motor or to further isolate the problem in the motor.

ATC turret will not rotate; turret motor is not getting power.

 Command a tool change check for power being applied to the turret motor.
 Check that the TC CW/ TC CCW LED on the I/O PCB is illuminated when a tool change takes

place.
If the LED lights, check the fuse FU5 on the POWER PCB or FU1 on the I/O PCB. Otherwise,
replace the I/O PCB (Electrical Service).
If the LED does not light, check cables I/O-P1-510 and I/O-P2-520.

 Check ATC turret relay.

96-8100 rev C

June 2001

TROUBLESHOOTING

1.5 GEARBOX AND SPINDLE MOTOR

The gearbox cannot be serviced in the field and must be replaced as a unit. NEVER remove a motor from a
VF-Series mill that has a gearbox, as this will damage the gearbox and void the warranty.

NOISE

When investigating complaints of gearbox noise, also refer to "Spindle" troubleshooting section. Gearboxes
can be damaged by, gearshift cylinders, or bearings, resulting in noisy operation. While gearbox vibration can
cause a poor finish on a workpiece, noisy gearbox operation may not.

Excessive or unusual noise coming from the gearbox and/or spindle motor.

Operate the machine in both high and low gears. Monitor the gearbox for noise in both gear positions and
if the pitch of the noise varies with the motor or the 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 gearbox, and it must be replaced ("Spindle Motor & Transmission"
section).

 If the noise occurs in both gear positions, disconnect the drive belt and repeat the previous step.

If the noise persists, the gearbox is damaged and must be replaced, ("Spindle Motor &
Transmission" section).

 With the drive belt disconnected, run the machine at 1000 RPM in high gear. Command a change

of direction and listen for a banging noise in the gearbox as the machine slows to zero RPM and
speeds back up to 1000 RPM in reverse. If the noise occurs, the motor has failed and the
gearbox must be replaced.

96-8100 rev C

35

TROUBLESHOOTING

GEARS WILL NOT CHANGE

Machine will not execute a gear change.

June 2001

NOTE: Whenever a gear change problem occurs, an alarm will also occur. Refer

When a gear change is performed, the following sequence of events occurs:

1. If the spindle is turning, it is commanded to stop,

2. Pause until spindle is stopped,

3. Gear change spindle speed is commanded forward,

4. Pause until spindle is at speed,

5. Command high or low gear solenoid active,

6. Pause until in new gear or reversal time,

7. Alarm and stop if max. gear change time elapsed,

8. If not in new gear, reverse spindle direction,

9. Turn off high and low gear solenoids.

ALARMS section to diagnose each problem before working on the machine.

 Check air supply pressure. If pressure is too low, the gears will not change.
 Check the air solenoid assembly on the solenoid bracket (rear of gearbox). If the solenoid

operates properly and the limit switches on the gearbox operate properly, the problem lies with the
gear change piston. Replace the gearbox ("Spindle Motor & Transmission" section).

 Check contactor CB4.

LOW PRESSURE ALARM

Alarm 179 (Low Pressure Transmission Oil) has been triggered.

 Check for low oil supply in reservoir.
 Check to see that pump motor is running.
 Check for an air leak in the suction side of the pump.
 Check for a bad pressure sensor.
 Check for a broken or damaged cable.
 Check for a worn pump head.

36

96-8100 rev C

June 2001

TROUBLESHOOTING

1.6 THROUGH THE SPINDLE COOLANT

COOLANT OVERFLOW

To begin troubleshooting, check the alarm history to determine the problems cause before any action is taken.

Coolant pouring out of spindle head covers.

 Check the customer's tooling for through holes in the pull stud, holder and tool.
 Check for seal failure. If failure is found, replace the seal housing (30-3286A). Refer

to the appropriate steps in "TSC-Tool Release Piston Replacement" section for procedure.

 Check that the TSC drain and purge lines are intact. If necessary, replace with 5/32" O.D.

nylon tubing.

 Check for coolant flowing from a failed fitting or check valve.
 Check precharge pressure in accordance with TSC "Pressure Regulator Adjustment' section and

reset if necessary. Low precharge pressure can cause coolant to dump into the spindle head.

 Check the coolant pump pressure (should be 300 psi. for high pressure TSC , and 140 psi. for old

system), with a standard (non-TSC) tool holder in spindle. If pump pressure is above 310 psi.
(above 140 psi for old system), reset the pump relief valve in accordance with the "Setting TSC
Pump Relief Valve" section.

Excessive coolant flow out of drain line.
Pulsating flow through tool and drain line.

 Check precharge pressure in accordance with TSC "Pressure Regulator Adjustment" section.

Reset precharge pressure if necessary. Low precharge pressure will cause heavy or pulsating
flow from the drain line.

 Ensure the coolant pump relief valve has not been tampered with (yellow paint band is intact).

Check the coolant pump pressure (should be 300psi. for high pressure TSC, and 140 psi. for old
system), with a standard (non-TSC) tool holder in spindle. If pump pressure is above 310 psi (above
140 psi. for old system), reset pump relief valve in accordance with "Setting Pump Relief Valve"
section.

96-8100 rev C

37

TROUBLESHOOTING

LOW COOLANT

Alarm 151, "Low Thru Spindle Coolant"

 Check coolant tank level.
 Check for slow coolant drainage from machine enclosure.
 Read the filter gauges and check the intake strainer to ensure there is no clogging. Read gauges

with TSC running with no tool in spindle. Check coolant lines for any clogging or kinking. Clean or
replace as needed.

 If received at start-up, check that the breaker hasn't tripped and that the pump is turning. Check

the electrical continuity of cables.

 Check for overheating TSC motor. Single phase motors have a built in thermal cut out. Three phase

TSC motors have a thermal circuit that interrupts power to the relay coil.

 For old TSC system, if the drawbar was replaced, check that the hole through the drawbar is 0.156

dia. not 0.190 dia. Replace if it is 0.190.

 Check for pressure switch failure (refer to "Testing the Coolant Pressure Switch" section), and

replace if necessary. Check "LO CLNT" bit in the diagnostics display (0 = pressure on, 1= pres
sure off). Leaking pressure switches can also give intermittent alarms.

 Check the pump pressure with TSC running and no tool in the spindle. Normal pressure is 75-95

PSI. Replace the pump if pressure is 60 psi or less.

 Another alarm generated during TSC operation can cause this alarm.

June 2001

COOLANT TIP WEAR

The carbide coolant tip should last for the life of the machine. The old bronze coolant
tip should be checked every 1000 hours of TSC operation.

Coolant tip is wearing quickly and needs frequent replacement.

 Check the filtration system and that the coolant is not contaminated.
 Check precharge pressure (refer to the TSC Pressure Regulator Adjustment" section). Heavy

wear will occur if this pressure is too high.

 Main air supply below 85 psi can cause excessive precharge pressure and heavy coolant tip

wear.

NOTE: Abrasive swarf from grinding or ceramic machining operations will cause

heavy wear of TSC coolant pump, coolant tip and drawbar. This is not covered
by the warranty. Notify HAAS Service Dept. if machine is being used for this
application.

38

96-8100 rev C

June 2001

TROUBLESHOOTING

PRE-CHARGE FAILURE

Alarm 198, "Precharge Failure"

NOTE: This alarm only applies to the TSC system. This alarm does not apply to 50

taper spindle machines. If this alarm is received on a 50 taper TSC machine,
check that parameter 235 is set to zero. A non-zero value will cause the control
to act as a 40 taper TSC.

 Check for broken or disconnected precharge air line, and replace if necessary.
 Check if the "Tool Clamped" limit switch is sticking, and replace if necessary.
 Check the "Tool Clamped" limit switch adjustment (refer to "Tool Clamp/Unclamp Switch Adjust

ment").

 Check for low precharge pressure (refer to "Pressure Regulator Adjustment" section).
 Check precharge solenoid for proper operation.
 May be generated if another alarm occurs during TSC operation.

96-8100 rev C

39

TROUBLESHOOTING

1.7 CHIP CONVEYOR

Chip conveyor does not turn

 Check that Parameter 209 bit switch ENA CNVR is enabled.
 Check that the front enclosure door is completely closed and door switches function properly.
 Check that hub is connected to auger with bolt.
 Check that all conveyor fuses are intact. [Single phase motor uses 2 fuses (VF-0,1/2 ; Three

phase motor uses 3 fuse (VF-3,4,6,8)]

 Check thermal reset button on conveyor motor body.

June 2001

NOTE: Thermal reset indicates further problems: Ensure conveyor is not jammed, all

Chip conveyor is moving in the wrong direction

necessary fuses are intact, check motor connector and I/O Board conveyor
relays

 Toggle Parameter 209 bit switch REV CNVR to reverse direction of conveyor.
 Check I/O Board conveyor relays.

Chip conveyor reverses, then shuts down

 Check that the conveyor is free of obstruction.
 Check that Parameters are at Default settings.
 Check that Discrete Input CNVYR (conveyor overload) cycles from 0 - 1 or 1 - 0 (0 means overload

condition).

NOTE: If it does cycle check the motor for burnout or binding. If it does not cycle check

the I/O board.

40

96-8100 rev C

June 2001

1.8 HYDRAULIC COUNTERBALANCE

Fill Valve

Pressure
Gauge

TROUBLESHOOTING

Hydraulic
Tank

Pressure
Switch
Cable

Pressure
Switch

120

140

100

80

160

psi

0

60

20

40

Outlet

Manifold

Hydraulic Tank Assembly

TOP OF TRAVEL PRESSURE

A reference table is listed below indicating top of travel pressure and switch setting pressure for each machine.

Machine Top of Travel Pressure (PSI) Switch Setting Pressure (PSI)

VF-E-2 750 600
VF-3, 4 1150 900
VF-5/40 875 750
VF-5/50 1100 1000
VF-6/40  11/40 750 600
VF-6/50, 7/50, 10/50 1150 900
VF-8/50, 9/50, 11/50 1550 1400
VR-11 1100 1000
VB-1 1550 1400
HS-1, 15AXT, 1R, 1RP 600 450
HS-3, 3R 1150 1000

Pressure

96-8100 rev C

TROUBLESHOOTING

The table below lists observable machine conditions and their probable cause. Find the appropriate corrective
action step to fix the observed faults.

41

TROUBLESHOOTING

June 2001

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Corrective Action

Tools Required

1. Check for sufficient oil in system: Block spindle head at top of travel. Attach charge/discharge kit
to schrader valve, slowly turn t-handle clockwise to begin releasing pressure and make one of the
following observations:

a) If oil is immediately present stop discharging, there is sufficient oil in the system. There

b) If nitrogen gas is immediately present stop discharging and proceed to Corrective Action 2.

Hand tools.

Charge/Discharge Kit P/N 35-4050A
Hydraulic Hand Pump Kit P/N 93-0206

are two courses of action at this point; add nitrogen to system to obtain top of travel
pressure specification. This step may last indefinitely depending on the severity of the
leak, or what caused it. The second course of action is to proceed to Corrective Action 2 if
it is felt that the leak is substantial.

There is not enough oil in the system.

42

96-8100 rev C

June 2001

TROUBLESHOOTING

2. Block spindle head at bottom of travel (if the cylinder is to be replaced block the head in the lowest
position that will permit access to the rod attachment).

a) Carefully drain remaining gas and oil.

b) Replace faulty component(s). (SAE straight thread o-ring fittings are to be lubricated with a

film of hydraulic oil prior to install) Note that machines built after August, 1999 use straight
thread fittings with o-rings, and sealed connectors on the switch wires. Earlier machines
have pipe thread connections. Replacing older style components with newer style requires
that all components of the counter balance system be changed as well as the cable back
to the control.

c) Pump new Mobil DTE-25 oil (see chart for qty.) into system using Hydraulic Hand Pump

Kit. (see Hydraulic Hand Pump Instructions below).

Machine Quarts of Mobile DTE-25 # of Pump Strokes
VF-E-11, VR-11, HS-1 2 per tank 93
VB-1, HS-3 3 per tank 0140

d) Pressurize with nitrogen using charge/discharge kit to spec. at top of travel.

3. Add 50 psi of nitrogen to the system at top of travel.

Does the alarm clear?

Yes: Now check if the head drifts up more than 1 upon E-stop at the bottom of travel. If it

does then replace the switch as described in corrective action 2.

No: Add another 50 psi to the system at top of travel. If the alarm still does not clear replace

the switch as described in corrective action 2. If the alarm clears check if the head drifts
up more than 1 upon E-stop at the bottom-of-travel. If it does then replace the switch as
described in corrective action 2.

4. If the counter balance system pressure is ok and there is an E-stop alarm that wont reset check
the cable for dirty contacts. Loose connections or broken wire can be tested by disconnecting the
cable at the switch and adding a jumper across the connector pins of the cable and clear the
alarm. If the alarm does not clear the cable is defective. Repair or replace the cable if necessary.

5. Check I/O board and replace if necessary.

96-8100 rev C

6. Test for short in cable. Repair or replace if necessary.

7. Does spindle head drift down from top of travel upon E-stop?

Yes: Replace switch as described in corrective action 2.
No: Replace pressure gauge as described in corrective action 2.

8. Invert tank to bleed about 50 psi of nitrogen gas. Re-evaluate machine condition.

43

TROUBLESHOOTING

LEAK FAILURES

Leaks can occur at any fitting connection, at the hydraulic cylinders rod seal (where the rod enters
the cylinder), at the cylinders piston seal, or through hose failures. Inspections for leaks are visual
although rod seal leaks may be inconclusive because of way oil spatter. Piston seal leaks, if ad­vanced, exit the top end of the cylinder and oil can be seen at the vent area. Early piston leaks
accumulate over time on top of the piston to about ¾ high before they are pushed out the cylinder
at top of travel. Leaks are normally very slow and machines can operate until the pressure switch
sends an E-stop alarm.

MECHANICAL DIAGNOSIS

Important! Hydraulic counterbalance oil contains red dye for easier recognition.

Noise in the system

 Slight moan or creaking at slow speeds is normal for rubber seals.
 While Z-axis is in motion a whistle sound at tank location is normal fluid flow.
 Verify cylinder is seated correctly in counterbore. If not then reseat the cylinder.
 Bumping or grinding noise indicates a mechanical cylinder failure. Replace cylinder assembly.
 Look for galling and wear on cylinder shaft. If so replace the cylinder assembly.

June 2001

System is not holding pressure and/or has an E-STOP (Alarm 107) that cannot be reset.

Check for accurate pressure readings. If low then the following items need to be checked:

 Check for leaks at all cylinder fittings. If leaking then replace cylinder assembly.
 Collapse the lower Z-axis waycover and look for any red oil pooled at the bottom of the base. If so,

then fittings or seals could be damaged. Replace cylinder assembly.

 Remove cylinder vent fitting. If there is red oil inside the vent cavity then the cylinder assembly

needs replacement.

 Check for leaks at all hydraulic tank fittings. If leaking then tank assembly needs replacement.

Over Current alarms

 Pressure is set too high.
 Pressure is set too low.
 Too much oil has been added. (Insufficient gas volume causes large pressure rise)
 Hydraulic cylinder is binding or is misaligned. Replace cylinder assembly.
 Length of replacement cylinder incorrect.

44

96-8100 rev C

June 2001

TROUBLESHOOTING

1.9 LINEAR SCALES

If any linear scale faults (alarms 279-290) are detected, contact the Haas service Department.

The following information is needed in order to properly diagnose the machine:

List of the faults and the dates
Any pertinent information on the conditions and circumstances surrounding the fault
All machine parameters
Software version
Machine serial number

Do not attempt to adjust or inspect the scale without notifying the service department.

1.10 AUTOMATIC PALLET CHANGER

Checking pallet repeatability on to the receiver.

 Maximum tolerance is .+/-0005.
 Pallets are not considered repeatable from one to the other. Pallets should use separate offsets.
 If pallet is out of tolerance check the alignment pins on the receiver base and bushings on the

bottom side of the clamp rails for damage.

 Check the height of the alignment pins on the receiver base, the top of the pin should be .450 to

.490 above the receiver base.

 If the alignment pins are out of the receiver body, check the depth of the hole. Depth should be

.510 to .550.

Sticking Pallet.

 Check for chips around the alignment pins or pallet clamp rail bushings.
 Check the torque on the bolts that fasten the clamp rails to the pallet. If the bolts are loose

realign the pallet according to the instructions in the APC section of Mechanical Service.

APC not responding to controller commands.

 If the APC does not run but the mill does, check the APC control cable.
 Make sure the E-Stop jumper is removed and that the APC control cable is plugged into the

5th axis port tightly.

96-8100 rev C

45

TROUBLESHOOTING

Recovery from an E-Stop initiated during a pallet change

June 2001

46

96-8100 rev C

June 2001

TROUBLESHOOTING

Figure 1

Pallet known locations. Pallet 1 is on the receiver and engaging

the Pallet Clamped switch. Pallet 2 is on the APC and engaging

the Pallet Home Switch under the control panel.

96-8100 rev C

Figure 2

Alignment Pin and Bushing alignment must be verified

when manually positioning a pallet on the receiver.

47

TROUBLESHOOTING

Chain/Sprocket
Rotation Tool

Pin Clear
Switch

Pallet Home
Switches

Figure 3
With pallet 2 clamped on the receiver, the trip
block must be engaging the switch as shown.

Trip Block

Pin Clear
Switch

Pallet Drive
Leg

June 2001

48

Figure 4

Press and hold the solenoid actuation buttons to

keep air pressure flowing to unclamp the receiver

and hold the door open. If the buttons are released

the door will close and the receiver will clamp.

96-8100 rev C

June 2001

TROUBLESHOOTING

1.11 ELECTRICAL TROUBLESHOOTING

CAUTION! Before working on any electrical components, power off the machine and

ELECTRICAL ALARMS

wait approximately 10 minutes. This will allow the high voltage 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, 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. Replace amplifier.
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.

96-8100 rev C

49

TROUBLESHOOTING

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.

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.

June 2001

Alarm 101, "MOCON Comm. Failure"

 During a self-test of communications between the MOCON and main processor, the main

processor does not respond, and is suspected to be dead. This alarm is generated and the servos
are stopped. Check all ribbon cable connections, and all grounding. Machine noise can also
cause this alarm, although it is less common.

Alarm 157, "MOCON Watchdog Fault"

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

Alarm 222, C Phasing Error

 If this alarm occurs on a VB-1, it is probably because parameter 176 bit 3 (SP AXIS DISABLED) is

set to 0. It should be set to 1.

Rotary CRC Error Alarm 261

 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.

50

96-8100 rev C

June 2001

TROUBLESHOOTING

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.

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.

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.

96-8100 rev C

51

TROUBLESHOOTING

PROCESSOR STACK 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 low voltage cable from the MOTIF PCB

 Processors LED's are normal then RUN goes out
 No screen

Remove the Data & or Address buss from the Video & Keyboard PCB

 Processors LED's Normal - then Run goes out

June 2001

Remove the Data & or Address buss from the MOTIF 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

52

96-8100 rev C

June 2001

TROUBLESHOOTING

KEYBOARD DIAGNOSTIC

NOTE: Refer to the "Cable Locations" section of this manual for a drawing of the

Keyboard Interface PCB.

96-8100 rev C

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.

53

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

June 2001

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 your 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 protocols 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.

54

If an Error 53 is still present, restore the protocol.ini file to its previous state and do the following to the NT
server:

96-8100 rev C

June 2001

1. Open the control panel

2. Double click on the Network icon

3. Select the Protocols tab.

4. Highlight NWLINK IPX/SPX Compatible Transport.

5. Select properties.

6. Select Manual Frame Type Detection.

7. Click on Add.

8. Select Ethernet 802.2

9. Click on Add.

10. Click OK.

11. Close all windows and reboot the NT server.

Once the NT server is rebooted the NWLINK IPX/SPX Compatible Transport Frames is set to 802.2 and
the mill will be able to see the desired server.

Mill code will not work

Make sure the command in the ser ver routes back to the mill.

TROUBLESHOOTING

96-8100 rev C

55

ALARMS

2. ALARMS

Any time an alarm is present, the lower right hand corner of the screen will have a blinking "ALARM". Push
the ALARM display key to view the current alarm. All alarms are displayed with a reference number and a
complete description. If the RESET key is pressed, one alarm will be removed from the list of alarms. If
there are more than 18 alarms, only the last 18 are displayed and the RESET must be used to see the
rest. The presence of any alarm will prevent the operator from starting a program.

The ALARMS DISPLAY can be selected at any time by pressing the ALARM MESGS button. When there
are no alarms, the display will show NO ALARM. If there are any alarms, they will be listed with the most
recent alarm at the bottom of the list. The CURSOR and PAGE UP and PAGE DOWN buttons can be used
to move through a large number of alarms. The CURSOR right and left buttons can be used to turn on and
off the ALARM history display.

Note that tool changer alarms can be easily corrected by first correcting any mechanical problem, pressing
RESET until the alarms are clear, selecting ZERO RET mode, and selecting AUTO ALL AXES. Some
messages are displayed while editing to tell the operator what is wrong but these are not alarms. See the
editing topic for those errors.

The following alarm list shows the alarm numbers, the text displayed along with the alarm, and a detailed
description of the alarm, what can cause it, when it can happen, and how to correct it.

June 2001

Alarm number and text: Possible causes:

101 Comm. Failure with MOCON During a self-test of communications between the MOCON and

main processor, the main processor does not respond, one of
them is possibly bad. Check cable connections and boards.

102 Servos Off Indicates that the servo motors are off, the tool changer is

disabled, the coolant pump is off, and the spindle motor is
stopped. Caused by EMERGENCY STOP, motor faults, tool
changer problems, or power fail.

103 X Servo Error Too Large Too much load or speed on X-axis motor. The difference between

the motor position and the commanded position has exceeded a
parameter. The motor may also be stalled, disconnected, or the
driver failed. The servos will be turned off and a RESET must be
done to restart. This alarm can be caused by problems with the
driver, motor, or the slide being run into the mechanical stops.

104 Y Servo Error Too Large Same as alarm 103.

105 Z Servo Error Too Large Same as alarm 103.

106 A Servo Error Too Large Same as alarm 103.

107 Emergency Off EMERGENCY STOP button was pressed. After the E-STOP is

released, the RESET button must be pressed once to correct
this to clear the E-STOP alarm.
This alarm will also be generated if there is a low pressure
condition in the hydraulic counterbalance system. In this case,
the alarm will not reset until the condition has been corrected.

56

96-8100 rev C

June 2001

ALARMS

108 X Servo Overload Excessive load on X-axis motor. This can occur if the load on the

motor over a period of several seconds or even minutes is large
enough to exceed the continuous rating of the motor. The servos
will be turned off when this occurs. This can be caused by
running into the mechanical stops but not much past them. It can
also be caused by anything that causes a very high load on the
motors.

109 Y Servo Overload Same as alarm 108.

110 Z Servo Overload Same as alarm 108.

111 A Servo Overload Same as alarm 108.

112 No Interrupt Electronics fault. Call your dealer.

113 Shuttle In Fault Tool changer is not completely to right. During a tool changer

operation the tool in/out shuttle failed to get to the IN position.
Parameters 62 and 63 can adjust the time-out times. This alarm
can be caused by anything that jams the motion of the slide or by
the presence of a tool in the pocket facing the spindle. A loss of
power to the tool changer can also cause this. Check relays K9­K12, and fuse F1 on IOPCB.

114 Shuttle Out Fault Tool changer not completely to left. During a tool change

operation the tool in/out shuttle failed to get to the OUT position.
Parameters 62 and 63 can adjust the time-out times. This alarm
can be caused by anything that jams the motion of the slide or by
the presence of a tool in the pocket facing the spindle. A loss of
power to the tool changer can also cause this. Check relays K9­K12, and fuse F1 on IOPCB.

115 Turret Rotate Fault Tool carousel motor not in position. During a tool changer

operation the tool turret failed to start moving, failed to stop
moving or failed to stop at the right position. Parameters 60 and
61 can adjust the time-out times. This alarm can be caused by
anything that jams the rotation of the turret. A loss of power to the
tool changer can also cause this. Check relays K9-K12, and fuse
F1 on IOPCB.

116 Spindle Orientation Fault Spindle did not orient correctly. This is either a vector drive

problem or a mechanical problem on machines without a vector
drive. During a spindle orientation function, the spindle is
rotated until the lock pin drops in; but the lock pin never dropped.
Parameters 66, 70, 73, and 74 can adjust time-out timers. This
can be caused by a trip of circuit breaker CB4, a lack of air
pressure, or too much friction with the orientation pin.

117 Spindle High Gear Fault Gearbox did not shift into high gear. During a change to high

gear, the spindle is rotated slowly while air pressure is used to
move the gears but the high gear sensor was not detected in
time. Parameters 67, 70 and 75 can adjust the time-out times.
Check the air pressure, circuit breaker CB4,the circuit breaker for
the air pressure solenoids, and the spindle drive.

96-8100 rev C

57

ALARMS

118 Spindle Low Gear Fault Gearbox did not shift into low gear. During a change to low gear,

the spindle is rotated slowly while air pressure is used to move
the gears but the low gear sensor was not detected in time.
Parameters 67, 70 and 75 can adjust the time-out times. Check
the air pressure, the solenoids circuit breaker CB4, and the
spindle drive.

119 Over Voltage Incoming line voltage is above maximum. The spindle, tool

changer, and coolant pump will stop. If this condition persists, an
automatic shutdown will begin after the interval specified by
parameter 296.

120 Low Air Pressure Air pressure dropped below 80 PSI for a period defined by

Parameter 76. The LOW AIR PR alarm will appear on the screen
as soon as the pressure gets low, and this alarm appears after
some time has elapsed. Check your incoming air pressure for at
least 100 PSI and ensure that the regulator is set at 85 PSI.

121 Low Lube or Low Pressure Way lube is low or empty or there is no lube pressure or too high

a pressure. Check tank at rear of mill and below control cabinet.
Also check connector on the side of the control cabinet. Check
that the lube lines are not blocked.

122 Regen Overheat The regenerative load temperature is above a safe limit. This

alarm will turn off the spindle drive, coolant pump, and tool
changer. One common cause of this overheat condition is an
input line voltage too high. If this condition persists, an automatic
shutdown will begin after the interval specified by parameter 297.
It can also be caused by a high start/stop duty cycle of spindle.

June 2001

123 Spindle Drive Fault Failure of spindle drive, motor or regen load. This can be caused

by a shorted motor, overvoltage, overcurrent, undervoltage, failure
of drive, or shorted or open regen load. Undervoltage and
overvoltage of DC bus are also reported as alarms 160 and 119,
respectively.

124 Low Battery Memory batteries need replacing within 30 days. This alarm is

only generated at power on and indicates that the 3.3 volt Lithium
battery is below 2.5 volts. If this is not corrected within about 30
days, you may lose your stored programs, parameters, offsets,
and settings.

125 Shuttle fault Tool shuttle not initialized at power on, CYCLE START or spindle

motion command. This means that the tool shuttle was not fully
retracted to the Out position.

126 Gear Fault Gearshifter is out of position when a command is given to start a

program or rotate the spindle. This means that the two speed
gear box is not in either high or low gear but is somewhere in
between. Check the air pressure, the solenoids circuit breaker
CB4, and the spindle drive. Use the POWER UP/RESTART
button to correct the problem.

127 No Turret Mark Tool carousel motor not in position. The turret motor only stops in

one position indicated by a switch and cam on the Geneva
mechanism. This alarm is only generated at power-on. The
AUTO ALL AXES button will correct this but be sure that the pocket
facing the spindle afterwards does not contain a tool.

58

96-8100 rev C

June 2001

ALARMS

129 M Fin Fault M-Fin was active at power on. Check the wiring to your M code

interfaces. This test is only performed at power-on.

130 Tool Unclamped The tool appeared to be unclamped during spindle orientation, a

gear change, a speed change, or TSC start-up. The alarm will
also be generated if the tool release piston is energized during
Power Up. This can be caused by a fault in the air solenoids,
relays on the I/O assembly, the drawbar assembly, or in the
wiring.

131 Tool Not Clamped When clamping or powering up the machine, the Tool Release

Piston is not HOME. This is a possible fault in the air solenoids,
relays on the IO Assembly, the drawbar assembly, or wiring.

132 Power Down Failure Machine did not turn off when an automatic power-down was

commanded. Check wiring to POWIF card on power supply
assembly, relays on the IO assembly, and the main contactor K1.

133 Spindle Locked Shot pin did not release. This is detected when spindle motion is

commanded. Check the solenoid that controls the air to the lock,
relay K16, the wiring to the sense switch, and the switch.

134 Tool Clamp Fault When UNCLAMPING, the tool did not release from spindle when

commanded. Check air pressure and solenoid circuit breaker
CB4. Can also be caused by misadjustment of drawbar
assembly.

135 X Motor Over Heat Servo motor overheat. The temperature sensor in the motor

indicates over 150 degrees F. This can be caused by an
extended overload of the motor such as leaving the slide at the
stops for several minutes.

136 Y Motor Over Heat Same as alarm 135.

137 Z Motor Over Heat Same as alarm 135.

138 A Motor Over Heat Same as alarm 135.

139 X Motor Z Fault Encoder marker pulse count failure. This alarm usually indicates

that the encoder has been damaged and encoder position data
is unreliable. This can also be caused by loose encoder
connectors.

140 Y Motor Z Fault Same as alarm 139.

141 Z Motor Z Fault Same as alarm 139.

142 A Motor Z Fault Same as alarm 139.

143 Spindle Not Locked Vector drive orientation lost or shot pin not fully engaged when a

tool change operation is being performed. Check air pressure
and solenoid circuit breaker CB4. This can also be caused by a
fault in the sense switch that detects the position of the lock pin.

96-8100 rev C

144 Time-out- Call Your Dealer Time allocated for use prior to payment exceeded. Call your

dealer.

59

ALARMS

145 X Limit Switch Axis hit limit switch or switch disconnected. This is not normally

possible as the stored stroke limits will stop the slides before
they hit the limit switches. Check the wiring to the limit switches
and connector P5 at the side of the main cabinet. Can also
be caused by a loose encoder shaft at the back of the motor or
coupling of motor to the screw.

146 Y Limit Switch Same as alarm 145

147 Z Limit Switch Same as alarm 145

148 A Limit Switch Normally disabled for rotary axis.

149 Spindle Turning Spindle not at zero speed for tool change. A signal from spindle

drive indicating that the spindle drive is stopped is not present
while a tool change operation is going on.

150 Z and Tool Interlocked Changer not at home and either the Z or A or B axis (or any

combination) is not at zero. If RESET, E-STOP, or POWER OFF
occurs during tool change, Z-axis motion and tool changer
motion may not be safe. Check the position of the tool changer
and remove the tool if possible. Re-initialize with the AUTO ALL
AXES button but be sure that the pocket facing the spindle
afterwards does not contain a tool.

June 2001

151 Low Thru Spindle Coolant For machines with Through the Spindle Coolant only. This alarm

will shut off the coolant spigot, spindle and pump all at once. It
will turn on purge, wait for the amount of time specified in
parameter 237 for the coolant to purge, and then turn off the
purge. Check for low coolant tank level, any filter or intake
strainer clogging, or for any kinked or clogged coolant lines. If no
problems are found with any of these, and none of the coolant
lines are clogged or kinked, call your dealer. Verify proper pump
and machine phasing.

152 Self Test Fail Control has detected an electronics fault. All motors and

solenoids are shut down. This is most likely caused by a fault of
the processor board stack at the top left of the control. Call your
dealer.

153 X-axis Z Ch Missing Z reference signal from encoder was not received as expected.

Likely encoder contamination or parameter error.

154 Y-axis Z Ch Missing Same as alarm 153.

155 Z-axis Z Ch Missing Same as alarm 153.

156 A-axis Z Ch Missing Same as alarm 153.

157 MOCON Watchdog Fault The self-test of the MOCON has failed. Replace the MOCON.

60

158 Video/Keyboard PCB Failure Internal circuit board problem. The VIDEO PCB in the processor

stack is tested at power-on. This could also be caused by a short
in the front panel membrane keypad. Call your dealer.

96-8100 rev C

June 2001

ALARMS

159 Keyboard Failure Keyboard shorted or button pressed at power on. A power-on test

of the membrane keypad has found a shorted button. It can also
be caused by a short in the cable from the main cabinet or by
holding a switch down during power-on.

160 Low Voltage The line voltage to control is too low. This alarm occurs when the

AC line voltage drops more than 10% below nominal.

161 X-Axis Drive Fault Current in X servo motor beyond limit. Possibly caused by a

stalled or overloaded motor. The servos are turned off. This can
be caused by running a short distance into a mechanical stop. It
can also be caused by a short in the motor or a short of one
motor leads to ground.

162 Y-Axis Drive Fault Same as alarm 161.

163 Z-Axis Drive Fault Same as alarm 161.

164 A-Axis Drive Fault Same as alarm 161.

165 X Zero Ret Margin Too Small This alarm will occur if the home/limit switches move or are

misadjusted.

This alarm indicates that the zero return position may not be
consistent from one zero return to the next. The encoder Z
channel signal must occur between 1/8 and 7/8 revolution of
where the home switch releases. This will not turn the servos off
but will stop the zero return operation.

166 Y Zero Ret Margin Too Small Same as alarm 165.

167 Z Zero Ret Margin Too Small Same as alarm 165.

168 A Zero Ret Margin Too Small This alarm will occur if the home/limit switches move or are

misadjusted. This alarm indicates that the zero return position
may not be consistent from one zero return to the next. The
encoder Z channel signal must occur between 1/8 and 7/8
revolution of where the home switch releases. This will not turn
the servos off but will stop the zero return operation.

169 Spindle Direction Fault Problem with rigid tapping hardware. The spindle started turning

in the wrong direction.

170 Phase Loss Problem with incoming line voltage. This usually indicates that

there was a transient loss of input power to the machine.

173 Spindle Ref Signal Missing The Z channel pulse from the spindle encoder is missing for

hard tapping synchronization.

96-8100 rev C

174 Tool Load Exceeded The tool load monitor option is selected and the maximum load

for a tool was exceeded in a feed. This alarm can only occur if the
tool load monitor function is installed in your machine.

175 Ground Fault Detected A ground fault condition was detected in the 115V AC supply. This

can be caused by a short to ground in any of the servo motors,
the tool change motors, the fans, or the oil pump.

61

ALARMS

176 Over Heat Shutdown An overheat condition persisted longer than the interval specified

by parameter 296 and caused an automatic shutdown.

177 Over Voltage Shutdown An overvoltage condition persisted longer than the interval

specified by parameter 296 and caused an automatic shutdown.

178 Divide by Zero Software Error; Call your dealer.

179 Low Pressure Transmission Oil Spindle coolant oil is low or low pressure condition in lines.

180 Pallet Not Clamped The APC pallet change was not completed for some reason

(pressing E-stop, reset, or feedhold), and an attempt was made
to run the spindle. Run M50 pallet change to reset the machine.

182 X Cable Fault Cable from X-axis encoder does not have valid differential

signals.

183 Y Cable Fault Same as alarm 182.

184 Z Cable Fault Same as alarm 182.

185 A Cable Fault Same as alarm 182.

June 2001

186 Spindle Not Turning Status from spindle drive indicates it is not at speed when

expected.

187 B Servo Error Too Large Same as alarm 103.

188 B Servo Overload Same as alarm 108.

189 B Motor Overheat Same as alarm 135.

190 B Motor Z Fault Encoder marker pulse count failure. This alarm usually indicates

that the encoder has been damaged and encoder position data
is unreliable. This can also be caused by loose encoder
connectors.

191 B Limit Switch Same as alarm 148.

192 B Axis Z Ch Missing Z reference signal from encoder was not received as expected.

Likely encoder contamination or parameter error.

193 B Axis Drive Fault Same as alarm 161.

62

194 B Zero Ret Margin Too Small This alarm will occur if the home/limit switches move or are

misadjusted. This alarm indicates that the zero return position
may not be consistent from one zero return to the next. The
encoder Z channel signal must occur between 1/8 and 7/8
revolution of where the home switch releases. This will not turn
the servos off but will stop the zero return operation.

195 B Cable Fault Same as alarm 182.

96-8100 rev C

June 2001

ALARMS

196 Coolant Spigot Failure Vertical mills only. Spigot failed to achieve commanded location

after two (2) attempts.

197 100 Hours Unpaid Bill Call your dealer.

198 Precharge Failure During TSC operation, the precharge failed for greater than 0.1

seconds. It will shut off the feed, spindle and pump all at once. If
received, check all air lines and the air supply pressure.

199 Negative RPM A negative spindle RPM was sensed.

201 Parameter CRC Error Parameters lost. Check for a low battery and low battery alarm.

202 Setting CRC Error Settings lost. Check for a low battery and low battery alarm.

203 Lead Screw CRC Error Lead screw compensation tables lost. Check for low battery and

low battery alarm.

204 Offset CRC Error Offsets lost. Check for a low battery and low battery alarm.

205 Programs CRC Error Users program lost. Check for a low battery and low battery

alarm.

206 Internal Program Error Possible corrupted program. Save all programs to floppy disk,

delete all, then reload. Check for a low battery and low battery
alarm.

207 Queue Advance Error Software Error; Call your dealer.

208 Queue Allocation Error Software Error; Call your dealer.

209 Queue Cutter Comp Error Software Error; Call your dealer.

210 Insufficient Memory Not enough memory to store users program. Check the space

available in the LIST PROG mode and possibly delete some
programs.

211 Odd Prog Block Possible corrupted program. Save all programs to floppy disk,

delete all, then reload.

212 Program Integrity Error Possible corrupted program. Save all programs to floppy disk,

delete all, then reload. Check for a low battery and low battery
alarm.

213 Program RAM CRC Error Electronics fault; possibly with main processor.

214 No. of Programs Changed Indicates that the number of programs disagrees with the

internal variable that keeps count of the loaded programs.
Possible processor board problem.

96-8100 rev C

215 Free Memory PTR Changed Indicates the amount of memory used by the programs counted

in the changed system disagrees with the variable that points to
free memory. Possible processor board problem.

216 EPROM Speed Failure Possible processor board problem.

63

ALARMS

217 X Axis Phasing Error Error occurred in phasing initialization of motor. This can be

caused by a bad encoder, or a cabling error.

218 Y Axis Phasing Error Same as alarm 217.

219 Z Axis Phasing Error Same as alarm 217.

220 A Axis Phasing Error Same as alarm 217.

221 B Axis Phasing Error Same as alarm 217.

222 C Axis Phasing Error Same as alarm 217.

223 Door Lock Failure In machines equipped with safety interlocks, this alarm occurs

when the control senses the door is open but it is locked.
Check the door lock circuit.

224 X Transition Fault Illegal transition of count pulses in X axis. This alarm usually

indicates that the encoder has been damaged and encoder
position data is unreliable. This can also be caused by loose
connectors at the MOCON or MOTIF PCB.

June 2001

225 Y Transition Fault Same as alarm 224.

226 Z Transition Fault Same as alarm 224.

227 A Transition Fault Same as alarm 224.

228 B Transition Fault Same as alarm 224.

229 C Transition Fault Same as alarm 224.

231 Jog Handle Transition Fault Illegal transition of count pulses in jog handle encoder. This

alarm usually indicates that the encoder has been damaged and
encoder position data is unreliable. This can also be caused by
loose connectors.

232 Spindle Transition Fault Illegal transition of count pulses in spindle encoder. This alarm

usually indicates that the encoder has been damaged and
encoder position data is unreliable. This can also be caused by
loose connectors at the MOCON.

233 Jog Handle Cable Fault Cable from jog handle encoder does not have valid differential

signals.

234 Spindle Enc. Cable Fault Cable from spindle encoder does not have valid differential

signals.

64

235 Spindle Z Fault Encoder marker pulse count failure. This alarm usually indicates

that the encoder has been damaged and encoder position data
is unreliable. This can also be caused by loose encoder
connectors.

236 Spindle Motor Overload This alarm is generated in machines equipped with a Haas

vector drive, if the spindle motor becomes overloaded.

96-8100 rev C

June 2001

ALARMS

237 Spindle Following Error The error between the commanded spindle speed and the

actual speed has exceeded the maximum allowable (as set in
Parameter 184).

238 Door Fault The control failed to detect a low signal at the Door Switch when

the door was commanded to close, or a high signal at the Door
Switch when the door was commanded to open after the time
allowed.

240 Empty Prog or No EOB DNC program not found, or no end of program found.

241 Invalid Code RS-232 load bad. Data was stored as comment. Check the

program being received.

242 No End Check input file for a number that has too many digits

243 Bad Number Data entered is not a number.

244 Missing ) Comment must end with a " ) ".

245 Unknown Code Check input line or data from RS-232. This alarm can occur

while editing data into a program or loading from RS-232. See
MESSAGE PAGE for input line.

246 String Too Long Input line is too long. The data entry line must be shortened.

247 Cursor Data Base Error Software Error; Call your dealer.

248 Number Range Error Number entry is out of range.

249 Prog Data Begins Odd Possible corrupted program. Save all programs to floppy disk,

delete all, then reload.

250 Program Data Error Same as alarm 249.

251 Prog Data Struct Error Same as alarm 249.

252 Memory Overflow Same as alarm 249.

253 Electronics Overheat The control box temperature has exceeded 135 degrees F. This

can be caused by an electronics problem, high room
temperature, or clogged air filter.

254 Spindle Overheat The motor driving spindle is too hot. The spindle motor

temperature sensor sensed a high temperature for greater than

1.5 seconds.

255 No Tool In Spindle There is an invalid tool number in the spindle entry of the

POCKET-TOOL table. The spindle entry cannot be 0 and must
be listed in the body of the table. If there is no tool in the spindle,
enter the number for an empty pocket into the spindle entry. If
there is a tool number in the spindle entry, make sure that it is in
the body of the table and that the pocket is empty.

96-8100 rev C

257 Program Data Error Possible corrupted program. Save all programs to floppy disk,

delete all, then reload. Possible processor board problem.

258 Invalid DPRNT Format Macro DPRNT statement not structured properly.

65

ALARMS

259 Language Version Possible processor board problem.

260 Language CRC Indicates FLASH memory has been corrupted or damaged.

Possible processor board problem.

261 Rotary CRC Error Rotary table saved parameters (used by Settings 30, 78) have a

CRC error. Indicates a loss of memory - possible processor
board problem.

262 Parameter CRC Missing RS-232 or disk read of parameter had no CRC when loading

from disk or RS-232.

263 Lead Screw CRC Missing Lead screw compensation tables have no CRC when loading

from disk or RS-232.

264 Rotary CRC Missing Rotary table parameters have no CRC when loading from disk or

RS-232

265 Macro Variable File CRC Error Macro variable file has a CRC error. Indicates a loss of memory.

Possible processor board problem.

266 Tool Changer Fault Run Toolchanger Recovery.

June 2001

267 Tool Door Out of Position Horizontal mills only. Alarm will be generated during a tool

change when parameter 278 TC DR SWITCH is set to 1, and the
tool carousel air door and the tool carousel air door switch
indicates that the door is open after commanded to be closed, or
closed after it was commanded to be open. This alarm will most
likely be caused by a stuck or broken switch.

268 Door open @ M95 Start Generated whenever an M95 (Sleep Mode) is encountered and

the door is open. The door must be closed in order to start sleep
mode

269 TOOL ARM FAULT The toolchanger arm is not in position. Run Toolchanger

Recovery.

270 C Servo Error Too Large Same as alarm 103.

271 C Servo Overload Same as alarm 108.

272 C Motor Overheat Same as alarm 135.

273 C Motor Z Fault Encoder marker pulse count failure. This alarm usually indicates

that the encoder has been damaged and encoder position data
is unreliable. This can also be caused by loose encoder
connectors.

66

274 C Limit Switch Same as alarm 145.

275 C Axis Z Ch Missing Z reference signal from encoder was not received as expected.

Likely encoder contamination or parameter error.

276 C Axis Drive Fault Same as alarm 161.

277 C Zero Ret Margin Too Small Same as alarm 165.

96-8100 rev C

June 2001

ALARMS

278 C Cable Fault Same as alarm 182.

279 X Axis Linear Scale Z Fault Encoder marker pulse count failure. This alarm usually indicates

that the Z Fault encoder has been damaged and encoder
position data is unreliable. This can also be caused by loose
scale connectors.

280 Y Axis Linear Scale Z Fault Encoder marker pulse count failure. This alarm usually indicates

that the Z Fault encoder has been damaged and encoder
position data is unreliable. This can also be caused by loose
scale connectors.

281 Z Axis Linear Scale Z Fault Encoder marker pulse count failure. This alarm usually indicates

that the Z Fault encoder has been damaged and encoder
position data is unreliable. This can also be caused by loose
scale connectors.

282 A Axis Linear Scale Z Fault Encoder marker pulse count failure. This alarm usually indicates

that the Z Fault encoder has been damaged and encoder
position data is unreliable. This can also be caused by loose
encoder connectors.

283 X Axis Linear Scale Z CH Missing Broken wires or encoder contamination. All servos are turned off.

This Z Channel Missing can also be caused by loose scale
connectors.

284 Y Axis Linear Scale Z CH Missing Broken wires or encoder contamination. All servos are turned off.

This Z Channel Missing can also be caused by loose encoder
connectors.

285 Z Axis Linear Scale Z CH Missing Broken wires or encoder contamination. All servos are turned off.

This Z Channel Missing can also be caused by loose encoder
connectors.

286 A Axis Linear Scale Z CH Missing Broken wires or encoder contamination. All servos are turned off.

This Z Channel Missing can also be caused by loose encoder
connectors.

287 X Axis Linear Scale Cable Fault Cable from X-axis scale does not have valid differential signals.

288 Y Axis Linear Scale Cable Fault Cable from Y-axis scale does not have valid differential signals.

289 Z Axis Linear Scale Cable Fault Cable from Z-axis scale does not have valid differential signals.

290 A Axis Linear Scale Cable Fault Cable from A-axis scale does not have valid differential signals.

291 Low Air Volume/Pressure During ATC An automatic tool change was not completed due to insufficient

volume or pressure of compressed air. Check air supply line.

292 320V Power Supply Fault Incomming line voltage is above maximum. The servo will be

turned off and the spindle, tool changer, and coolant pump will
stop. If this persists, an automatic shutdown will begin after the
interval specified by parameter 296.

96-8100 rev C

67

ALARMS

297 ATC Shuttle Overshoot The ATC shuttle has failed to stop within the standby position

window during a tool change. Check for a loose drive belt,
damaged or over heated motor, sticking or damaged shuttle
standby switch or shuttle mark switch, or burned ATC control
board relay contacts. Use tool changer restore to recover the
ATC, then resume normal operation.

298 ATC Double Arm Out of Position The ATC double arm mark switch, CW position switch or CCW

position switch is in an incorrect state. Check for sticking,
misaligned or damaged switches, mechanism binding,
damaged motor, or debris build up. Use tool changer restore to
recover the ATC, then resume normal operation.

299 ATC Shuttle Out of Position The ATC shuttle mark switch is in an incorrect state. Check for a

sticking, misaligned, or damaged switch, mechanism binding,
damaged motor, or debris build up. Use tool changer restore to
recover the ATC, then resume normal operation.

302 Invalid R In G02 or G03 Check your geometry. R must be greater than or equal to half the

distance from start to end within an accuracy of 0.0010 inches.

303 Invalid X, Y, or Z In G02 or G03 Check your geometry.

June 2001

304 Invalid I, J, Or K In G02 Or G03 Check your geometry. Radius at start must match radius at end

of arc within 0.001 inches (0.01 mm).

305 Invalid Q In Canned Cycle Q in a canned cycle must be greater than zero.

306 Invalid I, J, K, or Q In Canned Cycle I, J, K, and Q in a canned cycle must be greater than zero.

307 Subroutine Nesting Too Deep Subprogram nesting is limited to nine levels. Simplify your

program.

309 Exceeded Max Feed Rate Use a lower feed rate.

310 Invalid G Code G code not defined and is not a macro call.

311 Unknown Code Program contained a line of code that is not understood.

312 Program End End of subroutine reached before M99. Need an M99 to return

from subroutine.

313 No P Code In M97, M98, or G65 In M97, M98 or G65 a subprogram number must be put in the P

code. G47 must have P0 for text engraving or P1 for sequential
serial numbers.

314 Subprogram or Macro Not In Memory Check that a subroutine is in memory or that a macro is defined.

68

315 Invalid P Code In M97, M98 or M99 The P code must be the name of a program stored in memory

without a decimal point for M98 and must be a valid N number for
M99. G47 must have P0 for text engraving or P1 for sequential
serial numbers.

316 X Over Travel Range Commanded X-axis move would exceed the allowed machine

range. Machine coordinates are in the negative direction. This
condition indicates either an error in the users program or
improper offsets.

317 Y Over Travel Range Same as alarm 316.

96-8100 rev C

June 2001

ALARMS

318 Z Over Travel Range Same as alarm 316.

319 A Over Travel Range Commanded A-axis move would exceed the allowed machine

range. Machine coordinates are in the negative direction. This
condition indicates either an error in the users program or
improper offsets.

320 No Feed Rate Specified Must have a valid F code for interpolation functions.

321 Auto Off Alarm Occurs in debug mode only.

322 Sub Prog Without M99 Add an M99 code to the end of program called as a subroutine.

324 Delay Time Range Error P code in G04 is greater than or equal to 1000 seconds (over

999999 milliseconds).

325 Queue Full Control problem; call your dealer.

326 G04 Without P Code Put a Pn.n for seconds or a Pn for milliseconds.

327 No Loop For M Code Except M97, M98 L code not used here. Remove L Code.

328 Invalid Tool Number Tool number must be between 1 and the value in Parameter 65.

329 Undefined M Code That M code is not defined and is not a macro call.

330 Undefined Macro Call Macro name O90nn not in memory. A macro call definition is in

parameters and was accessed by user program but that macro
was not loaded into memory.

331 Range Error Number too large.

332 H and T Not Matched This alarm is generated when Setting 15 is turned ON and an H

code number in a running program does not match the tool
number in the spindle. Correct the Hn codes, select the right tool,
or turn off Setting 15.

333 X-Axis Disabled Parameters have disabled this axis. Not normally possible in VF

Series CNC Mill.

334 Y-Axis Disabled Same as alarm 333.

335 Z-Axis Disabled Same as alarm 333.

336 A-Axis Disabled An attempt was made to program the A-axis while it was

disabled (DISABLED bit in Parameter 43 set to 1) or invisible
(INVIS AXIS bit in Parameter 43 set to 1).

96-8100 rev C

337 GOTO or P line Not Found Subprogram is not in memory, or P code is incorrect. P not found

338 Invalid IJK and XYZ in G02 or G03 There is a problem with circle definition; check your geometry.

339 Multiple Codes Only one M, X, Y, Z, A, Q etc. allowed in any block, only one G

codes in the same group.

340 Cutter Comp Begin With G02 or G03 Select cutter compensation earlier. Cutter comp. must begin on

a linear move.

69

ALARMS

341 Cutter Comp End With G02 or G03 Disable cutter comp later.

342 Cutter Comp Path Too Small Geometry not possible. Check your geometry.

343 Display Queue Record Full Software error. Call your dealer.

344 Cutter Comp With G18 and G19 Cutter comp only allowed in XY plane (G17).

346 Illegal M Code There was an M80 or M81 commanded. These commands are

not allowed while Setting 51 DOOR HOLD OVERRIDE is OFF.
Also check Setting 131 for Auto Door and Parameter 57 for
DOOR STOP SP.

347 Invalid or Missing E Code All 5-axis canned cycles require the depth to be specified using a

positive E code.

348 Motion Not Allowed In G93 Mode This alarm is generated if the mill is in Inverse Time Feed mode,

and a G12, G13, G70, G71, G72, G150, or any Group 9 motion
command is issued.

349 Prog Stop W/O Cancel Cutter Comp An X/Y cutter compensation exit move is required before a

program stop.

June 2001

350 Cutter Comp Look Ahead Error There are too many non-movement blocks between motions

when cutter comp is being used. Remove some intervening
blocks.

351 Invalid P Code In a block with G103 (Block Lookahead Limit), a value between 0

and 15 must be used for the P code.

352 Aux Axis Power Off Aux C, U, V, or W axis indicate servo off. Check auxiliary axes.

Status from control was OFF.

353 Aux Axis No Home A ZERO RET has not been done yet on the aux axes. Check

auxiliary axes. Status from control was LOST.

354 Aux Axis Disconnected Aux axes not responding. Check auxiliary axes and RS-232

connections.

355 Aux Axis Position Mismatch between machine and aux axes position. Check aux

axes and Mismatch interfaces. Make sure no manual inputs
occur to aux axes.

356 Aux Axis Travel Limit Aux axes are attempting to travel past their limits.

357 Aux Axis Disabled Aux axes are disabled.

358 Multiple Aux Axis Can only move one auxiliary axis at a time.

70

359 Invalid I, J, or K In G12 or G13 Check your geometry.

360 Tool Changer Disabled Check Parameter 57. Not a normal condition for VF Series CNC

Mill.

361 Gear Change Disabled Check Parameter 57. Not a normal condition for VF Series CNC

Mill.

96-8100 rev C

June 2001

ALARMS

362 Tool Usage Alarm RESET. Tool life limit was reached. To continue, reset the usage count in

the Current Commands display and press

363 Coolant Locked Off Override is off and program tried to turn on coolant.

364 No Circ Interp Aux Axis Only rapid or feed is allowed with aux axes.

367 Cutter Comp Interference G01 cannot be done with tool size.

368 Groove Too Small Tool too big to enter cut.

369 Tool Too Big Use a smaller tool for cut.

370 Pocket Definition Error Check geometry for G150.

371 Invalid I, J, K, OR Q Check G150.

372 Tool Change In Canned Cycle Tool change not allowed while canned cycle is active.

373 Invalid Code in DNC A code found in a DNC program could not be interpreted

because of DNC restrictions.

374 Missing XYZA in G31 or G36 G31 skip function requires an X, Y, Z, or A move.

375 Missing Z or H in G37 G37 automatic tool length measurement function requires H

code, Z value, and tool offset enabled. X, Y, and A values not
allowed.

376 No Cutter Comp In Skip Skip G31 and G37 functions cannot be used with cutter

compensation.

377 No Skip in Graph/Sim Graphics mode cannot simulate skip function.

378 Skip Signal Found Skip signal check code was included but skip was found when it

was not expected.

379 Skip Signal Not Found Skip signal check code was included but skip was not found

when it was expected.

380 X, Y, A, or G49 Not Allowed in G37 G37 may only specify Z-axis and must have tool offset defined.

381 G43 or G44 Not Allowed in G36 or G136 Auto work offset probing must be done without tool offset.

382 D Code Required in G35 A Dnnn code is required in G35 in order to store the measured

tool diameter.

96-8100 rev C

383 Inch Is Not Selected G20 was specified but settings have selected metric input.

384 Metric Is Not Selected G21 was specified but settings have selected inches.

385 Invalid L, P, or R G10 was used to change offsets but L, P, or R code is missing or

Code In G10 invalid.

386 Invalid Address Format An address A...Z was used improperly.

387 Cutter Comp Not Allowed With G103 If block buffering has been limited, Cutter comp cannot be used.

71

ALARMS

388 Cutter Comp Not Allowed With G10 Coordinates cannot be altered while cutter comp is active.

Move G10 outside of cutter comp enablement.

389 G17, G18, G19 Illegal in G68 Planes of rotation cannot be changed while rotation is enabled.

390 No Spindle Speed S code has not been encountered. Add an S code.

391 Feature Disabled An attempt was made to use a control feature not enabled by a

parameter bit. Set the parameter bit to 1.

392 B Axis Disabled An attempt was made to program the B-axis while it was

disabled (DISABLED bit in Parameter 151 set to 1) or invisible
(INVIS AXIS bit in Parameter 151 set to 1).

393 Invalid Motion In G74 or G84 Rigid Tapping can only be in the Z minus G74 or G84 direction.

Make sure that the distance from the initial position to the
commanded Z depth is in the minus direction.

394 B Over Travel Range Same as alarm 316.

June 2001

395 No G107 Rotary Axis A rotary axis must be specified in order to perform cylindrical

mapping Specified (G107).

396 Invalid G107 Rotary Axis Specified The rotary axis specified is not a valid axis, or has been disabled.

397 Aux Axis In G93 Block This alarm is generated if a G-code block specifies any form of

interpolated motion that involves BOTH one or more of the
regular axes (X, Y, Z, A, B, etc...) AND one or more of the auxiliary
axes (C, U, V, W).

398 Aux Axis Servo Off Aux. axis servo shut off due to a fault.

400 Skip Signal During Restart A skip signal G-code (G31, G35, G36, G37, G136) was found

during program restart.

403 RS-232 Too Many Progs Cannot have more than 200 programs in memory.

404 RS-232 No Program Name Need name in programs when receiving ALL; otherwise has no

way to store them.

405 RS-232 Illegal Prog Name Check files being loaded. Program name must be Onnnnn and

must be at beginning of a block.

406 RS-232 Missing Code A receive found bad data. Check your program. The program will

be stored but the bad data is turned into a comment.

72

407 RS-232 Invalid Code Check your program. The program will be stored but the bad

data is turned into a comment.

408 RS-232 Number Range Error Check your program. The program will be stored but the bad

data is turned into a comment.

409 RS-232 Invalid N Code Bad Parameter or Setting data. User was loading settings or

parameters and something was wrong with the data.

96-8100 rev C

June 2001

ALARMS

410 RS-232 Invalid V Code Bad parameter or setting data. User was loading settings or

parameters and something was wrong with the data.

411 RS-232 Empty Program Check your program. Between % and % there was no program

found.

412 RS-232 Unexpected End of Input Check Your Program. An ASCII EOF code was found in the input

data before program receive was complete. This is a decimal
code 26.

413 RS-232 Load Insufficient Memory Program received does not fit. Check the space available in the

LIST PROG mode and possibly delete some programs.

414 RS-232 Buffer Overflow Data sent too fast to CNC. This alarm is not normally possible

as this control can keep up with even 115200 bits per second.
Computer sending data may not respond to X-OFF

415 RS-232 Overrun Data sent too fast to CNC. This alarm is not normally possible

as this control can keep up with even 115200 bits per second.

416 RS-232 Parity Error Data received by CNC has bad parity. Check parity settings,

number of data bits and speed. Also check your wiring.

417 RS-232 Framing Error Data received was garbled and proper framing bits were not

found. One or more characters of the data will be lost. Check
parity settings, number of data bits and speed.

418 RS-232 Break Break condition while receiving. The sending device set the line

to a break condition. This might also be caused by a simple
break in the cable.

419 Invalid Function For DNC A code found on input of a DNC program could not be

interpreted.

420 Program Number Mismatch The O code in the program being loaded did not match the O

code entered at the keyboard. Warning only.

421 No Valid Pockets Pocket Table is full of dashes.

422 Pocket Table Error If the machine is equipped with a 50 taper spindle there must be

2 dashes between Ls (large tools). Ls must be surrounded by
dashes.

429 Disk Dir Insufficient Memory Disk memory was almost full when an attempt was made to

read the disk directory.

430 Disk Unexpected End of Input Check your program. An ASCII EOF code was found in the input

data before program receive was complete. This is a decimal
code 26.

96-8100 rev C

431 Disk No Prog Name Need name in programs when receiving ALL; otherwise has no

way to store them.

432 Disk Illegal Prog Name Check files being loaded. Program must be Onnnnn and must

be at the beginning of a block.

433 Disk Empty Prog Name Check your program. Between % and % there was no program

found.

73

ALARMS

434 Disk Load Insufficient Memory Program received does not fit. Check the space available in the

LIST PROG mode and possibly delete some programs.

435 Disk Abort Could not read disk.

436 Disk File Not Found Could not find disk file.

501 Too Many Assignments In One Block Only one assignment macro assignment is allowed per block.

Divide block into multiple blocks.

502 [ Or = Not First Term In Expressn An expression element was found where it was not preceded by

[ or =, that start expressions.

503 Illegal Macro Variable Reference A macro variable number was used that is not supported by this

control, use another variable.

504 Unbalanced Paren. In Expression Unbalanced brackets, [ or ], were found in an expression. Add

or delete a bracket.

505 Value Stack Error The macro expression value stack pointer is in error. Call your

dealer.

June 2001

506 Operand Stack Error The macro expression operand stack pointer is in error. Call your

dealer.

507 Too Few Operands On Stack An expression operand found too few operands on the

expression stack. Call your dealer.

508 Division By Zero A division in a macro expression attempted to divide by zero. Re-

configure expression.

509 Illegal Macro Variable Use See "MACROS" section for valid variables.

510 Illegal Operator or Function Use See MACROS section for valid operators.

511 Unbalanced Right Brackets Number of right brackets not equal to the number of left brackets.

512 Illegal Assignment Use Attempted to write to a read-only macro variable.

513 Var. Ref. Not Allowed With N Or O Alphabetic addresses N and O cannot be combined with macro

variables. Do not declare N#1, etc.

514 Illegal Macro Address Reference A macro variable was used incorrectly with an alpha address.

Same as 513.

515 Too Many Conditionals In a Block Only one conditional expression is allowed in any WHILE or IF-

THEN block.

74

516 Illegal Conditional Or No Then A conditional expression was found outside of an IF-THEN,

WHILE, or M99 block.

517 Exprsn. Not Allowed With N Or O A macro expression cannot be linked to N or O. Do not declare

O[#1], etc.

518 Illegal Macro Exprsn Reference An alpha address with expression, such as A[#1+#2], evaluated

incorrectly. Same as 517.

96-8100 rev C

June 2001

ALARMS

519 Term Expected In the evaluation of a macro expression an operand was

expected and not found.

520 Operator Expected In the evaluation of a macro expression an operator was

expected and not found.

521 Illegal Functional Parameter An illegal value was passed to a function, such as SQRT[ or

ASIN[.

522 Illegal Assignment Var Or Value A variable was referenced for writing. The variable referenced is

read only.

523 Conditional Reqd Prior To THEN THEN was encountered and a conditional statement was not

processed in the same block.

524 END Found With No Matching DO An END was encountered without encountering a previous

matching DO. DO-END numbers must agree.

525 Var. Ref. Illegal During Movement Variable cannot be read during axis movement.

526 Command Found On DO/END Line A G-code command was found on a WHILE-DO or END macro

block. Move the G-code to a separate block.

527 = Not Expected Or THEN Required Only one Assignment is allowed per block, or a THEN statement

is missing.

528 Parameter Precedes G65 On G65 lines all parameters must follow the G65 G-code. Place

parameters after G65.

529 Illegal G65 Parameter The addresses G, L, N, O, and P cannot be used to pass

parameters.

530 Too Many I, J, or Ks In G65 Only 10 occurrences of I, J, or K can occur in a G65 subroutine

call. Reduce the I, J, or K count.

531 Macro Nesting Too Deep Only four levels of macro nesting can occur. Reduce the amount

of nested G65 calls.

532 Unknown Code In Pocket Pattern Macro syntax is not allowed in a pocket pattern subroutine.

533 Macro Variable Undefined A conditional expression evaluated to an UNDEFINED value, i.e.

#0. Return True or False.

534 DO Or END Already In Use Multiple use of a DO that has not been closed by and END in the

same subroutine. Use another DO number.

535 Illegal DPRNT Statement A DPRNT statement has been formatted improperly, or DPRNT

does not begin block.

96-8100 rev C

536 Command Found On DPRNT Line A G-code was included on a DPRNT block. Make two separate

blocks.

537 RS-232 Abort On DPRNT While a DPRNT statement was executing, the RS-232

communications failed.

538 Matching END Not Found A WHILE-DO statement does not contain a matching END

statement. Add the proper END statement.

75

ALARMS

539 Illegal Goto Expression after GOTO not valid.

540 Macro Syntax Not Allowed A section of code was interpreted by the control where macro

syntax is not permitted.

541 Macro Alarm This alarm was generated by a macro command in a program.

600 U Over Travel Range Same as alarm 316.

601 V Over Travel Range Same as alarm 316.

602 W Over Travel Range Same as alarm 316.

603 U Limit Switch Same as alarm 145.

604 V Limit Switch Same as alarm 145.

605 W Limit Switch Same as alarm 145.

609 U Servo Error Too Large Same as alarm 103.

610 V Servo Error Too Large Same as alarm 103.

June 2001

611 W Servo Error Too Large Same as alarm 103.

612 U Servo Overload Same as alarm 108.

613 Command Not Allowed In Cutter Comp. A command (m96, for example) in the highlighted block cannot

be executed while cutter comp. Is invoked.

614 V Servo Overload Same as alarm 108.

615 W Servo Overload Same as alarm 108.

616 U Motor Over Heat Same as alarm 135.

617 V Motor Over Heat Same as alarm 135.

618 W Motor Over Heat Same as alarm 135.

619 U Motor Z Fault Same as alarm 139.

620 C Axis Disabled Parameters have disabled this axis

621 C Over Travel Range C-axis will exceed stored limits. This is a parameter in negative

direction and is machine zero in the positive direction. This will
only occur during the operation of a user's program.

76

The following alarms apply only to the Vertical Mills with a sidemount tool changer:

622 Tool Arm Fault This alarm supports the side mount tool changers. It is

generated if the arm is not at the Origin position, or the arm
motor is already on when a tool change process is started.

96-8100 rev C

June 2001

ALARMS

623 Side Mount Carousel Error This alarm supports the side mount tool changers. It is

generated if the carousel motor is still on when the tool pocket is
unlocked and lowered prior to a tool change.

624 Invalid Tool This alarm is generated by a side mount tool changer if the tool

specified by the G-code program is not found in the POCKET­TOOL table, or the searching pocket is out of range.

625 Carousel Positioning Eror This alarm is generated by a side mount tool changer if

conditions are not correct when:
 The carousel or tool arm was started and one or more of the
following incorrect conditions existed:
The carousel or arm motor already on, arm not at Origin, tool
carousel not at TC mark.
 The tool carousel was in motion and Tool One Mark was
detected but the current pocket facing the spindle was not at
pocket one, or the current pocket was at pocket one but Tool One
Mark was not detected.

626 Tool Pocket Slide Error This alarm is generated by a side mount tool changer. It is

generated if the tool pocket has not moved to its commanded
position (and settled) within the total time allowed by parameters
306 and 62.

627 ATC Arm Position Timeout This alarm supports the side mount tool changers. It is

generated if the tool arm has not moved after the allowed time or
has not stopped after the allowed time. Refer to Parameter 309
MOTOR COAST TIME.

628 ATC ARM Positioning Error This alarm supports the side mount tool changers. It is

generated if:
 The arm was being moved from the ORIGIN position to the
CLAMP position and it coasted past the MOTOR STOP point or
could not get to the CLAMP point.
 The arm was being moved from the CLAMP position to the
UNCLAMP position and it coasted past the MOTOR STOP point
or could not get to the UNCLAMP point (same physical point as
CLAMP).
 The arm was being moved back to the ORIGIN position and it
coasted past the MOTOR STOP point or could not get to the
ORIGIN point.

629 Carousel Position Timeout This alarm supports the side mount tool changers. It is

generated if the tool carousel has not moved after the allowed
time or has not stopped after the allowed time specified by
parameter 60 TURRET START DELAY and parameter 61
TURRET STOP DELAY, respectively.

630 APC-Door SW Fault-Switch Not Equal To Solenoid

The APC Door Switch indicates the door is open but the solenoid
shows the door has been commanded to close. Either the door
failed to close and is stuck or the switch itself is broken or stuck.
Also, the door switch wiring may have a fault. Check switch then
cable.

96-8100 rev C

77

ALARMS

631 APC-Pallet Not Clamped Or Home DO NOT ATTEMPT TO MOVE X OR Y AXES OR MILL UNTIL APC

IS IN A SAFE CONDITION. CAUTION- The APC is not in a safe
operating condition. One pallet is at home but the other pallet is
neither clamped nor at home. Locate the unclamped pallet, go to
the lube/air panel at rear of mill and continuously press both
white buttons in center of solenoid air valves while an assistant
pulls the pallet off the receiver.

632 APC-Unclamp Error The pallet did not unclamp in the amount of time allowed. This

can be caused by a bad air solenoid, a blocked or kinked air line,
or a mechanical problem.

633 APC-Clamp Error The pallet did not clamp in the amount of time allowed by

parameter 316. This alarm is most likely caused by the VMC
table not being in the correct position. This can be adjusted
using the setting for the X position (#121, #125) as described in
the Installation section. If the pallet is in the correct position but
not clamped, push the pallet against the hard stop and run M18.
If the pallet is clamped, but not correctly, run an M17 to unclamp,
push the pallet to the correct position, and run an M18 to clamp
the pallet. Less common causes could be that the slip clutch is
slipping, the motor is at fault, or an air line is blocked or kinked.

634 APC-Mislocated Pallet A pallet is not in the proper place on the APC. The pallet must be

pushed back against the hard stop by hand.

June 2001

635 APC-Pal Num Conflict Rec & Ch Pallet Number Conflict Receiver and Pallet Changer: The pallet

number in memory does not agree with the actual pallet in use.
Run an M50 to reset this variable.

636 APC-Switch Missed Pal 1 Pallet #1 did not return from the receiver to the APC in the

allowed time. This can be caused by the chain switch block
missing the limit switch, or from another mechanical problem,
such as clutch slippage.

637 APC-Switch Missed Pal 2 Pallet #2 did not return from the receiver to the APC in the

allowed time. This can be caused by the chain switch block
missing the limit switch, or from another mechanical problem,
such as clutch slippage.

638 APC- Door Not Open The automatic door did not open (in the allowable time), or may

have fallen during an APC function. This can be caused by a bad
air solenoid, a blocked or kinked air line, or a mechanical
problem.

639 APC- Door Not Closed The automatic door did not close (in the allowable time), when

necessary after an APC function has been performed. This can
be caused by a bad air solenoid, a blocked or kinked air line, or a
mechanical problem.

640 APC- Missing Pallet @ Rec Pallet change sequence was halted because receiver switch

was not activated. Pallet is either unclamped or not on the
receiver. Ensure the pallet is correctly located on the receiver
(against the hard stop) then run M18 to clamp the pallet.

78

96-8100 rev C

June 2001

ALARMS

641 APC-Unknown Chain Location Neither chain location switch is tripped, so the control cannot

locate the chain position. This can occur if a pallet change is
interrupted for any reason, such as an alarm or an E-stop. To
correct this problem, the pallets and chain must be moved back
into a recognized position, such as both pallets home or one
pallet home and one on the receiver. The chain position
adjustment tool must be used to rotate the chain into position.
The pallets must be pushed into place by hand.

CAUTION! The pallets weigh 300 lbs. each, and can cause serious injury.

Use extreme caution when moving them.

642 APC- Incorrect Chain Location Chain not in position to load or unload pallets when necessary.

To correct this, the mislocated pallet must be moved back into
the proper position by hand.

CAUTION! The pallets weigh 300 lbs. each, and can cause serious injury.

Use extreme caution when moving them.

643 RP-Index Station Unlocked (Verify Lever Up) Or Front Doors Open

The index station is not in the correct orientation for a pallet
change or the front doors are open. Check whether the handle is
in the fully up position, close the front doors, check the function of
the front door switches.

644 RP-Pallet Changer Will Not Rise, Verify Air Supply To The Lift Cylinder

The pallet did not begin to lift within a reasonable time after
command, or did not complete lifting within a reasonable time.
Verify air supply to the pallet changer valve assembly, verify
proper adjustment of the lift cylinder regulator (40 PSI), verify the
function of the lift cylinder air valve and solenoid, verify the
operation of the lift cylinder position sense switches.

645 RP-Pallet Jammed, Check For Obstruction

The pallet changer has not rotated away from its original position
(CW/CCW) in a reasonable time, or has not achieved its final
position (CW/CCW) in a reasonable time, or has not been
permitted to lower to the fully DOWN position

646 RP-CW/CCW Switch Illegal Condition Both of the switches that sense the rotational position of the

pallet changer are indicating the impossible condition that the
pallet changer is rotated CW and CCW at the same time. Only
one switch should be tripped at a time. Check the function of the
rotational sense switches, their connectors, and their wiring.

647 RP-Up/Down Switch Illegal Condition, Lift Cylinder

The switches that sense the lifted and lowered position of the
pallet changer are indicating the impossible condition that the
pallet changer is both lifted and lowered at the same time.
Check the function of the lift and lower sense switches, check the
adjustment of the top switch, check both switch electrical
connections and their wiring.

96-8100 rev C

79

ALARMS

648 RP-Main Drawbar Locked In Pallet Clamped Position

The drawbar has not tripped the unclamp sense switch in a
reasonable amount of time. Check to see that the motor is
plugged in at the connector panel in the rear of the machine and
at the motor through the access panel; check the function of the
main drawbar motor (does it turn or try to turn); check the
condition of the drive belt, check power supply to the motor;
check the relays that supply power to the motor, check the
condition of the current limiting resistors.

649 RP-Main Drawbar Locked In Pallet Unclamped Position

The drawbar has not come off the unclamp sense switch in a
reasonable amount of time. Check to see that the motor is
plugged in at the connector panel in the rear of the machine and
at the motor through the access panel; check the function of the
main drawbar motor (does it turn or try to turn); check the
condition of the drive belt, check power supply to the motor;
check the relays that supply power to the motor, check the
condition of the current limiting resistors.

650 RP-Pallet Not Engaging RP Main Drawbar

This alarm occurs when the pullstud cannot properly engage the
Ball Pull Collet. If this happens, the Ball Pull Collet has been
pushed down into the Collet Housing and pallet clamping is not
possible. Check alignment of the H-frame with the adjustable
Hard Stops. Check the Pallet Pull Studs and the RP-Main
Drawbar Ball Collet for damage or obstruction. Remove any
debris that may have entered the Collet. Check that the six balls
in the collet float within the holes.

June 2001

651 Z Axis Is Not Zeroed The Z-axis has not been zeroed. In order to continue the

Toolchanger Recovery the Z-axis must be zeroed. Once the Z­axis has been zeroed, continue with the Toolchanger Recovery.

652 U ZERO RET MARGIN TOO SMALL Same as alarm 168.

653 V ZERO RET MARGIN TOO SMALL Same as alarm 168.

654 W ZERO RET MARGIN TOO SMALL Same as alarm 168.

655 U CABLE FAULT Same as alarm 182.

656 V CABLE FAULT Same as alarm 182.

657 W CABLE FAULT Same as alarm 182.

658 U PHASING ERROR Same as alarm 217.

659 V PHASING ERROR Same as alarm 217.

660 W PHASING ERROR Same as alarm 217.

661 U TRANSITION FAULT Same as alarm 224.

80

662 V TRANSITION FAULT Same as alarm 224.

663 W TRANSITION FAULT Same as alarm 224.

96-8100 rev C

June 2001

ALARMS

664 U AXIS DISABLED Same as alarm 336.

66 5 V AXIS DISABLED Same as alarm 336.

666 W AXIS DISABLED Same as alarm 336.

667 U AXIS LINEAR SCALE Z FAULT Same as alarm 279.

668 V AXIS LINEAR SCALE Z FAULT Same as alarm 279.

669 W AXIS LINEAR SCALE Z FAULT Same as alarm 279.

670 TT OVER TRAVEL RANGE Same as alarm 316.

671 TT LIMIT SWITCH Same as alarm 145.

673 TT SERVO ERROR TOO LARGE Same as alarm 103.

674 TT SERVO OVERLOAD Same as alarm 108.

675 TT MOTOR OVER HEAT Same as alarm 135.

676 TT MOTOR Z FAULT Same as alarm 273.

677 TT AXIS Z CH MISSING Same as alarm 275.

678 TT AXIS DRIVE FAULT Same as alarm 161.

679 TT ZERO RET MARGIN TOO SMALL Same as alarm 168.

680 TT CABLE FAULT Same as alarm 182.

681 TT PHASING ERROR Same as alarm 217.

682 TT TRANSITION FAULT Same as alarm 224.

68 3 T T AXIS DISABLED Same as alarm 336.

684 TT AXIS LINEAR SCALE Z FAULT Same as alarm 279.

685 V MOTOR Z FAULT Same as alarm 273.

686 W MOTOR Z FAULT Same as alarm 273.

687 U MOTOR Z FAULT Same as alarm 273.

96-8100 rev C

688 U AXIS Z CH MISSING Same as alarm 275.

689 V AXIS Z CH MISSING Same as alarm 275.

690 W AXIS Z CH MISSING Same as alarm 275.

691 U AXIS DRIVE FAULT Same as alarm 161.

81

ALARMS

692 V AXIS DRIVE FAULT Same as alarm 161.

693 W AXIS DRIVE FAULT Same as alarm 161.

694 ATC SWITCH FAULT Conflicting switch states detected, such as shuttle at spindle and

shuttle at chain simultaneously. Check for damaged or sticking
switches, damaged wiring, or debris build up.

695 ATC AIR CYLINDER TIME OUT The ATC double arm did not complete extending or retracting

within the time allowed by Parameter 61. Check for proper
spindle orientation, correct alignment of the double arm with the
chain or spindle, adequate air supply, mechanism binding, air
leakage, excessive tool weight, debris build up, adequate chain
tension, and correct chain guide strip adjustment. Use tool
changer restore to recover the ATC, then resume normal
operation.

696 ATC MOTOR TIME OUT The ATC shuttle motor or double arm motor failed to complete

the commanded movement within the time allowed by
Parameter 60. Check, for mechanism binding, correct motor and
switch operation, damaged ATC control board relays, damaged
electrical wiring, or blown fuses on the ATC control board. Use
tool changer restore to recover the ATC, then resume normal
operation.

June 2001

697 ATC MOTOR FAULT The ATC shuttle motor or double arm motor was on unexpectedly.

Use tool changer restore to recover the ATC, then resume normal
operation.

698 ATC PARAMETER ERROR The ATC type cannot be determined. Check Parameter 278, bit

10, HS3 HYD TC, or Parameter 209, bit 2, CHAIN TC, as
appropriate for the installed tool changer.

699 ATC CHAIN OUT OF POSITION An incorrect tool change position was detected during a tool

change. Use tool changer restore to recover the ATC, then
resume normal operation.

900 Par No xxx Has Changed. Old Value Was xxx.

When the operator alters the value of a parameter, alarm 900 will
be added to the alarm history. When the alarm history is
displayed, the operator will be able to see the parameter number
and the old value along with the date and time the change was
made. Note that this is not a resetable alarm, it is for information
purposes only.

901 Parameters Have Been Loaded By Disk

When a file has been loaded from floppy disk, alarm 901 will be
added to the alarm history along with the date and time. Note that
this is not a resetable alarm, it is for information purposes only.

902 Parameters Have Been Loaded By RS-232

When a file has been loaded from RS-232, alarm 902 will be
added to the alarm history along with the date and time. Note that
this is not a resetable alarm, it is for information purposes only.

82

903 CNC Machine Powered Up When the machine is powered up, alarm 903 will be added to

the alarm history along with the date and time. Note that this is
not a resetable alarm, it is for information purposes only.

96-8100 rev C

June 2001

ALARMS

904 TOOL CHANGER AXIS VISIBLE The tool changer axis must be invisible for tool change

operations with the HS tool changers. Set Parameter 462, bit 18,
INVIS AXIS to 1. This will make the tool changer axis invisible
and tool changes will be allowed.

NOTE: Alarms 1000-1999 are user defined by macro programs.

The following alarms only apply to horizontal mills with a pallet changer:

1001 Index St Unlocked The index station is not in the correct orientation for a pallet

change.

1002 Pallet Locked Down The pallet did not begin to lift within two seconds of command, or

did not complete lifting within six seconds.

1003 Pallets Jammed The lift cylinder has not moved from the clockwise position within

three seconds, or has not reached the counter clockwise
position within twelve seconds.

1004 CW/CCW Switch Illegal Condition One or both of the switches that sense the rotational position of

the pallet changer has failed it's self-test.

1007 Up/Down Switch Illegal Condition One or both of the switches that sense the lifted/lowered position

of the pallet changer has failed its self-test.

1008 Main Drawbar Locked In Up Position The main drawbar will not disengage from the pallet nut.

1009 Main Drawbar Locked In Down Position The main drawbar will not move upward to the pallet nut.

1010 Main Drawbar Switch Illegal Condition One or both of the switches that sense the up/down position of

the main drawbar has failed it's self-test.

1011 Main Drawbar Unclamp Timeout The main drawbar has disengaged from the pallet nut, but did

not reach the main drawbar down switch.

1012 Main Drawbar Clamp Timeout The main drawbar has begun to travel upward, but did not reach

the fully raised position within 15 seconds.

96-8100 rev C

83

MECHANICAL SERVICE

3. MECHANICAL SERVICE

RECOMMENDED TORQUE VALUES FOR MACHINE FASTENERS

The following chart should be used as a reference guide for torquing machine fasteners where specified.

DIAMETER TORQUE

1/4 - 20 15 ft. lb.
5/16 - 18 30 ft. lb.
3/8 - 16 50 ft. lb.*
M10 - 100 50 ft. lb.
M12 - 65 100 ft. lb.
1/2 - 13 80 ft. lb.
3/4 - 10 275 ft. lb.
1 - 8 450 ft. lb.

* 3/8-16 SHCS used on tool release piston torqued to 35 ft. lb.

3.1 HEAD COVERS REMOVAL / INSTALLATION

June 2001

Please read this section in its entirety before attempting to remove or replace covers.

REMOVAL -

NOTE: This procedure is for the VF-3/4. However, the procedure varies only slightly

for other models.

10-32 x 3/8" SHCS

Remove side

covers from

top side

84

Figure 3.1-1 View of VF-3/4 head covers.

96-8100 rev C

June 2001

MECHANICAL SERVICE

1. Zero return (ZERO RET) all axes, then HANDLE JOG to center X- and Y-axes under spindle.
Protect table surface with a piece of cardboard.

2. Remove the top and rear covers.

3. Pull front cover from the bottom until you can disconnect the tool release cable (quick disconnect),
then remove cover .

4. Remove the side covers. Jog Z-axis as necessary to make screw removal easier.

INSTALLATION -

1. Protect table surface with a piece of cardboard.

2. Replace each side cover from the top. Jog Z-axis as necessary to make access to screws easier.

3. Reconnect tool release cable, if equipped, then replace front cover from the bottom.

4. Replace rear cover and top cover.

96-8100 rev C

85

MECHANICAL SERVICE

3.2 TOOL RELEASE PISTON (TRP) ASSEMBLY

Please read this section in its entirety before attempting to replace tool release piston
assembly.

Overview

The Tool Release Piston is actuated by air. It forces the Tool Draw Bar down against the spring stack, releasing
the old tool and permitting the new tool to be inserted. Normally the piston is in the upper, retracted position.
During a tool change cycle the piston is forced down by air pressure, pushing the draw bar down until the pull
stud on the top of the tool is released.

As the piston finishes its downward stroke a hole in the side of the Tool Release Shaft comes clear of the
Cylinder Housing and is exposed to the compressed air within the cylinder. The air flows down through the
Shaft to the Tool Release Nut at the lower end of the shaft. This nut presses on the end of the Tool Draw Bar
and the air flows through a central hole drilled through both the Tool Release Nut and the Tool Drawbar to blow
any chips out of the tapered area of the Spindle Shaft.

June 2001

The Spring Retainer captures the compression spring that returns the Tool Change Piston and Shaft to the
normal position when the air is released from the cylinder. The Upper and Lower Limit Switches are actuated by
the Spring Retainer. The position of these switches is monitored by the computer control system during the
tool change cycle.

There is different tool release piston for the 40 and 50 taper spindles. In addition The tool change pistons have
different subassemblies that will need to be adjusted, or may need replacing. The section(s) that follow the

installation instructions must be completed as well or serious damage to the machine could result.

40 TAPER SPINDLE TRP REMOVAL

1. If machine is equipped with Through the Spindle Coolant (TSC), place a tool holder in the spindle.

2. Remove cover panels from the headstock area.

3. Remove the four 3/8-16 x 1¾" SHCS holding the tool release piston assembly to the head casting.

4. Disconnect the air line at the lube/air panel.

5. Disconnect the clamp/unclamp cables (quick disconnect) and the assembly's solenoid wiring
located on the solenoid bracket.

86

6. Remove the tool release air hose and precharge hose at the fitting shown in Fig. 3.2-1 If machine
is equipped with TSC, also remove the coolant hose.

7. Remove entire tool release piston assembly.

96-8100 rev C

June 2001

MECHANICAL SERVICE

NOTE: Steps 8 and 9 apply only to machines with TSC.

8. Remove the drain and purge lines from the seal housing.

9. Remove the seal housing from the TRP.

3/8" - 16 X 1 3/4" SHCS

1/4" Air Hose

Fitting

3/8" Air Hose

Fitting

TSC Fitting

(Optional)

Clamp
switch

CAUTION

Unclamp

switch

Figure 3.2-1 Tool Release Piston with Optional TSC fitting.

96-8100 rev C

Figure 3.3-2 Mounting location for tool release piston assembly

87

MECHANICAL SERVICE

40 TAPER SPINDLE TRP INSTALLATION

The following sections must be completed after installation:

 Set Pre-Charge
 Adjust the Tool Clamp/Unclamp Switches
 Set the Drawbar Height

1. Ensure drive belt has been properly replaced as described in "Belt Assembly" section.

2. Verify spindle sweep adjustment is correct (as shown in "Spindle Assembly" section) before
proceeding. If not correct, re-shim as necessary.

3. Reinstall tool release piston assembly loosely if the machine is equipped with TSC. Otherwise
tighten the four mounting bolts securely.

4. Reconnect the air hoses at the applicable fittings on the tool release piston assembly.

June 2001

5. Reconnect the clamp/unclamp cables and solenoid wire to the sides of the solenoid bracket.

6. Connect the 5/32" drain line and 5/32" purge line to the seal housing and install the seal housing
on the TRP (use Loctite on the screws). The drain line connector should point toward the rear of
the machine.

NOTE: The drain line must run straight through the cable clamp guide on the

NOTE: Steps 6, 7 and 8 apply only to machines with TSC.

transmission, and must not interfere with the pulley or belts. On VF-0/0E
machines, the drain line must go straight down through the cable clamp on
the bracket.

7. Apply precharge pressure several times to allow the seal to center itself with the drawbar. While
holding down precharge, tighten the bolts.

8. Install the coolant hose. A wrench must be used, tighten snug. Do not overtighten!!

9. Adjust the clamp/unclamp switches in accordance with the appropriate section.

88

96-8100 rev C

June 2001

MECHANICAL SERVICE

Setting Pre-Charge

NOTE: Do not perform this procedure on machines equipped with Through the

Spindle Coolant (TSC). It will damage the machine. Refer to the "Precharge
Regulator Adjustment" section and perform those adjustments.

10. Turn the air pressure regulator down to zero (0). The knob must be pulled out to unlock before
adjusting.

NOTE: At "0" pressure on the precharge regulator, the adjustment knob is out as far

as it will turn.

SPINDLELOCKED

SPINDLELOCKED
STATUSSWITCH

ST

ATUS

WITHOUTGEARBOX

WITHOUT

SWITCH
GEARBOX

TOOLCLAMPED

TOOLCLAMPED

STATUSSWITCH

STATUS

SWITCH

LOWGEAR

LOWGEAR

ST

STATUSSWITCH
JUMPERWITHOUT

JUMPER

ATUSSWITCH

GEARBOX

GEARBOX

WITHOUT

HIGHGEAR

HIGHGEAR

STATUSSWITCH

ST

ATUSSWITCH

96-8100 rev C

Figure 3.2-3. Air pressure regulator adjustment knob.

11. Ensure Parameter 149, Precharge DELAY, is set to 300. If not, set it at this time.

12. Execute a tool change. A banging noise will be heard as the tool release piston contacts the
drawbar.

13. Turn the air pressure regulator ½ turn in. Execute a tool change and listen for the noise described
previously. If it is heard, repeat this step until no noise is heard. There should be no noise with or
without a tool in the spindle.

CAUTION! Only increase the pressure to the point where tool changes become

obviously quiet. Any further pressure increases are not beneficial. Exces­sive pressure to the precharge system will cause damage to the tool
changer and tooling in the machine.

14. Replace the head covers.

89

MECHANICAL SERVICE

TOOL CLAMP/UNCLAMP SWITCH ADJUSTMENT - INITIAL PREPARATION

Please read this section in its entirety before adjusting clamp/unclamp switches or setting
drawbar height.

TOOLS REQUIRED

 Machined aluminum block (2" x 4" x 4")
 6" flexible ruler or .020" shim
 1" diameter pipe (approx. 1' long)

1. Remove cover panels, as described in "Head Covers Removal".

2. Place a sheet of paper under the spindle for table protection, then place a machined block of
aluminum (approximately 2" x 4" x 4") on the paper.

June 2001

Tool Holder

Sheet of

paper

Aluminum Block

Figure 3.2-4 Placement of aluminum block under spindle.

3. Power on the VMC.

4. Insert a tool holder WITHOUT ANY TYPE OF CUTTER into the spindle taper.

5. Go to the HANDLE JOG mode. Choose Z-axis and set jog increments to .01.

90

96-8100 rev C

June 2001

MECHANICAL SERVICE

6. Jog Z-axis in the negative (-) direction until the tool holder is approximately .03 from the block. At
this point, stop jogging the spindle and push the TOOL RELEASE button (top left). You will notice
that the tool holder comes out of the taper.

NOTE: The clearance from the tool holder to the block should be zero (0).

7. To accomplish this, set the jog increments to .001 and jog in the negative (-) Z direction a few
increments of the hand wheel at a time. Between these moves, push the tool release button and
feel for movement by placing your finger between the tool holder and the spindle. Do this until no
movement is felt. You are now at zero (0).

CAUTION! Do not jog too far in the negative (-) direction or else it will cause an

overload of the Z-axis.

SETTING DRAWBAR HEIGHT

1. Press MDI and turn hand wheel to zero (0).

2. Press HANDLE JOG button and set increments to .01. Jog the Z-axis in the positive (+) direction

0.100".

3. Press and hold the TOOL RELEASE button, grasp the block and try to move it. The block should
be tight at .100 and loose at .110. If block moves at .100, jog the Z-axis in the negative (-) direc­tion one increment at a time. Press the TOOL RELEASE button and check for movement between
increments until block is tight.

NOTE: The increments jogged in the Z negative (-) direction are the amount of shim

washers that must be added to the tool release bolt (or coolant tip for TSC).
Refer to the "Shim Washers" section.

4. If the block is tight at .110, move the Z-axis in the positive (+) direction one increment at a time.
Press the TOOL RELEASE button and check movement between increments until block is loose.

96-8100 rev C

The increments jogged in the Z positive (+) direction are the amount of shim washers that must be removed.
(Refer to the "Shim Washers" section).

91

MECHANICAL SERVICE

SHIM WASHERS

1. To add or subtract shim washers, remove tool release piston assembly ("Tool Release Piston"
section) from head casting.

2. Check the condition of the tool release coolant tip and the draw bar. Repair or replace these items
before setting the drawbar height.

June 2001

NOTE: Shims may need to be added or removed when spindle cartridge, tool release

piston assembly, or drawbar is replaced. If none have been replaced, skip this
section.

Figure 3.2-5 Tool release piston assembly (TSC shown).

3. Remove tool release bolt. If machine is equipped with TSC, loosen the three set screws and
remove the TSC coolant tip.

92

4. Add or subtract required shim washers (See previous section for correct amount to add or remove).

5. Before installing tool release bolt, put a drop of serviceable (blue) Loctite® on the threads and
install. If replacing TSC coolant tip, put a drop of Loctite® on the threads of the three set screws
before installing.

6. Install tool release piston assembly in accordance with the "Tool Release Piston - Installation"
section and recheck settings. If within specifications, continue; if not, readjust.

96-8100 rev C

June 2001

ADJUSTMENT OF SWITCHES

LOWER (UNCLAMP) SWITCH -

1. Drawbar height must be set properly before adjusting switches. Add or subtract shim washers to
the tool release piston until proper height is achieved.

2. Push the PARAM/DGNOS twice to enter the diagnostic mode and confirm that DB OPN =0 and
DB CLS =1.

3. Using the same set-up for setting the drawbar height, jog the Z-axis to 0.06" above from where the
tool holder was resting on the aluminum block.

3/8" Air Hose

Fitting

MECHANICAL SERVICE

3/8" - 16 X 1 3/4" SHCS

1/4" Air Hose

Fitting

TSC Fitting

(Optional)

Clamp
switch

N

O

I

T

U

A

C

Unclamp

switch

Figure 3.2-6 Tool release piston assembly.

4. Using the pressure regulator on the air/lube panel to reduce the inlet pressure to 75 PSI. Be sure
to back regulator down past 75 PSI then adjust back up to 75 PSI. This will decrease the amount
of upward deflection on the spindle head from TRP force.

5. Press the tool release button and hold it in. Adjust the switch in or out until the switch just trips
(DB OPN =1).

6. Check the adjustment. The switch must trip (DB OPN =1) at 0.06" above the block and not trip
(DB OPN =0) at 0.05" above the block.

96-8100 rev C

7. Re-adjust and repeat steps 1-6 if necessary.

8. Set the pressure regulator back to 85PSI.

93

MECHANICAL SERVICE

UPPER (CLAMP) SWITCH -

1. Remove the tool holder from the spindle.

2. Delete everything in MDI mode and write #1120=1.

3. Start with the upper switch all the way in. Place a 0.02 shim between the tool release piston
adjustment bolt and the drawbar.

4. Push the PARAM/DGNOS button twice to enter the diagnostics mode.

5. Press CYCLE START.

6. If DB CLS=0 (tool Unclamp) you are done (do not check with 0.04 shim).
If not, adjust the upper switch out until the switch is just un-tripped (DB CLS=0).

7. Press RESET. Replace the 0.02 shim with a 0.04 shim. Press CYCLE START. See that DB
CLS=1. Readjust and repeat steps 1-7 if necessary.

June 2001

Checking with the 0.04 shim assures that the switch is not backed off too far. If switch is all the way in, this
check is not needed.

Figure 3.2-7 Placement of shim before checking switch adjustment.

94

96-8100 rev C

June 2001

MECHANICAL SERVICE

50 TAPER SPINDLE TRP REMOVAL

1. For TSC equipped machines, place a tool holder in the spindle.

2. Remove cover panels from the headstock area in accordance with "Head Covers Removal and
Installation".

3. For TSC equipped machines the rotary union and extension tube must be removed before proceed­ing. They both have left handed threads.

4. Disconnect the air line at the lube/air panel.

5. Disconnect the clamp/unclamp cables (quick disconnect) and the assembly's solenoid wiring
located on the solenoid bracket.

6. Remove the three tool release air hoses.

7. Remove the four shoulder screws holding the tool release piston assembly to the head casting.
Make sure to keep all the washers and shims.

8. Remove entire tool release piston assembly, by sliding it forward then lifting it upward. The assem­bly is heavy so use great care when removing it.

TRP DISASSEMBLY

1. Loosen the shaft clamp and remove. It may be necessary to use a punch and mallet to break the
clamp loose.

2. Remove the switch trip and compression spring.

3. Remove the 50T upper spacer.

4. Push the TRP shaft down.

5. Remove the 8 bolts holding the TRP assembly together.

6. Separate and remove the upper half of the housing.

7. Remove the upper TRP piston.

96-8100 rev C

8. Remove the lower half of the TRP housing.

9. Remove the TRP lower spacer.

95

MECHANICAL SERVICE

10. Remove the lower TRP 50T piston.

11. Remove the TRP sub plate.

O' Ring Replacement

1. Remove and replace the 4 O'rings (57-0027) on the TRP 50T shaft

2. Remove and replace the 2 O'rings (57-0092) on the TRP 50T piston, 1 O'ring per piston.

3. Remove and replace the 3 O'rings (57-0095). 2 in the center of the TRP 50T housings and 1 in the
center of the TRP 50T sub plate.

TRP ASSEMBLY

1. Place the TRP sub plate over the TRP shaft.

2. Place the lower TRP piston, grooved side up, over the TRP shaft.

June 2001

3. Place the TRP lower spacer over the TRP shaft.

4. Place the lower TRP housing over the TRP shaft.

5. Place the upper TRP piston, grooved side up, over the TRP shaft.

6. Place upper TRP housing over the TRP shaft.

7. Replace the 8 bolts holding the TRP assembly together. Pattern torque to 100 ft. lbs.

8. Place the TRP upper spacer over the TRP shaft.

9. Push the TRP shaft up from the bottom, using the mallet handle. The shaft will bottom out with
approximately 1/4" of the shaft still showing.

10. Place the switch trip and compression spring over the TRP shaft.

11. Tighten the shaft clamp on the TRP shaft, then the shaft clamp locking bolt.

96

96-8100 rev C

June 2001

MECHANICAL SERVICE

50 TAPER SPINDLE TRP INSTALLATION

The following sections must be completed after installation:

 Tool Push-Out Adjustment
 Setting TRP Switches
 Extension Tube Installation ( if equipped with TSC)

Figure 3-10.. Shim and spacer location diagram.

1. Place the TRP on the machine. The TRP will rest on the spindle lift fork. Caution: Be careful of the
spindle lift fork. Place the assembly toward the front of the machine before lowering it. The assem­bly is heavy so use great care when replacing it.

2. Install the 4 bolts, with the shim stock and spacers under the TRP.

Part No. Description 30-0013A (NEW) 30-0013 (OLD STYLE)

Fork: (45-0014) 0.010 Shim Washer 1 ea. None

(45-0015) 0.018 Shim Washer 7 ea. 5 ea.

TRP (45-0019) 0.093 Nylon Washer 1 ea. 1 ea.
Spacers: (45-0017) 0.010 Shim Washer 2 ea. 2 ea.

(45-0018) 0.015 Shim Washer 3 ea. 2 ea.

(NOTE: TRP Spacers: the nylon washer goes on top of the shims.)

96-8100 rev C

97

MECHANICAL SERVICE

3. If the machine is equipped with TSC, re-install the Extension Tube and Rotating Union in the
following manner. Otherwise, skip this step.

June 2001

NOTE: If the Spindle, Drawbar or Extension Tube has been replaced the Extension

Tube Runout

Extension

TRP

must be adjusted.

High Pressure

Coolant Hose

Rotating

Union

Tube

Purge Air
Hose

Check
Valve
Assy

Drain hose

a) Put a tool holder in the Spindle (this is absolutely required!).

b) Prevent Spindle from rotating to allow for tightening of Extension Tube (inserting a bolt into

one of the holes in the pulley and bracing a bar against the inside of the spindle head is
one way of doing this).

c) Apply grease lightly to the O-ring on the end of the extension tube.

d) Apply blue Loctite to end of extension tube threads.

e) Insert the extension tube into drawbar. The Extension Tube has left hand threads.

Tighten the Extension Tube and turn until the reference marks line up (there should be a
paint line on the extension tube and on the drawbar).

f) Check the runout of the extension tube with a dial indicator at the top of the extension

tube. If the runout is greater than 0.010 TIR max., follow the instructions for

Adjusting Extension Tube Runout.

g) Slip Support Bracket over Rotating Union (check that the edge strip is intact).

h) Lightly grease the O-ring on the Rotating Union, and install the union onto the top of the

extension tube (it has left hand threads). Tighten using two wrenches.

i) Install the (4) support bracket screws loosely. Allow the Rotating Union to find its own

center. Tighten the screws carefully so the bracket does not pull to one side.

98

96-8100 rev C

June 2001

MECHANICAL SERVICE

j) Apply grease to the surface of the Rotating Union that passes through the Support

Bracket.

k) Connect the hose to the check valve assembly and the drain line hose (secure the hose

with a cable tie so coolant drains downward to protect rotating union).

4. Plug the 3 air hoses in the TRP.

5. Plug in the clamp and unclamp switches.

6. Set the main air regulator to 85 psi.

NOTE: Tool Push Out Adjustment and Setting TRP Switches must be completed.

TOOL PUSH OUT ADJUSTMENT

1. Put tool holder in spindle.

2. Place machined aluminum block onto machine table. Place a clean sheet of paper under the
block to protect the table.

Tool Holder

Sheet of

paper

Aluminum Block

Figure 3.2-9 Pushout Adjustment.

96-8100 rev C

3. Jog Z-Axis down until tool holder is about 0.030 above the aluminum block. Switch to 0.001
increments. Jog down one increment at a time until no movement can be felt in the block. This is
our zero point. Do not press the tool release button now, this can cause a Z-Axis overload!

99