Haas Service and Operator Manual Archive SL-Series Service Manual 96-8710 English January 1999
Haas Service and Operator Manual Archive SL-Series Service Manual 96-8710 English January 1999
Haas Service and Operator Manual Archive SL-Series Service Manual 96-8710 English January 1999
June 6, 2013
Haas Technical Publications
• 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 qualified
and knowledgeable about the processes.
• Only authorized personnel with the proper training and certification should do many repair procedures.
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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NO Normally Open
OD Outside Diameter
OPER Operator
PARAM Parameter
PCB Printed Circuit 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
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
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1. TROUBLESHOOTING
This section is intended for use in determining the solution to a known problem. Solutions given are intended
to give the individual servicing the machine a pattern to follow in, first, determining the problems source
and, second, solving the problem.
The troubleshooting tips are organized in this section according to the area of the machine 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.
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VIBRATION
Vibration is a subjective evaluation with perceptions varying among individuals, making it difficult to
determine in mild cases if there is an actual problem. In obvious cases, it is a matter of determining the source
which is not easy, since all parts rotate together and sound can be transferred readily. Vibrations also need
to be distinguished from noise such as a bad bearing. We will assume that vibrations would be something
that could be felt by putting your hand on the spindle ring. One crude method of measurement would be to
take an indicator on a magnetic base extended 10 inches between the turret and spindle ring 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 jog handle.
The HAAS control uses very high gain accelerations curves. This vibration as you jog is simply the
servos quickly trying to follow the handle divisions. If this is a problem, try using a smaller
division on the handle. You will notice the vibration more at individual clicks than when you are
turning the handle faster. This is normal.
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ACCURACY
Before you complain of an accuracy problem, please make sure you follow these simple dos and donts:
l 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).
l Dont use a wiggler test indicator for linear dimensions. They measure in an arc and have sine/cosine
errors over larger distances.
l Dont use magnetic bases as accurate test stops. The high accel/decel of the axis can cause them to
move.
l Dont attach test points to the sheet metal of the spindle head.
l Dont check for accuracy/repeatability using an indicator with a long extension.
l Ensure that test indicators and stops are absolutely rigid and mounted to machined casting surfaces.
l Check a suspected error with another indicator or method for verification.
l Ensure that the indicator is parallel to the axis being checked to avoid tangential reading errors.
l Center drill holes before using jobber length drills if accuracy is questioned.
l Once machining practices have been eliminated as the source of the problem, determine specifically
what the machine is doing wrong.
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FINISH
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January 1999 TROUBLESHOOTING
THERMAL GROWTH
A possible source of accuracy and positioning errors is thermal growth of the leadscrews. As the machine
warms up, the leadscrews expand in both linear axes (X and Z), causing accuracy and positioning errors. This
is especially critical in jobs that require high accuracy.
Note: Thermal growth will be more noticeable in the X-axis, since errors will be doubled
when cutting a diameter.
Note: The leadscrew will always expand away from the motor end.
There are a number of ways to verify the problem. The following procedure will verify thermal growth of the
X-axis leadscrew in a machine that has not been warmed up:
1. Home the machine. In MDI mode, press POSIT and PAGE DOWN to the OPER page.
2. Jog to an offset location. Select the X axis and press the ORIGIN key to zero it.
3. Press the OFSET key, then scroll down to G110 (or any unused offset). Cursor to X and press the PART
ZERO SET key. This will set X0 at this position.
4. Enter a program that will start at the new zero position, rapid a certain distance in the X direction, feed
the final .25 inches slowly, and then repeat the X movement.
5. In order to set up the indicator, run the program in SINGLE BLOCK mode, and stop it when X is at the end
of it's set travel. Set the magnetic base on the spindle retainer ring or other rigid surface, with the indicator
tip touching the turret in the X-axis, and zero it.
6. Exit SINGLE BLOCK mode, and run the program for a few minutes. Enter SINGLE BLOCK mode again,
stop the program when X is at the end of it's set travel, and take a final reading on the indicator. If the
problem is thermal growth, the indicator will show a difference in the X position.
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 Z-axis.
SOLUTIONS
Since there are many variables that affect thermal growth, such as the ambient temperature of the shop and
program feed rates, it is difficult to give one solution for all problems.
Thermal growth problems can generally be eliminated by running a warm-up program for approximately 20
minutes before machining parts. The most effective warm-up is to run the current program, at an offset Z
position before the part. This will allow the leadscrews to warm up to the correct temperature and stabilize.
Once the machine is at temperature, the leadscrews won't expand any further, unless they're allowed to cool
down. A warm-up program should be run after each time the machine is left idle.
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1.2 SPINDLE
NOT TURNING
Note: Before using the replacement spindle, the cause of the previous failure must be
determined.
NOISE
Most noises attributed to the spindle actually lie in the motor or drive belt of the machine. Isolate the
sources of noise as follows:
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The transmission cannot be serviced in the field and must be replaced as a unit. Never remove the motor from
the transmission, as this will damage the transmission and void the warranty.
NOISE
l If the noise only occurs in one gear throughout the entire RPM range of that gear position, the
problem lies with the transmission, and it must be replaced.
l If the noise occurs in both gear positions, disconnect the drive belts (see "Transmission" section,
Mech. Service) and repeat the previous step. If the noise persists, the transmission is damaged and
must be replaced.
l Disconnect the drive belts (see "Transmission" section, Mech. Service) and run the machine in high
gear. Command a change of direction and listen for a banging noise in the transmission as the
machine slows down to zero RPM and speeds back up in reverse. If the noise occurs, the motor has
failed and the transmission must be replaced.
l Check the voltage to the gear shifter motor. The voltage between pins 2 and 3 should be approximately
+28V when high gear is commanded and -28V when low gear is commanded. If these voltages are
correct, the gear shifter motor has failed and the transmission must be replaced. If these voltages
are incorrect, the cabling or transmission power supply is at fault.
l Monitor the discrete inputs and outputs SP HIG and SP LOW on the Diagnostics display while
commanding high and low gear. The output SP HIG should be 1 when high gear is selected, and SP
LOW should be 1 when low gear is selected. The inputs SP HIG and SP LOW should be 0 when that
gear is engaged, and should both be 1 when the transmission is between gears. These inputs should
never read 0 at the same time.
If any of these inputs/outputs are incorrect, either the gear change limit switches or the wiring to
the I/O PCB is at fault. The limit switches are located inside the transmission, and cannot be
replaced.
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NOT OPERATING
All problems that are caused by servo motor failures should also register an alarm. Check the alarm history
to determine the problems cause before any action is taken.
Note: If a lead screw fails, it is most often due to a failed bearing sleeve.
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.
Ø 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.
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Misalignment in the lead screw itself will tend to cause the lead screw to tighten up and make excessive noise
at both ends of the travel. The ballnut may get hot. Misalignment radially at the yoke where the lead screw
ball nut mounts is indicated by heating up of the ball nut on the lead screw, and noise and tightness
throughout the travel of the lead screw. Misalignment at the yoke where the ball nut mounts is indicated by
noise and tightness at both ends of the travel of the lead screw. The ball nut may get hot.
ACCURACY / BACKLASH
Accuracy complaints are usually related to tooling, programming, or fixturing problems. Eliminate these
possibilities before working on the machine.
Initial Preparation-
Turn the lathe ON. ZERO RET the machine and move the carriage to the approximate center of its travel in
the Z-axis. Move the turret to the approximate center of the X-axis travel.
X-AXIS:
1. Place a dial indicator and base on the spindle retaining ring with the tip of the indicator positioned on
the outside diameter of the turret, as shown in Fig. 1-1.
2. Set dial indicator and the Distance to go display in the HANDLE JOG mode to zero as follows:
l Zero the dial indicator.
l Press the MDI button on the control panel.
l Press the HANDLE JOG button on the control panel.
The Distance to go display on the lower right hand corner should read: X=0 Z=0
3. Set the rate of travel to .001 on the control panel and jog the machine .010 in the positive (+) X
direction. Jog back to zero (0) on the display. The dial indicator should read zero (0) ± .0001.
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TOTAL DEVIATION BETWEEN THE DIAL INDICATOR AND THE CONTROL PANEL DISPLAY SHOULD NOT EXCEED
.0002.
An alternate method for checking backlash is to place the dial indicator as shown in Fig. 4-1 and manually
push on the turret in both directions. The dial indicator should return to zero after releasing the turret.
Z-AXIS:
1. Place a dial indicator and base on the spindle retaining ring with the indicator tip positioned on the face
of the turret as shown in Fig. 1-2.
2. Set dial indicator and the Distance to go display in the HANDLE JOG mode to zero as follows:
l Zero the dial indicator.
l Press the MDI button on the control panel.
l Press the HANDLE JOG button on the control panel. The Distance to go display on the lower
right hand corner should read: X=0 , Z=0
3. Set the rate of travel to .001 on the control panel and jog the machine .010 in the positive (+) Z
direction. Jog back to zero (0) on the display. The dial indicator should read zero (0) ± .0001.
TOTAL DEVIATION BETWEEN THE DIAL INDICATOR AND THE CONTROL PANEL DISPLAY SHOULD
NOT EXCEED .0002.
An alternate method for checking backlash is to place the dial indicator as shown in Fig. 4-2 and
manually push on the turret in both directions. The dial indicator should return to zero after releasing
the turret.
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January 1999 TROUBLESHOOTING
VIBRATION
OVERHEATING
SERVO ERROR
´ "Servo Error Too Large" alarms occur on one or more axes sporadically.
l Check motor wiring for shorts.
l Driver card may need replacement.
l Servo motor may need replacement.
l Check for binding in motion of lead screw.
HYDRAULIC PRESSURE
HYDRAULIC CHUCK
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Note: Noise in hydraulic unit should decrease a few minutes after start up.
HYDRAULIC TAILSTOCK
CAUTION! Before working on any electrical components, power off the machine and wait
approximately 10 minutes. This will allow the high voltage power on the brushless amplifiers
to be discharged.
ELECTRICAL ALARMS
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.
l 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
l 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.
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´ Phasing Error
l 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 condition occurs when the amplifier is blown, is not receiving the commands, or the 320 volt
power source is dead. If the MOCON is not sending the correct commands to the amplifier, it is
probably due to a broken wire, or a PHASING ERROR that was generated.
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´ Remove the Data & or Address buss from the Video & Keyboard PCB.
l Processors LED's Normal - then Run goes out.
´ Remove the Data & or Address buss from the MOTIF PCB.
l Processors LED's Normal - then Run goes out.
´ Remove the Data & or Address buss from the Micro Processor PCB.
l Processors LED's - CRT and Run are out.
KEYBOARD DIAGNOSTIC
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Example: 1. Pressing the RESET button will cause diodes 1 and 17 to conduct.
l With the POWER OFF read across diode 1.
l 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.
l If your reading was .486 and it dropped to .460 for a difference of .026; the
diode is good.
l 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.
l Press and hold <RESET>. The meter should read a short (0 ohms); if not, the
keypad is bad.
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January 1999 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.
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. Check cable connections and grounding.
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 EMER
GENCY STOP, motor faults, tool changer problems, or power fail.
103 X Servo Error Too much load or speed on X-axis motor. The difference between the
Too Large 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.
107 Emergency Off EMERGENCY STOP button was pressed. Servos are also turned off.
After the E-STOP is released, the RESET button must be pressed at
least twice to correct this; once to clear the E-STOP alarm and once to
clear the Servos Off alarm.
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.
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113 Turret Unlock Fault The turret took longer to unlock and come to rotation position than allowed
for in Parameter 62. The value in Parameter 62 is in milliseconds. This may
occur if the air pressure is too low, the tool turret clamp switch is faulty or
needs adjustment, or there is a mechanical problem.
114 Turret Lock Fault The turret took longer to lock and seat than allowed for in Parameter 63.
The value in Parameter 63 is in milliseconds. This may occur if the air
pressure is too low, the tool turret clamp switch is faulty or needs adjust
ment, or there is a mechanical problem.
115 Turret Rotate Fault Tool motor not in position. During a tool changer operation the tool turret
failed to start moving or failed to stop at the right position. Parameters 62
and 63 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, so check CB5 and relays 1-8, 2-3, and 2-4.
116 Spindle Orientation Fault Spindle did not orient correctly. 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 the time-out times. 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 high
gear sensor was not detected in time. Parameters 67, 70 and 75 can adjust
the time-out times. Check circuit breaker CB4,the circuit breaker for the air
pressure solenoids , and the spindle drive.
118 Spindle Low Gear Fault Gearbox did not shift into low gear. During a change to low gear, the low
gear sensor was not detected in time. Parameters 67, 70 and 75 can adjust
the time-out times. Check the solenoids circuit breaker CB4, and the spindle
drive.
119 Over Voltage Incoming line voltage is above maximum. The servos will be turned off and
the spindle, tool changer, and coolant pump will stop. If this condition
remains for 4.5 minutes, an automatic shutdown will begin.
120 Low Air Pressure Air pressure dropped below 80 PSI for a period of time defined by
Parameter 76. Check your incoming air pressure for at least 100 PSI and
ensure that the regulator is set at 85 PSI.
121 Low Lub or Way lube is low or empty or there is no lube pressure or too high a pressure.
Low Pressure Check tank at rear of machine 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 control internal temperature is above a safe limit. This can be caused
by almost anything in the control overheating. But is usually caused by
overheat of the two regen resistors for servos and spindle drive. This alarm
will also turn off the servos, spindle drive, coolant pump, and tool changer.
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January 1999 ALARMS
One common cause of this overheat condition is an input line voltage too
high. If this condition remains for 4.5 minutes, an automatic shutdown will
begin.
123 Spindle Drive Fault Overheat or failure of spindle drive or motor. The exact cause is indicated
in the LED window of the spindle drive inside the control cabinet. This can
be caused by a stalled motor, shorted motor, overvoltage, undervoltage,
overcurrent, overheat of motor, or drive failure.
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 Tool Turret Fault Turret has not seated itself properly. There may be something obstructing
the turret between the housing and the turret itself.
126 Gear Fault Gearshifter is out of position when a command is given to 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 solenoids circuit
breaker CB4, and the spindle drive.
127 Door Fault The control failed to detect a high signal at the Automatic DOOR input after
an M85 was commanded and the Automatic DOOR input was not received
before a certain period of time. The units are in milliseconds.
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 Chuck Unclamped The control detected that the chuck is unclamped. This is a possible fault
in the air solenoids, relays on the I/O 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 com
manded. Check the solenoid that controls the air to the lock, relay 2-8, the
wiring to the sense switch, and the switch.
134 Low Hydraulic Hydraulic pressure is sensed to be low. Check pump pressure and
Pressure hydraulic tank oil level.
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.
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 connectors at P1-P4.
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143 Spindle Not Locked Shot pin not fully engaged when a tool change operation is being per
formed. 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.
144 Time-out- Time allocated for use prior to payment exceeded. Call your dealer.
Call Your Dealer
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.
149 Spindle Turning Spindle not at zero speed for tool change. A signal from the spindle
drive indicating that the spindle drive is stopped is not present while a
tool change operation is going on.
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 Broken wires or encoder contamination. All servos are turned off. This can
Ch Missing also be caused by loose connectors at P1-P4.
157 MOCON Watchdog The self-test of the MOCON has failed. Replace the MOCON.
Fault
158 Video/Keyboard Internal circuit board problem. The VIDEO PCB in the processor stack is
PCB Failure tested at power-on. This could also be caused by a short in the front
panel membrane keypad. Call your dealer.
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.
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January 1999 ALARMS
160 Low Voltage The line voltage to control is too low. This alarm occurs when the AC
line voltage drops below 190 when wired for 230 volts or drops below
165 when wired for 208 volts.
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 lead to ground.
165 X Zero Ret This alarm will occur if the home/limit switches move or are misadjusted.
Margin Too Small 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 Problem with rigid tapping hardware. The spindle started turning in the
Fault wrong direction.
170 Phase Loss Problem with incoming line voltage between legs L1 and L2. This usually
indicates that there was a transient loss of input power to the machine.
173 Spindle Ref The Z channel pulse from the spindle encoder is missing for hard tapping
Signal Missing synchronization.
174 Tool Load The tool load monitor option is selected and the maximum load for a tool
Exceeded was exceeded in a feed. This alarm can only occur if the tool load monitor
function is installed in your machine.
175 Ground Fault A ground fault condition was detected in the 115V AC supply. This can be
Detected caused by a short to ground in any of the servo motors, the tool change
motors, the fans, or the oil pump.
176 Overheat Shutdown An overheat condition persisted for 4.5 minutes and caused an automatic
shutdown.
177 Over voltage An overvoltage condition persisted for 4.5 minutes and caused an
Shutdown automatic shutdown.
178 Divide by Zero Software error, or parameters are incorrect. Call your dealer.
182 X Cable Fault Cable from X-axis encoder does not have valid differential signals.
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ALARMS January 1999
186 Spindle Not Turning Trying to feed while spindle is in the stopped position.
198 Spindle Stalled Control senses that no spindle fault has occurred, the spindle is at speed,
yet the spindle is not turning. Possibly the belt between the spindle drive
motor and spindle has slipped or is broken.
201 Parameter CRC Error Parameters lost maybe by low battery. Check for a low battery and low
battery alarm.
202 Setting CRC Error Settings lost maybe by low battery. Check for a low battery and low
battery alarm.
203 Lead Screw CRC Error Lead screw compensation tables lost maybe by low battery. Check for
CRC Error low battery and low battery alarm.
204 Offset CRC Error Offsets lost maybe by low battery. Check for a low battery and low
battery alarm.
205 Programs CRC Error Users program lost maybe by low battery. 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.
210 Insufficient Memory Not enough memory to store users program. Check the space available in
the LIST PROG mode and possibly delete some programs.
26 96-8710
January 1999 ALARMS
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; Call your dealer.
214 No. of Programs Indicates that the number of programs disagrees with the internal
Changed variable that keeps count of the loaded programs. Call your dealer.
215 Free Memory PTR Indicates the amount of memory used by the programs counted in the
Changed system disagrees with the variable that points to free memory. Call your
dealer.
216 Probe Arm Down Indicates that the probe arm was pulled down while a program was
While Running running.
217 X Axis Phasing Error Error occurred in phasing initialization of brushless motor. This can be
caused by a bad encoder, or a cabling error.
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.
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.
236 Spindle Motor Overload This alarm is generated in machines equipped with a Haas vector drive, if the
spindle motor becomes overloaded.
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).
96-8710 27
ALARMS January 1999
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.
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.
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.
249 Prog Data Possible corrupted program. Save all programs to floppy disk, delete all,
Begins Odd then reload.
253 Electronics Overheat The control box temperature has exceeded 145 degrees F. This can be
caused by an electronics problem, high room temperature, or clogged air
filter.
258 Invalid DPRNT Format Macro DPRNT statement not structured properly.
260 Bad Language CRC Indicates FLASH memory has been corrupted or damaged.
262 Parameter CRC Missing RS-232 or floppy read of parameter had no CRC when loading from floppy
or RS-232.
263 Lead Screw CRC Missing Lead screw compensation tables have no CRC when loading from floppy or
RS-232.
265 Macro Variable File Macro variables lost maybe by low battery. Check for a low battery and low
CRC Error battery alarm. Reload the macro variable file.
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.
28 96-8710
January 1999 ALARMS
292 Mismatch Axis with I, (K) was commanded as X axis (Z axis) in the block with chamfering.
I, K Chamfering
293 Invalid I,K or R The move distance in the block commanded with chamfering, corner R is
in G01 less than the chamfering, corner R amount.
294 Not G01 after The command after the block commanded with chamfering, corner R is not
Chamfering, Corner R G01.
295 Invalid Move After The command after the block commanded with chamfering, corner R is
Chamfering either missing or wrong. There must be a move perpendicular to that of the
chamfering block.
296 Not One Axis Move Consecutive blocks commanded with chamfering, corner R (i.e., G01 Xb Kk;
with Chamfering G01 Zb Ii). After each chamfering block, there must be a single move
perpendicular to the one with chamfering, corner R amount.
302 Invalid R Code Check your geometry. R must be less than or equal to half the distance from
start to end within an accuracy of 0.0010 inches.
304 Invalid I, J, or K In Check your geometry. Radius at start must match radius at end of arc
G02 or G03 within 0.0010 inches.
305 Invalid Q In Q in a canned cycle must be greater than zero and must be a valid N number.
Canned Cycle
308 Invalid Tool Offset A tool offset not within the range of the control was used.
310 Invalid G Code G code not defined and is not a macro call.
311 Unknown Code Possible corruption of memory by low battery. Call your dealer.
312 Program End End of subroutine reached before M99. Need an M99 to return from sub-
routine.
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ALARMS January 1999
314 Subprogram or Macro Check that a subroutine is in memory or that a macro is defined.
Not In Memory
315 Invalid P Code In The P code must be the name of a program stored in memory without a
M97, M98 or M99 decimal point for M98 and must be a valid N number for M99, G70, 71, 72,
and 73.
316 X Over Travel Range X-axis will exceed stored stroke 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.
320 No Feed Rate Specified Must have a valid F code for interpolation functions.
321 Auto Off Alarm A fault turned off the servos automatically; 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).
326 G04 Without P Code Put a Pn.n for seconds or a Pn for milliseconds.
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.
332 H and T This alarm is generated when Setting 15 is turned ON and an H code
Not Matched 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.
30 96-8710
January 1999 ALARMS
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).
337 GOTO or P line Subprogram is not in memory, or P code is incorrect. P not found
Not Found
338 Invalid IJK and XYZ There is a problem with circle definition; check your geometry.
in G02 or G03
339 Multiple Codes Only one M, X, Y, Z, A , Q, etc. allowed in any block or two G codes in the
same group. Two or more I,K, R are commanded in the same block with
chamfering, corner rounding
340 Cutter Comp Begin Select cutter compensation earlier. Cutter comp. must begin on a linear
With G02 or G03 move.
342 Cutter Comp Path Geometry not possible. Check your geometry.
Too Small
343 Display Queue A block exists that is too long for displaying queue. Shorten title block.
Record Full
344 Cutter Comp With Cutter comp only allowed in XY plane (G17).
G18 and G19
348 Illegal Spiral Motion Linear axis path is too long. For helical motions, the linear path must not
be more than the length of the circular component.
349 Prog Stop W/O Cutter compensation has been cancelled without an exit move. Potential
Cancel Cutter Comp damage to part.
350 Cutter Comp Look There are too many non-movement blocks between motions when cutter
Ahead Error 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 B, 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 LOSS.
354 Aux Axis Aux axes not responding. Check auxiliary axes and RS-232 connections.
Disconnected
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.
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ALARMS January 1999
358 Multiple Aux Axis Can only move one auxiliary axis at a time.
360 Tool Changer Disabled Check Parameter 57. Not a normal condition for the Lathe.
362 Tool Usage Alarm Tool life limit was reached. To continue, reset the usage count in the
Current Commands display and press RESET.
363 Coolant Locked Off Override is off and program tried to turn on coolant.
364 No Circ Interp Only rapid or feed is allowed with aux axes.
Aux Axis
372 Tool Change In Tool change not allowed while canned cycle is active.
Canned Cycle
373 Invalid Code in DNC A code found in a DNC program could not be interpreted because of
restrictions to DNC.
374 Missing XBZA in G31 skip function requires an X, B, Z, or A move.
G31 or G36
376 No Cutter Comp In Skip Skip G31 function cannot be used with cutter compensation.
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.
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 changes offsets but L, P, or R code is missing or
Code In G10 invalid.
387 Cutter Comp Not If block buffering has been limited, Cutter comp cannot be used.
Allowed With G103
32 96-8710
January 1999 ALARMS
388 Cutter Comp Not Coordinates cannot be altered while cutter comp is active. Move G10
Allowed With G10 outside of cutter comp enablement.
389 G17, G18, G19 Planes of rotation cannot be changed while rotation is enabled.
Illegal in G68
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.
393 Invalid Motion In Rigid Tapping can only be in the Z minus G74 or G84 direction.
G84 or G184 Make sure that the distance from the initial position to the commanded Z
depth is in the minus direction.
394 B Over Travel Range The tailstock (B-axis) has exceeded it's maximum range of travel.
395 Invalid Code In Any canned cycle requiring a PQ path sequence may not have an M code in
Canned Cycle the same block. That is G70, G71, G72, and G73.
396 Conflicting Axes An Incremental and Absolute command can not be used in the same block
of code. For example, X and U cannot be used in the same block.
397 Invalid D Code In the context that the D code was used it had an invalid value. Was it
positive ?
398 Aux Axis Servo Off Aux. axis servo shut off due to a fault.
399 Invalid U Code In the context that the U code was used it had an invalid value. Was it
positive ?
403 RS-232 Too Many Progs Cannot have more than 200 programs in memory.
404 RS-232 No Program Need name in programs when receiving ALL; otherwise has no way to
Name store them.
405 RS-232 Illegal Prog Check files being loaded. Program name must be Onnnn and must be
Name 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.
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 Check your program. The program will be stored but the bad data is
Error 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.
410 RS-232 Invalid V Code Bad parameter or setting data. User was loading settings or parameters
and something was wrong with the data.
96-8710 33
ALARMS January 1999
411 RS-232 Empty Program Check your program. Between % and % there was no program found.
412 RS-232 Unexpected Check Your Program. An ASCII EOF code was found in the input data
End of Input before the complete program was received. This is a decimal code 26.
413 RS-232 Load Insufficient Program received doesnt fit. Check the space available in the LIST PROG
Memory 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 38400 bits per second.
415 RS-232 Overrun Data sent too fast to CNC. This alarm is not normally possible as this
control can keep up with as much as 38400 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 A code found on input of a DNC program could not be interpreted.
For DNC
420 Program Number The O code in the program being loaded did not match the O code
Mismatch entered at the keyboard. Warning only.
429 Flpy Dir Insufficient Floppy memory was almost full when an attempt was made to read the
Memory floppy directory.
430 Floppy Unexpected Check your program. An ASCII EOF code was found in the input data
End of Input before the complete program was received. This is a decimal code 26.
431 Floppy No Prog Need name in programs when receiving ALL; otherwise has no way to
Name store them.
432 Floppy Illegal Prog Check files being loaded. Program must be Onnnn and must be at the
Name beginning of a block.
433 Floppy Empty Prog Check your program. Between % and % there was no program found.
Name
434 Floppy Load Insufficient Program received doesn't fit. Check the space available in the LIST
Memory PROG mode and possibly delete some programs.
436 Floppy File Not Found Could not find floppy file.
437 TS Under Shoot The tailstock did not reach it's intended destination point.
34 96-8710
January 1999 ALARMS
438 TS Moved While Holding The tailstock moved more than a preset amount while holding a part (e.g.,the
Part part slips in the chuck).
439 TS Found No Part During an M21 or G01, the tailstock reached the hold point without
encountering the part.
450 Bar Feeder Fault This means that discrete input 1027 (BFSPLK) is too high. See parameter
278 bit 20 CK BF status.
451 Bar Feeder Spindle This means that discrete input 1030 (BF FLT) is high. See parameter 278
Interlock bit 21 CK BF SP ILK.
501 Too Many Assignments Only one assignment = is allowed per block. Divide block in error into
In One Block multiple blocks.
502 [ Or = Not First Term An expression element was found where it was not preceded by [ or
In Expressn =, that start expressions.
503 Illegal Macro Variable A macro variable number was used that is not supported by this control,
Reference use another variable.
504 Unbalanced Paren. In Unbalanced brackets, [ or ], were found in an expression. Add or
Expression delete a bracket.
505 Value Stack Error The macro expression value stack pointer is in error. Call your dealer.
506 Operand Stack Error The macro expression operand stack pointer is in error. Call your dealer.
507 Too Few Operands On An expression operand found too few operands on the expression stack.
Stack Call your dealer.
511 Unbalanced Right Number of right brackets not equal to the number of left brackets.
Brackets
513 Var. Ref. Not Allowed Alphabetic addresses N and O cannot be combined with macro variables.
With N Or O Do not declare N#1, etc.
514 Illegal Macro Address A macro variable was used incorrectly with an alpha address. Same as
Reference 513.
515 Too Many Conditionals Only one conditional expression is allowed in any WHILE or IF-THEN
In a Block block.
96-8710 35
ALARMS January 1999
516 Illegal Conditional A conditional expression was found outside of an IF-THEN, WHILE,
Or No Then or M99 block.
517 Exprsn. Not Allowed A macro expression cannot be concatenated to N or O. Do not declare
With N Or O O[#1], etc.
518 Illegal Macro Exprsn An alpha address with expression, such as A[#1+#2], evaluated
Reference incorrectly. Same as 517.
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 An illegal value was passed to a function, such as SQRT[ or ASIN[.
Parameter
522 Illegal Assignment A variable was referenced for writing. The variable referenced is read
Var Or Value only.
523 Conditional Reqd THEN was encountered and a conditional statement was not processed
Prior To THEN in the same block.
524 END Found With No An END was encountered without encountering a previous matching
Matching DO DO. DO-END numbers must agree.
525 Var. Ref. Illegal Variable cannot be read during axis movement.
During Movement
526 Command Found On A G-code command was found on a WHILE-DO or END macro block.
DO/END Line Move the G-code to a separate block.
527 = Not Expected Or Only one Assignment is allowed per block, or a THEN statement is missing.
THEN Required
528 Parameter Precedes On G65 lines all parameters must follow the G65 G-code. Place
G65 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 Ks Only 10 occurrences of I, J, or K can occur in a G65 subroutine call.
In G65 Reduce the I, J, or K count.
531 Macro Nesting Too Only four levels of macro nesting can occur. Reduce the amount of
Deep nested G65 calls.
532 Unknown Code In Macro syntax is not allowed in a pocket pattern subroutine.
Pocket Pattern
533 Macro Variable A conditional expression evaluated to an UNDEFINED value, i.e. #0.
Undefined Return True or False.
534 DO Or END Already Multiple use of a DO that has not been closed by and END in the same
In Use subroutine. Use another DO number.
36 96-8710
January 1999 ALARMS
535 Illegal DPRNT A DPRNT statement has been formatted improperly, or DPRNT does
Statement not begin block.
536 Command Found On A G-code was included on a DPRNT block. Make two separate blocks.
DPRNT Line
537 RS-232 Abort While a DPRNT statement was executing, the RS-232 communications
On DPRNT failed.
538 Matching END Not A WHILE-DO statement does not contain a matching END statement.
Found Add the proper END statement.
540 Macro Syntax A section of code was interpreted by the control where macro statement
Not Allowed syntax is not permitted. In lathe controls, PQ sequences describing part
geometry cannot use macro statements in the part path description.
600 Code Not Expected During program interpretation, the control found code out of context. This
In This Context may indicate an invalid address code found in a PQ sequence. It may also
indicate faulty memory hardware or lost memory. Look at the highlighted
line for improper G-code.
601 Maximum PQ Blocks The maximum number of blocks making up a PQ sequence was exceeded.
Exceeded Currently, no more than 65535 blocks can be between P and Q.
602 Non Monotonous PQ The path defined by PQ was not monotonic in the X axis. A monotonic path
Blocks in X is one which does not change direction starting from the first motion block.
603 Non Monotonous PQ The path defined by PQ was not monotonic in the Z axis. A monotonic path
Blocks in Z is one which does not change direction starting from the first motion block.
604 Non Monotonous Arc A non-monotonic arc was found in a PQ block. This will occur in PQ blocks
In PQ Block within a G71 or G72 if the arc changes it's X or Z direction. Increasing the
arc radius will often correct this problem.
605 Invalid Tool Nose Angle An invalid angle for the for the cutting tool tip was specified. This will occur
in a G76 block if the A address has a value that is not from 0 to 120 degrees.
606 Invalid A Code An invalid angle for linear interpolation was specified. This will occur in a
G01 block if the A address was congruent to 0 or 180 degrees.
607 Invalid W Code In the context that the W code was used it had an invalid value. Was it
positive ?
609 Tailstock Restricted When the axes move into the tailstock restricted zone at any time during
Zone program execution. To eliminate the problem, change the program or
Settings 93 and 94 to open up the restricted zone.
610 G71/G72 Domain The number of troughs nested has exceeded the control limit. Currently, no
Nesting Exceeded more than 10 levels of trough can be nested. Refer to the explanation of G71
for a description of trough nesting.
96-8710 37
ALARMS January 1999
611 G71/G72 Type I Alarm When G71 or G72 is executing and the control detects a problem in the
defined PQ path. It is used to indicate which method of roughing has been
selected by the control. It is generated to help the programmer when
debugging G71 or G72 commands.
The control often selects Type I roughing when the programmer has
intended to use Type II roughing. To select Type II, add R1 to the G71/G72
command block (in YASNAC mode), or add a Z axis reference to the P block
(in FANUC mode).
612 G71/G72 Type II Alarm This alarm is similar to Alarm 611, but indicates that the control has
selected Type II roughing.
613 Command Not Allowed A command (M96, for example) in the highlighted block cannot be
In Cutter Comp. executed while cutter comp. is invoked.
614 Invalid Q Code A Q address code used a numeric value that was incorrect in the context
used. Q used to reference tip codes in G10 can be 0...9. In M96 Q can
reference only bits 0 to 31. Use an appropriate value for Q
615 No Intersection to While cutter comp was in effect, a geometry was encountered whose
Offsets in CC compensated paths had no solution given the tool offset used. This can
occur when solving circular geometries. Correct the geometry or change
the tool radius.
616 Canned Cycle Using A canned cycle using P & Q is already executing. A canned cycle can not
P & Q is Active be executed by another PQ canned cycle.
End Of List
38 96-8710
January 1999 MECHANICAL SERVICE
3. MECHANICAL SERVICE
The following chart should be used as a reference guide for torquing machine fasteners where specified.
DIAMETER TORQUE
3.1 TURRET
1. Change Setting 7, "Parameter Lock", to OFF. Move to Parameter 43 on the Parameters Display. This is
the tool turret motor parameters. Change INVIS AXIS from 1 to 0 (zero).
2. Move to the Alarm Display and type DEBUG and then press the WRITE key. Verify that the debug line
is displayed.
Note: Ensure there is adequate clearance between the turret and chuck before perform-
ing the next step.
3. Press PRGRM/CNVRS, then the MDI key. Type M43 into MDI and press CYCLE START. This will unlock
the turret by pushing it in the Z-direction.
4. Press the HANDLE JOG key, and then the POSIT key to get into the Position Display and Jog mode.
The A axis should be displayed below the X and Z axes.
5. Press the letter "A", then "HANDLE JOG", and then a jog speed other than ".1". A message should indicate
that the A axis is being jogged.
6. Turn the JOG handle until the obstruction is cleared and the turret rotates freely. If an OVERCURRENT
alarm is received, press RESET and turn the JOG handle in the opposite direction.
7. Move to Parameter 43 on the Parameter Display and change INVIS AXIS back to 1. Change Setting
7 back to ON.
8. Turn the control power off and then back on. The turret can now be positioned by pressing either
POWER UP/RESTART or AUTO ALL AXES.
96-8710 39
MECHANICAL SERVICE January 1999
Note: If alarms 111 or 164 occur after the obstruction is cleared, you may need to adjust
the turret motor coupling.
IMPORTANT!!
After a crash the following procedures should be performed in order to verify proper turret alignment.
REMOVAL
2. Change Parameter 76 from 500 to 50000 ( so you will not trip on a low air pressure alarm).
4. Put a 3/4 " wrench on the bolt at the end of the air cycle. Pull down (-X) until the turret is fully unclamped.
5. Place a block snugly between the back of the turret shaft and the casting to keep the turret shaft from
shifting.
Caution: If the shaft moves back when the turret is disconnected the ball bearings in the turret
cam will fall and have to be replaced before the turret can be reassembled.
6. Empty the oil from the turret assembly. Remove the screw from the bottom of the plate located just behind
the turret on the turret assembly and allow the oil to drain into a bucket.
7. Remove the four bolts from the turret retainer and remove the retainer.
Note: If a shaft extension is available install it at this time. Using the extension gives you
greater movement of the turret and allows you to remove and easily install the key,
washers and needle bearings
Caution: The turret is heavy and could be slippery. Be careful to not lose the key as it will be
facing down at this point.
9. The two washers, needle bearing, and key should be removed from the shaft and put aside at this time.
INSTALLATION
2. Place the washer on the surface of the turret and center it using your fingers. Be sure to keep grease off
the surface facing the needle bearing.
40 96-8710
January 1999 MECHANICAL SERVICE
4. Place the washer on the spring retainer on the lip of the turret shaft. Clean any grease that may have gotten
on the shaft.
5. Place the needle bearing on the lip and stick it to the washer. Be sure the other surface of the bearing is
clean and free of grease.
Note: Check that the turret key did not fall off.
Check that the washer is centered on the turret.
Check that the washer and needle bearing are still on the shaft lip.
Note: Check the turret "O" ring. If you can see either the washer or the needle bearing
they have slid off the shaft. Return to step 7 of the turret removal section.
11. Replace the screw in the bottom of the plate located just behind the turret on the turret assembly.
13. Remove the brace from between the turret shaft and the casing.
16. Replace the turret assembly and sliding tool change covers.
Note: The turret must be at tool #1 and clamped to perform this procedure.
4. Loosen the turret motor coupling clamp screw closest to the motor. (Refer to Figure 3-1)
5. Press the ZERO RET key, then the A key, and the ZERO SINGL AXIS key. This will cause the motor to
go to the first encoder Z pulse.
6. With the servos on, move the turret motor coupling back and forth to find the center of its backlash, and
tighten the clamp screw as close to the center of the backlash as possible.
96-8710 41
MECHANICAL SERVICE January 1999
Note: If it is tight (no backlash) it will be necessary to force it in one direction or the other
until it pops into its backlash area. If it gets tighter when it is turned, STOP; this is the
wrong direction.
8. Press the ZERO RET key, A key, and ZERO SINGL AXIS key. This will home the turret at tool #1.
9. Press the EMERGENCY STOP button and turn the turret motor coupling back and forth to verify that the
backlash is centered.
TOOLS REQUIRED:
3 MAGNETIC INDICATOR BASE 3 DIAL INDICATOR (0.0005" OR LESS RESOLUTION)
3. Place the magnetic indicator base on the spindle retainer ring. Position the indicator tip on the turret
face so there is at least 3.5" of travel in each direction from the center of the X axis and 1/4" below the
center cap. Refer to Figure 3-2.
4. Jog the X axis so the indicator is at one end travel then zero the indicator.
5. Jog the X-axis to the other end of travel and check your reading (tolerance 0.0003" TIR)
6. If the reading is greater than the tolerance specified the turret needs to be realigned.
42 96-8710
January 1999 MECHANICAL SERVICE
It is recommended that you read the following sections in their entirety before starting the alignment
procedures.
Note: Be sure to remove the 4 SHCS located behind the turret. The X-axis wiper may
also need to be replaced if damaged.
3. Remove top plate cover to the turret housing. Be sure to check the gasket and see if it needs replacement.
4. Remove the SHCS that mount the coolant adapter block to the turret housing. The turret must be in the
unclamped position(M43) in order to lift the coolant line over the black access plate.
5. Remove the black access plate. The plate may need to be pried off with a screwdriver.
Note: Have a bucket ready to catch oil draining from the housing.
6. Loosen all turret housing mounting bolts except for the front left bolt nearest the turret.
7. Clamp the turret (M44) and jog to the center of the X-travel.
8. Tap on the turret casting in order to bring the face of the turret into alignment.
Note: In order to help keep the turret housing from slipping down during the alignment
procedure, keep the turret housing bolts as snug as possible.
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9. Apply Loctite and torque all turret housing mounting bolts to 50 FT LBS.
10. Recheck the turret face to ensure the measurement did not change.
12. Pour 10 cups of oil (DTE 25) into gear side of turret housing.
After the turret face has been realigned it is important to verify that the spindle is still in alignment.
Proceed to Chapter 2, Spindle Alignment Verification.
Note: All alignments done could change spindle centerline. Verify and enter new
spindle centerline position in Parameter 254.
This procedure should be performed after spindle alignment has been checked.
TOOLS REQUIRED:
3 SPINDLE ALIGNMENT TOOL OR A DIAL INDICATOR AND MAGNETIC BASE
3 DIAL INDICATOR (0.0005" OR LESS RESOLUTION)
3. Mount the spindle alignment tool onto the spindle retainer ring with the dial indicator mounted to the
end of the tool. Refer to Figure 3-3.
4. Jog the X axis to the spindle center line. This is the value stored in Parameter 254, found on the "Position
Raw Data" page (this page is entered through Debug mode).
5. Position the indicator tip just inside pocket #1 so that it is parallel to the X- axis. Zero the indicator, then
rotate the spindle180 0 , the indicator should read ZERO.
Note: Use the jog handle in tenths mode to zero the pocket.
6. Next, rotate the spindle and take readings at both the top and bottom of the pocket.
7. If the reading exceeds .0010" from the centerline or .0020" TIR, the inner coupling may need adjustment.
Note: If the reading is within specifications, but the X axis position is different from
parameter 254, enter the new number in parameter 254.
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TOOLS REQUIRED:
3 MAGNETIC INDICATOR BASE 3 DIAL INDICATOR (0.0005" OR LESS RESOLUTION)
3 A BAR APPROXIMATELY 12"x 4"x 1" (GROUND TO WITHIN 0.0001" ON THE 1" WIDTH SIDE)
2. Clean the turret pockets and tool holders then command tool #1 to the cutting position.
3. Place a clean and undamaged tool holder loosely (do not thread nuts) in the nearest pocket
to the spindle and the other in the opposite tool holder.
4. Place the 12" x 4" x 1" bar across the small diameter of the two tool holders (ground side down).
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6. Mount the indicator to the spindle retainer ring. Position the indicator tip at the bottom edge of
the bar.
7. Jog the X axis so the indicator is at one end of the bar, and zero the indicator.
8. Jog the X axis to the other end of the bar, and check your reading (tolerance is 0.0003" TIR).
9. If the reading is not within tolerance, loosen all (10) turret bolts the turret in the clamped position
10. Rotate the turret 180 degrees and check reading of indicator for .0003" TIR or less.
11. Tap on the turret until the readings are within tolerance.
- If the reading is greater than the tolerance specified, proceed to the appropriate coupling
adjustment procedure.
This procedure should only be performed if there is not enough adjustment to perform an outer coupling
alignment.
Note: If the turret has a 1/4" brass plug, proceed to the next section.
2. Pull the turret air cylinder all the way forward (unclamp) and place something snugly between the back
of the turret shaft and the casting to keep the turret shaft from shifting.
3. Remove the four bolts from the center turret shaft cover.
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4. To gain access to the rear coupling, either remove the turret or install a turret shaft extension and slide
the turret onto it. (Be careful not to loosen the key way, it will be facing down at this point.)
5. Loosen the 10 bolts on the inner coupling and center the coupling to the bolt holes. Retighten them to
to the required specifications. (Refer to torque chart at beginning of the section)
6. Install the thrust bearing and both thrust bearing washers to the shoulder of the turret shaft.
7. Go to Parameter 43 and change the INVIS AXIS to zero (0). Then go to the Alarms page, type DEBUG
and press the WRITE key. Press the HANDLE JOG key. Press the key in the lower right corner of the
jog keys (its unmarked and directly below the Z+ jog key). Then jog the A axis so the key way slot is
on top.
8. Reinstall the turret and turret shaft cover. Make sure that the turret makes it over the O-ring before the
bolts are tightened completely. If the bolts tighten up and the O-ring is still visible, one of the thrust
washers is not on the shoulder of the turret shaft.
9. Return to Step 1 of the "Turret Alignment Verification" section and verify your readings.
10. When the turret alignment is complete, go to the Alarms page and type DEBUG, then press the WRITE
key. Change Parameter 43, INVIS AXIS to 1.
Note: All alignments done could change spindle centerline. Verify and enter new
spindle centerline position in Parameter 254.
This procedure is only to be performed if there is not enough adjustment to perform an outer coupling
alignment.
Note: This procedure is only to be performed if the turret is equipped with a 1/4" brass
plug.
1. Remove the 1/4" brass plug to gain access to the rear coupling.
3. Pull the turret air cylinder all the way forward (unclamp) with a wrench.
4. Go to Parameter 43 and change the INVIS AXIS to zero. Then go to the Alarms page, type DEBUG and
press the WRITE key. Press the HANDLE JOG key. Press the key in the lower right corner of the jog
keys (its unmarked and directly below the Z+ jog key).
5. Loosen, then lightly retighten all 10 inner coupling bolts (jogging the A axis for access) and center the
coupling to the bolt holes.
6. Clamp the couplings by pushing the turret air cylinder back to its original position.
7. Return to Step 1 of the "Turret Alignment Verification" section and verify your readings.
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9. Tighten all 10 inner coupling bolts (jogging the A axis for access) and torque them to the required
specifications. Refer to torque chart at beginning of section.
12. Connect air to machine and change parameter 76 back to original value (default: 500)
14. When the turret alignment is complete, go to the Alarms page and type DEBUG", then press the
WRITE key. Change Parameter 43, INVIS AXIS to 1.
Note: All alignments done could change spindle centerline. Verify and enter new
spindle centerline position in Parameter 254.
3. Press POSIT, and PAGE UP until you see the debug screen POS-RAW DAT 1.
4. Observe the x axis COMMAND position. This will be encoder steps. Ignore the negative sign and the
decimal point.
5. Copy this number to parameter 254 as a positive number with no decimal point.
6. ALARMS, enter "DEBUG," press WRITE. Or simply turn the power off and back on. This deactivates debug
mode.
Note: Alarms 113 and 114, "Turret Unlock Fault" and "Turret Lock Fault", can indicate
that a turret in/out adjustment is necessary. These alarms occur when the Turret Clamp
and Unclamp switches sense a turret positioning error.
1. Before hooking the cylinder end to the lever cam, manually insure that the Turret is in its furthest clamped
position.
2. Screw the cylinder rod end in so that the lever cam mounting hole aligns with the rod end attachment.
3. Start the mounting bolt with the spacer through the cylinder rod end and into lever cam, then tighten.
4. If the turret travel is not .150", ensure there is no mechanical problem or obstruction affecting the travel.
If no problem is found, the air cylinder rod travel needs to be adjusted. To make this adjustment, loosen
the two jam nuts, and screw the extension sleeve away from the air cylinder to increase the
turret travel, or towards the air cylinder to decrease the turret travel. When adjustment is
complete, tighten the jam nuts to the extension sleeve.
5. Once the turret travel is set, the Clamp/Unclamp switches must be adjusted. Enter the diagnostic data page
in order to monitor the TT UNL (Turret Unlocked) and TT LOK (Turret Locked) discrete inputs.
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Section I - For production units making turret in / out adjustments with trip switches.
Section II - For production units making turret in / out adjustments using air cylinder mounted reed
switches
Section I
a. In MDI, enter an M43 (Unlock Turret). The Turret Unclamp switch should be tripped at this point,
and discrete input TT UNL should read "1".
b. Place a 0.160" gage block between the Turret Clamp switch and the side of the cam, ensuring it is flat
against the cam. The Turret Clamp switch should trip and the discrete input TT LOK should read "1".
Remove the gage block.
If either switch does not trip when the gage block is in place, the switches need to be adjusted. Adjust
the switches by loosening the two SHCS and moving the entire switch bracket; DO NOT move the
individual switches unless absolutely necessary.
c. Enter an M44 (Lock Turret). The Turret Clamp switch should be tripped at this point, and discrete
input TT LOK should be "1".
d. Place a 0.160" gage block between the Turret Unclamp switch and the side of the cam, ensuring it is
flat against the cam. The Turret Unclamp switch should trip and discrete input TT UNL should read "1".
Remove the gage block.
e. If either switch does not trip when the gage block is in place, the switches need to be adjusted. Adjust
the switches by loosening the two SHCS and moving the entire switch bracket; DO NOT move the
individual switches unless absolutely necessary. Refer to Figure 3-6.
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Section II
a. In MDI, enter an M43 (Unlock Turret). The Turret Unclamp switch should be tripped at this point, and
discrete input TT UNL should read "1".
If this does not occur, the lower air cylinder mounted reed switch needs to be adjusted by loosening
the worm drive clamp retaining the sensor and moving it into position until this discrete input
appears consistently. Retighten sensor. When the turret is in any other position than
Unlock Turret, the discrete input should read "0."
b. In MDI, enter an M44 (Lock Turret). The Turret Clamp switch should be tripped at this point, and
discrete input TT LOK should read "1".
If this does not occur the upper air cylinder mounted reed switch needs to be adjusted by loosening
the worm drive clamp retaining the sensor and moving it into position until this discrete input
appears consistently. Retighten sensor. When the turret is in any other position than
Lock Turret, the discrete input should read "0."
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TURRET REMOVAL
2. Rotate turret until it is on tool number one, and position X axis for easy removal of turret.
3. In MDI mode enter and execute M43 to unclamp the turret then E-stop the machine.
5. Remove retainer plate and O-ring from the turret (either four or eight bolts).
6. Remove turret.
8. Remove thrust washers and needle bearings inspect these before installation.
TURRET REPLACEMENT
1. Grease (red grease) and install thrust washers and needle bearings.
3. Install O-ring and retainer plate of turret. Start bolts and run them up flush with retainer plate.
2. Mark the retaining ring and turret casting for alignment purposes.
4. Remove inspection plate which will allow the gearbox oil to drain. Catch oil in a bucket.
5. Remove the bolt that holds the rod end to the lever cam. Do not adjust the rod end
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8. Remove the two set screws on the home switch cam at the back of the shaft, then remove the key. Turn
the motor shaft to gain access to key or set screws. (servos off, E-stop).
10. Remove assembly (coupling holder and shaft) being careful to keep tension on the assembly to hold the
cam and bearings in place.
2. Install coupling mount (cams and bearing) using the installation tool, and line up key way with the bolt
that is equidistant between the springs (or previous marked alignment).
3. Install turret shaft assembly (align mark on retaining ring with the mark on the casting).
5. Install back half of curvic coupling on to gearbox snug two bolts and center the play between the bolt holes.
Install the remainder of the bolts and torque to specifications.
Turret motor coupling adjustment procedure must be completed for proper alignment.
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3.2 SPINDLE
This procedure should be performed after the turret face has been realigned.
TOOLS REQUIRED:
3 SPINDLE ALIGNMENT TEST BAR (P/N# T-1312)
2. Install Spindle Alignment Test Bar. Take up any slack between bolts with washers.
3. Place the indicator tip onto the test bar near the spindle. Rotate the spindle to determine the runout.
The tolerance is .0001"
- If the tolerance is greater than .0001 then loosen the test bar mounting bolts, rotate the
spindle and tap on the mounted end of the fixture until the runout within tolerance.
4. Tighten the bolts to the test bar being careful not to alter the alignment.
5. Move the indicator tip to the end of the test bar and check for runout. Tolerance should not exceed
0.0005".
- If the reading is greater than 0.0005" remove the test bar, clean both mating surfaces.
6. Next rotate the test bar until the reading is 1/2 of the total runout. Using the Z-axis, jog the indicator tip
over 10 inches of the test bar to determine if the spindle is high or low. Tolerance should not exceed
(0.0004/10")
- If the measurement is greater than the allowable tolerance then the spindlehead casting
must be realigned. Before realigning the spindlehead, perform a coupling adjustment
- If the measurement is within the allowable tolerance, go to step 7.
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7. Position the indicator tip on the backside of the test bar. Jog the indicator tip over 10 inches of the test
bar to determine spindle parallelism. The maximum allowable tolerance is 0.0004/10".
SPINDLE REMOVAL
Note: POWER OFF THE MACHINE BEFORE PERFORMING THE FOLLOWING PROCE-
DURE.
1. Remove the chuck or collet nose from the Lathe and the necessary covers to gain access to the spindle
assembly.
2. Disconnect oil return hose and coolant drain hose after powering OFF machine.
4. Loosen the SHCS from the adapter, and detach the hydraulic cylinder.
5. Loosen the eight SHCS on the inside of adapter and detach from spindle shaft.
6. Unplug the encoder. Unscrew the encoder bracket, remove the encoder, then remove the belt.
7. Loosen the four SHCS holding the spindle motor. Slide the motor up by squeezing the belts. Tighten
the SHCS and remove the drive belts from the spindle assembly.
8. Loosen the six SHCS and remove the spindle drive pulley.
9. Disconnect the two lubrication hoses and unscrew the fittings from the spindle housing. Note the di
rection of the flat sides of the fittings for lubricating the spindle bearings.
10. Unscrew the six SHCS holding the spindle retaining ring and remove. Also remove the O-ring.
11. Remove Spindle Carefully. (For SL-40 spindle removal, contact HAAS Service for removal tool)
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SPINDLE INSTALLATION
Tools Required:
3 (1) Blue Loctite 3 (1) 1/2" Torque Wrench (Up to 250 ft-lbs)
3 (1) HAAS Belt Tensioning Tool P/N# T1510 (SL 20), P/N# T1537 (SL 30 and 40)
1. Install spindle into housing. Check location of oil holes for proper alignment.
2. Place the retainer ring on the spindle with the O-ring toward the spindle. Ensure that the drain holes are
at the bottom of the retainer ring and that the O-ring remains in place.
3. Apply blue Loctite to the six retainer ring mounting bolts and install them. Place a .001 shim between
the spindle and retainer ring. Torque the mounting bolts to 50 FT-LBS.
Note: The bolts should be torqued in a star pattern and in increments of 10, 20, 30,40
and finally 50 FT-LBS. Check alignment of the spindle and retaining ring with a .001
shim at each torque value.
4. Ensure that the spindle can spin freely and the spindle and housing oil mist holes are aligned. If not,
remove the retainer ring and spindle and reinstall.
5. Screw the oil mist nozzles in by hand until they bottom. Then back off the nozzles 1.5- 2 turns ensuring
that the holes on the nozzles and spindle housing are aligned correctly and pointed towards the bearings.
Make sure the nozzles do not come into contact with spindle shaft.
6. Tighten the hex nut on the nozzles, ensuring the nozzles do not spin. After tightening the nuts, verify
the nozzle oil mist holes are still positioned correctly.
7. Attach the two 1/4" nylon tubes onto the swivel fittings.
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9. Install the drive belts onto the spindle and motor pulleys.
10. Apply proper tension to belts by wedging the T-shaped belt tensioner tool underneath the spindle head
casting web, between the spindle head pulleys and motor / gearbox pulleys and the motor / gearbox
mounting plate. Attach the 1/2" drive torque wrench to tensioner tool and apply the required torque value.
The path of the applied torque should be inline with the motor assembly. The following chart includes
values for proper belt tensioning.
11. While applying correct torque amount, tighten the four mounting motor / gearbox plate bolts.
CAUTION! This procedure should be performed with two service persons. One will apply
correct torque amount and the other will tighten mounting bolts simultaneously.
12. Place the 3/8" timing belt on the spindle pulley, with the other end on the encoder pulley.
13. Mount the encoder onto the spindle housing below the spindle shaft with four mounting bolts.
14. Align and attach the hydraulic cylinder adapter onto the spindle shaft with the mounting bolts.
Tolerance on the face of the adapter plate .0007". Check tolerance of large I.D. bore .002".
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15. Slide the hydraulic cylinder into spindle shaft. Insert and tighten the mounting bolts.
16. Attach and clamp the oil drain hose and coolant drain hose onto hydraulic cylinder.
18. Set the magnetic base on top of the spindle housing with the indicator touching the top of the hydraulic
cylinder indication point.
19. Spin the hydraulic cylinder and verify that the runout is under 0.003 inches. If runout is over 0.003
inches, spin the hydraulic cylinder to its high point and tap cylinder with a rubber mallet. Tighten and
torque the bolts.
20. Replace the left end panel with the panel mounting screws.
Tools Required:
3 (1) Dual Indicator Stand
Depending on lathe model, the following sheet metal pieces may need to be removed:
a. The front left panel
b. The front bottom panel
c. The drain rail
d. The front door
2. Loosen the locknuts on the two jack screws (adjustment bolts) underneath the spindle head casting.
3. Bolt spindle alignment bar tool to spindle and attach a 0.0001" indicator onto the face of the turret.
4. Jog indicator such that the indicator runs tangent to alignment bar along the Z-axis.
5. Level the spindle head assembly by adjusting the jack screws up or down and jogging the indicator along
the alignment bar in the Z-axis. The tolerance reading should be .0001" within 10".
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6. Once the spindle head assembly is level, setup dual indicators on the large magnetic base and place on
the base casting to the rear. Indicate them at the machined bosses to maintain the spindle head
level. See Figure 3-12.
Note 1: This setup is to ensure the spindle remains parallel in the Z-axis plane while
raising the spindlehead. It is recommended to only turn the jackscrews a quarter turn
each time so that the spindle head does not become positioned too high above the
turret pocket. Should this happen, you will have to start the procedure again.
Note 2: If the boss on the spindle head casting is not machined, then an alternate
method to set up the indicators is to retract the B-axis waycover from the left side and
mount the mag base to the base casting. Then position two indicators on the machined
surface beneath the spindle head casting.
7. Place the tenths indicator at the end of the spindle alignment bar and jog tool turret in the Z- axis towards
the spindle until the indicator rest on the inside of the tool pocket.
8. Align the tool pocket holder along the X-axis with the spindle alignment bar by rotating the spindle and
sweeping the indicator 180 o along the axis. Refer to Figure 3-3.
9. Jog the turret along the X-axis until a measurement reading within .001" is indicated.
10. Next, zero the spindle alignment at the top and bottom of the turret pocket by sweeping the indicator
at those positions and adjusting the jack screws equally. See Notes 1 and 2.
11. Rotate the spindle 180 o and adjust the jackscrews until the indicator reads within a .001" at the top and
bottom of pocket. Repeat Steps 8 and 9, to ensure the X-axis is zeroed for each adjustment in the vertical
direction.
12. Torque the spindle head mounting bolts to 500 ft-lbs carefully so as not to change the spindles position.
13. Once the pocket is zero, X-axis value on the screen becomes the new machine spindle centerline.
14. Tighten the jam nuts on the jack screws under the spindle head.
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Note 4: The x-axis value in the Positions page is the new machine centerline. This
value should be stored in Parameter 254.
15. Repeat Steps 3-5 to ensure that the shaft has remained horizontal. If the shaft has moved, return to Step
11 and recheck the pocket position.
16. Test the other pockets in the same way as pocket #1 (Step 11) without moving the x-axis position. The
tolerances for the other pockets are 0.003 inch from the centerline.
Note 5: All alignments done could change spindle centerline. Verify and enter new
spindle centerline position in Parameter 254. (Refer to Section 1.9)
Tailstock alignment procedures should only be done after the X and Z axes have been checked for proper
alignment.
There are two different tailstocks, a one-piece original design and the newer two-piece design. If the tailstock
needs to be aligned, follow the procedure for that type of tailstock
Tools Required:
ü Spindle Alignment Test Bar (P/N# T-1312) ü Tailstock Taper Bar (P/N# T-1416)
ü .0001" Indicator and Magnetic Base
Note: Make sure all contact surfaces, including the test bar, are clean.
4. Place the indicator tip at the base of the tailstock test bar (closest to the tailstock). Check the total
runout at base of the test bar by rotating the indicat 360 0. Max. tolerance is .001" from centerline.
- If this measurement is out of tolerance from top to bottom (900 and 2700), then proceed to
the Tailstock Leveling Procedure.
- If this measurement is out of tolerance from side to side (0 0 and 1800), then the insert
needs to be replaced and realigned as described in the Tailstock Insert Removal and
Installation section.
5. Jog the tailstock back and measure the runout at the end of the tailstock test bar.
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This procedure should only be performed after the tailstock In/Out has been checked.
Tools Required:
ü (2) Tenths Indicator ü (1) Tailstock Alignment Tool (Test Bar P/N# T-1416)
ü (1) Tailstock Leveling Assembly (Leveling Stand P/N# 93-6001)
ü (1) Round Rigid Bar (1", diameter min.)
1. Carefully remove the center from tailstock (TS) and thoroughly inspect the tapered insert for damage or
debris. Clean tapered insert and firmly install Test Bar.
2. Loosen the mounting bolts that attach the TS to the linear guide trucks, allowing TS to rest on bolts.
Place the Leveling Stand under the bottom edge of TS and manually raise the jack bolts. (Refer to Figure
3-13)
3. Attach a tenths indicator to the face of the turret. Level the TS by jogging the indicator along the test
bar in the Z-axis and level to within .0005" by adjusting the jack bolts.
4. Clamp the rigid bar into the chuck or collet and mount the tenths indicator at the end. Sweep the diameter
of the Test Bar and note the vertical runout. Refer to Figure 3-13.
5. Raise the TS and bring up to center by equally turning the jack bolts ( do not turn one jack bolt more than
1/4 turn without turning the other). Adjust to within .0003" and lightly snug bolts during procedure.
6. Check for TS level change. Adjust by setting the indicator to zero at the right end of the Test Bar and
jog the indicator over to left end of bar. Snug bolts in upper left corner and loosen the others. Adjust
the right-hand jack bolt only and bring the indicator to within .0005".
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7. Once the TS is leveled, the mounting bolts should be torqued to 50 ft-lbs in a clockwise fashion (first, the
inner mounting bolts than the outside). If the horizontal runout is unacceptable, the tapered insert may
have to be reset as described in the following section
1. Using a spindle alignment tool and a Morse taper tool, indicate from spindle to tailstock. Measure flatness
and TIR (total indicated run-out). Determine which direction the tailstock is out of alignment (Figure 3-14).
Figure 3-14
2. If the tailstock is out of alignment in both flatness and parallelism, remove the head from the tailstock base.
Mark the shims so they can be installed in the same order, and inspect them. If the tailstock is only out of
parallel alignment go to step 6.
3. Check the top surface of the tailstock base for parallelism to the Z axis. Check for dents and lightly stone
the top mating surface of the tailstock. Indicate from the turret to the top of the tailstock base. Readings must
be no more than +/- .004" for 10 inches of travel.
4. Install the shims, lightly stone and clean the shims before installing
5. Install the head of the tailstock and snug the four retaining nuts.
6. Rotate the spindle and measure parallelism. Tap the head into place using a mallet. If flatness is within
tolerance, proceed to step 8.
7. Measure flatness from base to end of tailstock. Add or remove shims if necessary using the tailstock head
alignment tool. To adjust the number of shims, bolt on alignment tool, snug alignment bolts against the
tailstock head, then remove the tool (Figure 3-15). Loosen either the front or rear pair of tailstock retaining
nuts and add or remove shims as necessary. This will keep parallelism. Re-tighten the nuts. If necessary
loosen the other end to add or remove shims as well. To re-align, install the alignment tool and position the
tailstock against the adjustment bolts of the alignment tool. Snug the tailstock nuts and remove the tool.
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Figure 3-15
8. Rotate the spindle and measure run-out at the base and the end of the tailstock. Tap into place using a
mallet. Tolerance is less than .001 TIR.
Tools Required:
ü Press Fixture and Spacer ü Blow torch
ü Spindle Alignment Test Bar (P/N# T-1312) ü Devcon liquid steel (P/N# 99-4530)
ü Tailstock Taper Alignment Bar (P/N# T-1416)
Removal -
1. Remove the six screws that mount the back plate to the tailstock insert.
3. Run the screw nut completely down to its farthest travel (far right).
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5. Pump the hydraulic press a few times so that the fixture stabilizes itself against the tailstock.
WARNING! Keep hydraulic lines away from the blow torch flame or serious injury could result.
6. Use the blow torch to heat the insert casting. This will take approx. 30 minutes.
7. Pump the hydraulic press to its maximum pressure while continuing to heat the casting.
Note: When the pressure on the gauge begins to drop the insert should begin to slip
out. Once the press is fully extended, run the nut down again and repeat step 6.
Note: Use a spacer if the adjustment screw on the press is not long enough to remove
the insert.
8. Once the insert is removed, use a small screw driver or chisel to remove any Devcon. Make sure fill hole
is clear.
Installation -
1. Clean the tailstock bore and all mounting surfaces.
4. Make sure the fill hole at the back of the tailstock casting is not clogged
7. Position the indicator tip at the base of the tailstock test bar.
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8. Adjust the insert until the runout at the base of the test bar is less than .0003" TIR. Then tighten all three
screws.
9. Install the rear insert plate. Tighten the three 1/4 x 20 but leave the three 10 x 32 screws loose.
10. Position the indicator at the end (far left) of the tailstock taper alignment bar.
11. Insert a pry bar into the rear of insert and adjust the runout at the end of the shaft until the reading
is .001" or less from centerline. Then tighten the remaining screws.
WARNING! Before performing any service on the hydraulic cylinder or pump, the machine
should be powered off.
REMOVAL -
1. Remove front and rear waycovers.
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CAUTION! Although the hydraulic system is not under pressure oil will spill out of the hydraulic
lines once disconnected from the cylinder. Have a bucket ready to catch any oil that spills
out.
4. Remove the (2) SHCS that mount the cylinder rod end block to the rear of the hydraulic tailstock adapter.
5. Remove the 1/4 - 20 SHCS that mounts the encoder rail to the bottom of the cylinder rod end block
6. Extend the cylinder shaft so that you can place a wrench on the end of the cylinder rod in order to unscrew
it from the end block.
7. Remove the (2) SHCS that mount the hydraulic cylinder body to the base casting.
9. Collapse the hydraulic cylinder then push the tailstock to the rear of travel.
10. Pull the hydraulic cylinder out from the frontside of the tailstock.
INSTALLATION -
11. With the new cylinder in position, push the tailstock to the front of travel.
12. Install the (2) SHCS the mount the cylinder body to the base casting. Before tightening move the
tailstock to the front end of travel.
13. Thread the end block onto the end of the cylinder rod and tighten.
14. Install the (2) SHCS that attach the end block.
15. Install the 1/4 - 20 SHCS that holds the encoder rail to the bottom of the mounting block.
16. Attach the hydraulic lines to both the front and rear of the cylinder. Check for leaks.
18. Check the fluid level at the hydraulic tank to determine how much fluid needs to be added.
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3.4 TRANSMISSION
REMOVAL
Tools Required:
ü Hoist and lifting straps OR floor jack and (4) wood blocks
2. Remove the left side panel to access the spindle motor and transmission assembly.
Note: If you are using a floor jack, the bottom left front panel needs to be removed.
3. Disconnect all electrical lines from the motor and transmission assembly.
4. Position the hoist directly to the rear of the motor and place the lifting straps around the motor and
transmission. Make sure there is enough tension on the straps so that when you loosen the mounting
bolts, the motor assembly doesn't shift.
Note: If you are using a floor jack, slide the jack under the transmission assembly from
the front side of the machine. Being careful not to damage any components, place the
wood block supports under the transmission and motor .
5. Remove the four transmission mounting plate bolts. Raise the transmission enough to remove the drive
belts, then slide the entire assembly out.
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TRANSMISSION INSTALLATION
1. Place lifting straps under new transmission assembly and lift just enough to put tension on the cables.
Note: If you are using a floor jack, slide the jack under the front side of the machine.
Being careful not to damage any components, place the wood block supports on the
jack and slide the transmission and motor onto the jack.
2. Ensure the new transmission is seated securely on the straps and lift up slowly. Lift only high enough
to install the drive belts, then gently swing the assembly into place.
3. Insert the four bolts that secure the transmission mounting plate to the spindle head.
4. Adjust the drive belt tension, then tighten down screws completely. Refer to the Spindle Installation
section, for proper belt tension procedures and tension chart.
Note: If you are using a floor jack, replace the bottom left front panel.
Please read this section in its entirety before attempting to set the grid offset.
GUIDELINES -
The encoder Z channel signal must occur between 1/8 and 7/8 revolution from where the home switch is
released. If DISTANCE TO GO is less than 1/8 (.0295) or greater than 7/8 (.2065) of a revolution, it will alarm
to Zero Return Margin Too Small.
In ZERO RETURN mode, the DISTANCE TO GO is the amount the encoder rotated from when the switch was
released until it found the Z channel signal. The ideal amount for the DISTANCE TO GO are; X-axis =.236,
Z-axis=.118, B-axis = .050 (This equals ½ of a revolution of the encoder).
2. Press ZERO RET and ZERO SINGL AXIS the axis you are setting (X, Z, or A).
3. Calculate the grid offset using the following formula, and write the result in Parameter 125, 127, or 128
(depending on the axis being set).
The Ratio (steps/unit) for the X, Z, and A axes are the values in Parameters 5, 33, and 47, respectively.
Note: If X-axis grid offset is reset, Parameter 254 should be checked and adjusted
accordingly.
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The following is a list of the Lube Air Panel Assembly components, each with a description of its specific
function.
1. Oil Pressure Gauge - Indicates the pressure (in psi) at which the oil is pumped from the reservoir.
2. Oil Pump - Pumps the oil from the reservoir to various parts of the lathe. Every 30 minutes the pump
cycles and pumps 2.8 to 3.8 cc of oil (at approximately 20 psi).
3. Oil Reservoir - Stores the oil (Vactra #2) that is used for lubrication in the linear guides and lead screws.
Oil is also mixed with air and sent to the spindle bearing for lubrication and cooling.
4. Oil Filter - Filters the oil from the reservoir before it is pumped to the necessary areas.
5. Air Pressure Gauge - Indicates the pressure (in psi) at which the air is being regulated.
6. Air Filter - Filters the air and removes moisture before it is sent to the solenoid valves.
7. Air Pressure Regulator - Maintains the air supplied from the outside source (via the main air line) at a
constant, desired pressure (approximately 85-90 psi).
8. Air Solenoid Assembly - 4-way 2-position valve that controls the air to the turret air cylinder.
9. Air Solenoid Assembly- 3-way 2-position valve that controls the air to the parts catcher air cylinder. This
assembly is only on machines equipped with a part catcher.
10. Power Cable - Supplies power to the Lube Air Panel from the main control box and carries signals from
switches to control box.
11. Foot Pedal Cable - Connects chuck actuator foot pedal to the lube air panel.
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The following is a list of the Lube Air Panel Assembly components on the rear of the panel, each with a
description of its specific function.
1. Air Pressure Switch - Monitors the air supply pressure, and sends a signal to the control panel to alarm
out, or stop, the machine when the air pressure falls below 70 psi.
2. Solenoid Valve - Opens when the spindle is turning to permit air to be sent to the spindle bearings.
3. Air Regulator - Maintains the correct air pressure (15 psi) being sent to the spindle bearings.
4. Oil Mist Ports - Connect to nylon tubing that carries the oil-air mist to the spindle bearings. One port
supplies the front spindle bearing, and one supplies the rear bearing.
5. Air Pressure Gauge - Indicates the pressure of the air being mixed with oil and supplied to the spindle
bearings.
6. Connector Plate - Contains all of the connectors for the Lube Air Panel.
7. Pressure Switch - Monitors the oil supply pressure, and sends a signal to the control panel to stop the
machine if the pressure drops below the minimum level for a set period of time.
8. Oil Line - Carries oil to the ports, where it is then sent to the lead screws, linear guides, and spindle
bearings.
9. Oil Ports - Connect to nylon tubing that carries the oil to the lead screws and linear guides.
10. Flowmeters - Maintain the correct amount of oil dropping from the upper ports to the lower ports where
they are mixed with air and sent to the spindle bearings.
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NOTE: All plastic ties must be cut in order to remove the lube air panel.
8. Remove the mounting screws located at the top of the lube panel.
REMOVAL
3. If the unit comes with a hydraulic tailstock solenoid, disconnect the 2 hoses that lead to the
tailstock cylinder. Disconnect chuck hoses. Remember to mark the hoses or else the tailstock and chuck
will not function properly.
Note: Right clamp/unclamp hose of hydraulic unit is attached to bottom port of hydraulic
cylinder and left hose is attached to top port. The ports are located on the side of the
hydraulic cylinder.
4. Unclamp and remove oil return hose from hydraulic unit and hydraulic cylinder.
Note: The oil return hose is shrink-fitted and should be replaced with a new one
whenever removed.
7. Loosen and remove the four bolts from base of unit, then slide hydraulic unit out.
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INSTALLATION
1. Slide hydraulic power unit into place and attach with four mounting bolts.
4. Replace oil return hose and clamp to hydraulic unit and hydraulic cylinder.
Note: The oil return hose is shrink-fitted and should be replaced with a new one if
damaged during removal.
Note: Right clamp/unclamp hose of hydraulic unit is attached to bottom port of hydraulic
cylinder and left hose is attached to top port. The ports are located on the side of the
hydraulic cylinder.
6. Replace any panels that were removed to access the hydraulic unit.
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BULB REPLACEMENT
1. Jog the Z-axis all the way to the right (positive direction).
5. Remove the light bulb and replace with a 24", 20 watt (F20T12-CW) bulb.
6. Replace the light lens and retainer then tighten down the 14 BHCS.
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WARNING! Power on machine, but DO NOT PRESS EMERGENCY STOP, or turret will fall
during spring removal.
REPLACEMENT
1. Remove sliding tool changer cover, located in the back of the machine, to gain access to spring.
4. Insert a wood block between ballscrew support and ballscrew nut to safely block the assembly.
5. Loosen 3/8" SHCS that holds lower pivot arm to spring bracket, then loosen 3/4" nut of upper pivot arm
of spring bracket.
6. Place a 3/4" wrench on the pivot arm and push the spring forward slowly to relieve the spring tension.
Note: Recommend using 3/4" wrench with cheater bar for leverage when relieving
spring tension.
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5. Remove cross slide spring and remove spring retainer located inside turret housing. Use access hole
located on the opposite side of turret to remove spring retainer. Replace used spring retainer with new
beveled spring retainer.
Note: Old style bracket is not equipped with a cylinder spring retainer. Remove the two
mounting bolts and old style bracket then replace with new bracket equipped with pivot
arm and remount with two mounting bolts. Skip to Step 7.
6. Remove cylinder spring retainer attached to pivot arm and replace with new cylinder spring retainer.
7. Install new cross slide spring. Attach spring to spring retainer in turret housing and cylinder spring
retainer of pivot arm.
8. Place 3/4" wrench on pivot arm then pull towards rear of bracket until pivot arm locks to restore spring
tension.
9. Tighten 3/8" SHCS of lower pivot arm and 3/4" nut of upper pivot arm on spring bracket.
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REMOVAL
3. Loosen 1 1/2" shaft collar that locates the parts catcher tray, and slide out tray and inner
shaft.
4. Unclamp outer retaining ring that retains the shaft collar on the outer shaft, remove shaft collar and
inner retaining ring.
6. Detach 5/32" airlines attached to the barrel end and rod end ports of the air cylinder.
7. Remove 7/16" hex nut that attaches the air cylinder to the parts catcher shaft.
8. Loosen and remove 1/4" SHCS and washer that attaches air cylinder to cylinder mount and remove air
cylinder.
9. Remove 3/8" SHCS holding the parts catcher pivot mount assembly to the spindle head casting and slide
out mount assembly.
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INSTALLATION
1. Slide parts catcher pivot mount assembly through the sheet metal seal and attach to
spindle head casting using 3/8" SHCS.
2. Install air cylinder to cylinder mount using 1/4" SHCS and washer.
3. Attach air cylinder rod in its fully retracted position to parts catcher shaft with the hex nut.
6. Place inner retaining ring on outer shaft, slide shaft collar on and attach outer retaining ring.
Note: Machine must be powered up and controlled in MDI mode to check for proper
activation and deactivation of parts catcher. It must be stopped with the rod fully
extended to properly position chute assembly to the collector door.
8. Slide the inner shaft of the tray assembly into outer shaft of pivot assembly. Locate tray assembly
far back enough to catch the part and clear chuck.
9. Rotate the tray position to open the sliding door of the collector. Tighten the shaft collar to the parts
catcher shaft. Step through MDI program and check tray operation
PROBE SETTING
1. Power off the machine and unfasten the forward end panel on the left side of the machine.
3. Lower tool setter arm to horizontal position. Install a turning tool in the cutting position pocket on the
turret and jog the Z axis in slow motion until the tool tip touches the square tip of the probe.
4. By tightening 1/4-20 set screw on the mounting block, adjust the height of probe so the tip of the turning
tool touches the middle of the side of square tip. After proper alignment, tighten all four 3/8-16
screws on mounting block and torque them to 50 ft/lb. Also tighten the 1/4-20 nut on the set screw
against the mounting block.
5. Install .0001 indicator on a safe place on the turret, align the tip of probe within .0005 to X and
Z axes by loosening the four 4-40 clamping screws and rotating the probe body. Tighten the
clamping screws.
6. Rotate tool setter arm to vertical position (home position) and check the alignment of probe, ball
stud and home switch actuator groove to home assembly. If there is misalignment, loosen the two
1/4-20 button head screws and let home assembly self center to the ball stud. Tighten screws after
proper alignment.
7. Home position verify by jog functions normal on X and Z axes.
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8. Move turret away and pull down tool setter arm. Control should switch to Tool set offset screen. X and
Z will jog only in slow motion. Using your finger, trigger probe, speaker should beep and diagnostics
input should change from 0 __ > 1 __> 0. Using slow jog button, move X or Z clear of the part, tap the
probe, the motion in current direction should stop, offset should update.
1. Install stylus tip with supplied wrenches. Additional information can be found in the probe manufacturer's
manual.
2. Install .0001" indicator on a safe place on the turret, align the tip of probe within .0005" to X and
Z axes by loosening the four 4-40 clamping screws and rotating the probe body. Finally tighten the
clamping screws.
1. Clamp a piece of material in the chuck and take a finish cut on the outside diameter. Move away in the Z,
do not move in the X.
2. Measure the diameter of the part using a micrometer and record the measurement on a piece of
paper.
3. With the tool tip positioned to the outside diameter of the part and using the origin key, zero the X register
of the operator position display.
4. Using the operator position display as a guide move the tool in the X direction until the display reads
the same value as the measured diameter and using the origin key, zero the X register of the display.
5. Move the tool to a safe position and lower the tool setter arm and touch the tool tip using the jog handle in
the .0001 mode.
Note: While jogging, when the tool comes in contact with the probe the control will
beep and jogging in the current direction will stop.
6. Record the value shown in the X operator position display into Setting 59 PROBE OFFSET X+.
7. Subtract 2 times the probe width from the X operator position display and store this value into Setting
60 PROBE OFFSET X-.
1. The value of Setting 61 PROBE OFFSET Z+ should be Zero. The value of Setting 62 PROBE OFFSET Z- should
be the width of the probe (i.e. if the probe measures .3937 Setting 62 PROBE OFFSET Z- would be .3937).
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Please read this section in its entirety before attempting to remove or replace the lead screws.
TOOLS REQUIRED:
1. Turn the machine ON. ZERO RETURN all axes and put the machine in HANDLE JOG mode.
2. Remove rear and right side covers. Remove the hard stops from the bearing support and
motor end of the lead screw.
3. Remove the cover from the motor housing. Disconnect the oil line from the lead screw nut.
Figure 3-26
a. At the bearing support side, loosen the lock nut screw. Unscrew the clamp nut an 1/8" and
retighten clamp nut screw. Attach shaft lock tool to bearing support side of lead screw.
b. At the motor end, loosen the motor coupling on the lead screw side of the coupling. Remove
the four motor mount SHCS and the motor. Remove the Woodruff key from the key way on the lead
screw.
c. In the motor housing, loosen the lock nut screw, attach the spanner wrench to the clamp nut
and remove the nut from the lead screw in the motor housing. Unfasten the six ¼-20 x 1 SHCS from
the bearing sleeve and remove the bearing sleeve from the motor housing. On the bearing support
side, remove bearing support clamp nut.
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d. Push the wedge all the way towards the motor end. Underneath the wedge, remove the SHCS that
attach the lead screw nut to the nut housing. Pull the lead screw forward to clear the nut from the housing
and angle the lead screw towards the right of the bearing support. Carefully remove lead screw.
CAUTION!: Be careful during removal or installation of lead screw, to protect the surfaces.
a. At the bearing support side, loosen the lock nut screw. Unscrew the clamp nut an 1/8"
away from the bearing support and retighten clamp nut screw. Attach shaft lock tool.
b. At the motor end, loosen the motor coupling on the lead screw side of the coupling.
Remove the four motor SHCS and the motor. Remove the Woodruff key from the key way on the
lead screw. In the motor housing, loosen the lock nut screw and attach the spanner wrench.
Remove the clamp nut.
d. Underneath the wedge, remove the SHCS from the lead screw nut and push the wedge towards
the motor housing.
e. On the bearing support side, remove the shaft lock tool and clamp nut. Remove the alignment
pins and the SHCS from the bearing support casting. Make note of any shims. Hold the lead screw in place
and remove the bearing support. Pull forward on the lead screw and carefully remove.
CAUTION!: Be careful during removal or installation of ball screw, to protect the surfaces.
Ensure all mating surfaces on the bearing sleeve, motor housing, nut housing and the lead screw nut
are free of dirt, burrs, grease or other contaminants.
CAUTION!: Mating surfaces must be clean or misalignment may occur, seriously affecting
the proper operation of the machine.
1. Reinsert the lead screw, with the motor housing bumper on it, from the right hand side of the bearing
support into the motor housing. Align the lead screw with the bearing support end and insert the lead screw.
Prevent contact with the screw threads, to avoid any possible damage.
2. Hold the lead screw level on the motor side. Slide the bearing sleeve onto the lead screw and insert bearing
sleeve into motor housing. Attach bearing sleeve to the housing with six ¼-20 x 1 SHCS. Place a drop of
blue Loctite on each of the SHCS before inserting. Torque the bearing sleeve SHCS to 15 FT-LBS.
CAUTION! Do not use more than one drop of Loctite. An excessive amount will cause a film
to develop between the sleeve and housing which could result in backlash.
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3. The following sequence is important to ensure proper installation of the lead screw:
a. On the bearing support end, install the lock nut an 1/8" away from the bearing. Tighten the
lock nut screw. Install the shaft lock onto the bearing support end of the lead screw.
CAUTION! Do not attach bearing clamp nut against bearing support until the motor side
clamp nut is torqued to its proper specification. Damage will occur to the bearing and lead
screw on the support side.
c. Place a spanner wrench on to the lock nut in the motor housing and torque it against the
bearing to 15 FT-LBS.
d. Torque the clamp nut screw and mark with yellow paint.
e. At the bearing support end, remove the shaft lock and loosen the clamp nut screw. Tighten
the lock nut against the bearing to 4 IN-LBS. Retighten the clamp nut screw and mark with yellow
paint.
f. Align the lead screw nut to the nut housing on the wedge, check oil line fitting is in the correct
position. Apply a drop of blue Loctite to the five SHCS and fasten the nut to the housing. Torque
the lead screw nut SHCS to 15 FT-LBS.
g. Place the Woodruff key back into the key way slot on the lead screw.
h. Install the motor with the coupling attached check condition of the couper and tighten the
four motor mounting SHCS. Torque the motor mounting SHCS to 30 FT-LBS.
4. Tighten the collar on the motor coupling to the lead screw and torque to 15 FT-LBS. Attach bumper, and
replace motor housing cover.
5. Check for binding in the beginning, middle and end of travel. You should be able to rotate the lead screw
by hand when the servos are off. Check for backlash or noisy operation.
6. Replace the bearing support end hardstops and reconnect oil line to the lead screw nut.
7. Zero return Z axis and set grid offset according to section 3.5.
1. Reinsert the lead screw with bumpers into the bearing sleeve in the motor housing. (Make sure the lead
screw nut will be able to slide in to the wedge nut housing). Support the lead screw on the bearing support
end and re-attach the bearing support housing and bearing.
2. Reinsert alignment pins through the housing into the base casting, replace shims if needed. Fasten to the
base casting using the six bearing support housing SHCS, lock washers and Loctite.
3. The following sequence is important to ensure proper installation of the lead screw:
a. On the bearing support end, install the lock nut an 1/8" away from the bearing and tighten
clamp nut screw. Install the shaft lock into the bearing support end of the lead screw.
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CAUTION! Do not attach bearing clamp nut against bearing support until the motor side
clamp nut is torqued to its proper specification. Damage will occur to the bearing and lead
screw on the support side.
b. Attach the clamp nut onto the motor side of the lead screw.
c. Place a spanner wrench on the lock nut at the motor end of the assembly.
Torque the clamp nut against the bearing to 50 FT-LBS.
d. At the motor end, tighten the lock nut screw and mark with yellow paint.
f. Align the lead screw nut with the nut housing on the wedge. Apply a drop of blue Loctite to
the five SHCS and attach the nut to the housing. Torque lead screw nut SHCS to 30 FT-LBS.
g. Place the Woodruff key back into the key way slot on the lead screw.
h. Install the motor with the coupling attached to the lead screw and tighten the four motor
mounting SHCS. Torque the motor mount SHCS to 30 FT-LBS.
4. Tighten the collar on the motor coupling and re-torque the collar SHCS to 15 FT-LBS. Replace the motor
housing cover.
5. Move turret to support housing end, taking care to stop before hitting the support housing.
6. Torque the bearing support housing SHCS to 30 FT-LBS. Prevent contact with the lead screw threads, to
avoid any possible damage.
7. Loosen the lock nut screw. Tighten the lock nut against the bearing to 4 IN-LBS. Retighten the clamp screw
and mark with yellow paint.
8. Check for binding in the beginning, middle and end of travel. You should be able to rotate the lead screw
by hand when the servos are off. Check for backlash or noisy operation.
9. Replace the lead screw hardstops and reconnect oil line to the lead screw nut.
10. Zero return Z axis and set grid offset according to section 3.5.
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4. ELECTRICAL SERVICE
4. 1 SOLENOIDS
Please read this section in its entirety before attempting to replace any solenoid assem-
blies.
REMOVAL -
1. Turn machine power off and remove the air supply from the machine.
2. Disconnect the two air hoses from the pneumatic chuck clamp/unclamp solenoid (see Figure 4-1).
3. Unplug the solenoid electrical lead at the switch bracket (located on the rear of the lube air panel).
4. Remove the two SHCS holding the assembly to the bracket and remove the assembly.
INSTALLATION -
5. Replace the air solenoid assembly and attach to the bracket with the two SHCS. Tighten securely.
7. Reconnect the two air lines, ensuring that all connections are tight and do not leak.
REMOVAL -
1. Turn machine power off and remove the air supply from the machine.
2. Disconnect the three air hoses from the turret clamp/unclamp solenoid (see Figure 4-1).
3. Unplug the solenoid electrical lead in the wire channel (located on the rear of the lube air panel).
4. Remove the two SHCS holding the assembly to the bracket and remove the assembly.
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INSTALLATION -
5. Replace the air solenoid assembly and attach to the bracket with the two SHCS. Tighten securely.
7. Reconnect the three air lines, ensuring that all connections are tight and do not leak.
REMOVAL -
1. Turn the machine power off and remove the air supply from the machine.
2. Disconnect the lube line from the spindle lube air solenoid assembly.
3. Disconnect the electrical leads from the main air line pressure switch.
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INSTALLATION -
9. Reconnect the electrical leads to the main air line pressure switch.
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Please read this section in its entirety before attempting to adjust the line voltage.
TOOLS REQUIRED:
ü LARGE FLAT TIP SCREWDRIVER
ü DIGITAL VOLTMETER
ADJUSTING VOLTAGE
Note: The machine must have air pressure at the air gauge or an interlock will prevent it
from powering up.
CAUTION! Working with the electrical services required for the lathe can be extremely
hazardous. The electrical power must be off and steps must be taken to ensure that it will
not be turned on while you are working with it. In most cases this means turning off a circuit
breaker in a panel and then locking the panel door. However, if your connection is different
or you are not sure how to do this, check with the appropriate personnel in your organization
or otherwise obtain the necessary help BEFORE you continue.
WARNING! The electrical panel should be closed and the three screws on the door should
be secured at all times except during installation and service. At those times, only qualified
electricians should have access to the panel. When the main circuit breaker is on, there is
high voltage throughout the electrical panel (including the circuit boards and logic circuits)
and some components operate at high temperatures. Therefore extreme caution is
required.
1. Hook up the three power lines to the terminal on top of the main switch at upper right of electrical panel
and the separate ground line to the ground bus to the left of the terminals. The hydraulic unit is a 3 phase
pump. Refer to the "Hydraulic Unit Phasing" section for proper phasing instructions.
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Note: Make sure that the service wires actually go into the terminal-block clamps. It is
easy to miss the clamp and tighten the screw. The connection looks fine but the
machine runs intermittently or has other problems, such as servo overloads. To check,
simply pull on the wires after the screws are tightened.
2. After the line voltage is connected to the machine, make sure that main circuit breaker (at top-right of
rear cabinet) is off (rotate the shaft that connects to the breaker counterclockwise until it snaps off).
Turn on the power at the source. Using an accurate digital voltmeter and appropriate safety procedures,
measure the voltage between all three pair phases at the main circuit breaker and write down the
readings. The voltage must be between 195 and 260 volts or 353 and 480 volts, depending on which
transformer is in the machine.
Note: Wide voltage fluctuations are common in many industrial areas; you need to know
the minimum and maximum voltage which will be supplied to the machine while it is in
operation. U.S. National Electrical Code specifies that machines should operate with a
variation of +5% to -5% around an average supply voltage. If problems with the line
voltage occur, or low line voltage is suspected, an external transformer may be required.
If you suspect voltage problems, the voltage should be checked every hour or two during
a typical day to make sure that it does not fluctuate more than +5% or -5% from an
average.
CAUTION! Make sure that the main breaker is set to OFF and the power is off at your supply
panel BEFORE you change the transformer connections. Make sure that all three black wires
are moved to the correct terminal block and that they are tight.
3. Check the connections on the transformer at the bottom-right corner of the rear cabinet. The three black
wires labeled 74, 75, and 76 must be moved to the terminal block triple which corresponds to the average
voltage measured in step 2 above. There are four positions for the input power to this transformer. The
input voltage range for each terminal block is as follows:
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ELECTRICITY REQUIREMENTS
40-30HP SYSTEM
VOLTAGE REQUIREMENTS HIGH VOLTAGE REQUIREMENTS
(195-260V) (360-480V)
WARNING!
- A separate earth, or cold-water-pipe, ground is required (conduit types are not sufficient)!
- Do not connect to 480V, unless machine includes high voltage option.
- Maximum voltage leg-to-leg or leg-to-ground should not exceed 260 volts or 540 volts for high
voltage machines!
Figure 4-6a. Transformer with 354-488V range Figure 4-6b Transformer with 195-260V range.
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4. Set the main switch to on (rotate the shaft that engages the handle on the panel door clockwise until
it snaps into the on position). Check for evidence of problems, such as the smell of overheating
components or smoke. If such problems are indicated, set the main switch to off immediately and call
the factory before proceeding.
5. After the power is on, measure the voltage across the upper terminals on the contactor K1 (located
below the main circuit breaker). It should be the same as the measurements where the input power
connects to the main breaker. If there are any problems, call the factory.
6. Apply power to the control by pressing the Power-On switch on the front panel. Check the high voltage
bus voltage on the Vector Drive (pin 2 with respect to pin 3 on the terminal bus at the bottom of the
drive). It must be between 310 and 360 volts. If the voltage is outside these limits, turn off the power
and recheck steps 2 and 3. If the voltage is still outside these limits, call the factory. Check the DC
voltage displayed in the second page of the Diagnostic data on the CRT. It is labeled DC BUS. Verify
that the displayed voltage matches the voltage measured at pins 2 and 3 of the Vector Drive +/- 7 VDC.
7. Turn off the power (rotate the shaft that engages the handle on the panel door counterclockwise until
it snaps into the off position). Also, set the main switch handle on the panel door to off. (Both the
handle and the switch must be set to off before the door can be closed). Close the door, latch the
latches, and turn the power back on.
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Please read this section in its entirety before attempting to replace any fuses.
TOOLS REQUIRED:
ü REPLACEMENT FUSES
OVERVOLTAGE FUSES
WARNING! The electrical panel will have residual voltage, even after power has been shut
off and/or disconnected. Never work inside this cabinet until the small red CHARGE light on
the servo drive assembly goes out. The servo drive assembly is on the left side of the main
control cabinet and about halfway down. This light is at the top of the circuit card at the center
of the assembly. Until this light goes out, there are dangerous voltages in the assembly EVEN
WHEN POWER IS SHUT OFF.
2. Turn the main switch (upper right of electrical cabinet) to the off position.
Figure 4-8. Unscrew the two screws to open the cabinet door. (Control cabinets require a key)
3. Using a large flat tip screwdriver, loosen the two screws on the cabinet door and then open the door
enough to safely work on the electrical panel. Wait until at least the red CHARGE light on the servo drive
assembly goes out before beginning any work inside the electrical cabinet.
4. On the POWER SUPPLY board there are three fuses located in a row at the upper right of the board; these
are the overvoltage fuses. An orange light will be on to indicate the blown fuse(s).
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5. Using a flat tip screwdriver, turn the fuse(s) counterclockwise to remove and replace the blown fuse(s)
with ones having the same type and rating (½ amp, type AGC, 250V).
CAUTION! When the left fuse is blown, it is still possible to operate the machine, thereby
making an overvoltage situation possible. VERIFY absolute voltage to the machine does not
exceed 260 volts.
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Please read this section in its entirety before attempting to replace any PCBs.
Note: The arrangement of these boards may differ from the order of replacement that
follows. The steps for replacement will only differ in which board may need to be
removed before getting to the necessary board.
WARNING! The electrical panel will have residual voltage, even after power has been shut
off and/or disconnected . Never work inside this cabinet until the small red CHARGE light
on the servo amplifiers (servo drive assembly on brush machines) goes out. The servo
amplifiers / servo drive assembly is on the left side of the main control cabinet and about
halfway down. This light(s) is at the top of the circuit card at the center of the assembly. Until
this light goes out, there are dangerous voltages in the assembly EVEN WHEN POWER IS
SHUT OFF.
2. Turn the main switch (upper right of electrical cabinet) to the off position.
3. Loosen the two screws on the cabinet door and then open the door enough to safely work on the
electrical panel. Wait until at least the red CHARGE light on the servo amplifiers (servo drive assembly
on brush machines) goes out before beginning any work inside the electrical cabinet.
4. Disconnect all leads to the Motor Controller (MOCON), or Motor Interface (MOTIF) board (for brush
machines). Ensure all cables are properly labeled for reconnecting later.
5. After all cables have been disconnected, unscrew the standoffs, taking care to hold the board in place
until all standoffs have been removed.
Note: If the VIDEO / KEYBOARD or PROCESSOR boards need replacing, please skip
the next step.
6. Replace the MOCON (or MOTIF) board, attaching it to the VIDEO / KEYBOARD (beneath the MOCON /
MOTIF board) with the standoffs.
VIDEO / KEYBOARD -
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9. Disconnect all leads to the Video / Keyboard. Ensure all cables are properly labeled for reconnecting later.
10. After all cables have been disconnected, unscrew the standoffs, taking care to hold the board in place
until all standoffs have been removed.
Note: If the PROCESSOR board need replacing, please skip the next step.
11. Replace the Video / Keyboard, attaching it to the PROCESSOR board (beneath the Video / Keyboard) with
the standoffs.
PROCESSOR BOARD -
13. Remove the MOCON (or MOTIF) board as described in Steps 1-5, and the Video / Keyboard as
described in Steps 8-9.
14. Disconnect all leads to the Processor board. Ensure all cables are properly labeled for reconnecting
later.
15. After all cables have been disconnected, unscrew the standoffs, taking care to hold the board in place
until all standoffs have been removed.
16. Replace the Processor board, attaching it to the electrical cabinet (beneath the Processor board)
with the standoffs.
1. Follow all precautions noted previously before working in the electrical cabinet.
2. Turn the main switch (upper right of electrical cabinet) to the off position.
3. Using a large flat tip screwdriver, loosen the two screws on the cabinet door and then open the door
enough to safely work on the electrical panel.
4. Disconnect all leads to the Input/Output board and move aside for removal. Ensure all cables are
properly labeled for reconnecting later. The following illustration shows all cable numbers and the
locations on the I/O board.
5. Remove the board by first removing the twelve screws that fasten it to the cabinet. Take care to hold
the board in place until all screws have been removed.
6. Replace the I/O board, attaching it to the cabinet with the twelve screws previously removed.
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POWER BOARD -
1. Follow all precautions noted previously before working in the electrical cabinet .
2. Turn the main switch (upper right of electrical cabinet) to the off position.
3. Using a large flat tip screwdriver, loosen the two screws on the cabinet door and then open the door
enough to safely work on the electrical panel.
4. Disconnect all leads to the Power Distribution (POWER) board and move aside for removal. Ensure all
cables are properly labeled for reconnecting later.
5. After all cables have been disconnected, remove the seven screws holding the POWER board to the
cabinet and remove the board. Take care to hold the POWER board in place until all screws have been
removed.
Note: If you need to replace the LOW VOLTAGE POWER SUPPLY board, please skip the
next step.
6. Replace the POWER board, attaching it with the seven screws previously removed. Don't forget to use
the lower left screw for a ground connection.
9. Disconnect all leads to the Low Voltage Power Supply (LVPS) board. Ensure all cables are properly
labeled for reconnecting later.
10. After all cables have been disconnected, unscrew the two standoffs at the bottom of the board. Unscrew
the remaining two screws at the top of the LVPS board, taking care to hold the board in place until all
screws have been removed.
11. Replace the LVPS board, attaching it to the cabinet with the two screws and two standoffs previously
removed.
RS-232
1. Follow all precautions noted previously before working in the electrical cabinet.
2. Turn the main switch (upper right of electrical cabinet) to the off position.
3. Using a large flat tip screwdriver, loosen the three screws on the cabinet door and then open the door
enough to safely work on the electrical panel.
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Note: It is suggested to make use of a step ladder high enough to allow you to work
from the top of the electrical cabinet. It will be necessary, when replacing the RS-232
board, to work from the inside and outside of the cabinet at the same time.
4. On the left side of the cabinet, at the top of the side panel are two serial port connections labeled "SERIAL
PORT #1" and "SERIAL PORT #2", SERIAL PORT #1 being the upper connection.
5. To remove the RS-232 board, unscrew the two hex screws (on the exterior of the cabinet) holding
the connector to the cabinet. From the inside of the cabinet, pull the connector through the panel, and
disconnect the cable.
6. Replace the RS-232 board by first connecting the appropriate cable to the board (850 to SERIAL
PORT #1, 850A to SERIAL PORT #2, then inserting the board (cable side up) through the left side
panel. Attach with the two hex screws previously removed. Ensure the board for Serial Port #1 is the
upper connector and the board for Serial Port #2 is the lower connector.
7. Replace the Serial Keyboard Interface (KBIF) board, using the four screws previously removed, starting
at the top right. Attach the screw and standoff loosely, then all other screws and standoffs, until all are
mounted. Tighten down completely.
8. Reconnect all cables to the Serial KBIF board at their proper locations.
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Please read this section in its entirety before attempting to replace any component of the control
panel.
2. Remove the screws holding the cover panel on the back of the control panel. Take care to hold the cover
panel in place until all screws have been removed.
3. At this time, remove the end cap on the support arm and unplug the white cable at the connection inside,
then unplug the black cable at the connection in the control panel. It may be necessary to cut straps off
the black cable's connector to unplug.
4. Unscrew the four hex nuts on the bottom row of the CRT bracket and remove, along with the washers.
Set aside in a safe place.
5. While holding up the CRT assembly, remove the four hex nuts on the top row of the CRT bracket, along
with the washers.
CAUTION! Take extreme care to not drop or damage the CRT assembly when removing from
the control panel.
6. CAREFULLY pull the CRT assembly out toward the rear until it is clear of the control panel and all wiring.
Set CRT assembly down in a safe place so as not to damage.
7. Replace by sliding the new assembly onto the eight bolts (four each on top and bottom). Starting with
the bottom right, place the washers and hex nuts on the bolts to hold in place. Refer to Fig. 5-1 for the
order of replacement.Once all washers have been attached and nuts have been hand-tightened, tighten
down completely with the socket.
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8. Plug the black cable and white cable into the matching cables. Feed the white cable through the opening
in the top of the control panel.
9. Replace the back cover panel and attach with the four screws previously removed.
The JOG handle is actually a 100-line-per-revolution encoder. We use 100 steps per revolution to move one
of the servo axes. If no axis is selected for jogging, turning of the crank has no effect. When the axis being
moved reaches its travel limits, the handle inputs will be ignored in the direction that would exceed the travel
limits.
2. Remove the screws holding the cover panel on the back of the control panel. Take care to hold the cover
panel in place until all screws have been removed.
3. Unplug the cable leading to the jog handle encoder. IMPORTANT! The blank pin side of the connector
must face as shown in Fig. 4-12 when reconnecting; otherwise, damage may occur to the machine.
4. Using the 5/64" allen wrench, loosen the two screws holding the knob to the control panel and remove.
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5. Remove the three screws holding the jog handle encoder to the control panel and remove.
SWITCH REPLACEMENT
Note: This section is applicable for the POWER ON, POWER OFF, EMERGENCY STOP,
CYCLE START, and FEED HOLD switches.
2. Remove the 16 screws holding the cover panel on the back of the control panel. Take care to hold the
cover panel in place until all screws have been removed.
3. Disconnect all leads to the switch's connectors. Ensure all leads are properly marked for reconnecting
later. Refer to Fig. 4-11 for proper locations.
4. Unscrew the two small set screws, one on top and one on the bottom, and turn the switch counterclock-
wise to loosen. Separate from the front portion and pull out.
5. For replacement, screw the front and rear portions together (reverse of removal) and tighten down the
two small set screws when the switch is properly positioned.
Note: The POWER ON, POWER OFF, and EMERGENCY STOP switches must all have
the connectors on the bottom of the switch.
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2. Remove the 16 screws holding the cover panel on the back of the control panel. Take care to hold the
cover panel in place until all screws have been removed.
3. Disconnect the two leads at the back of the spindle load meter assembly. Ensure the two leads are
properly marked for reconnecting later.
4. Unscrew the four screws that hold the spindle load meter assembly to the control panel. Take care to hold
the assembly in place until all screws have been removed. Remove the assembly.
KEYPAD REPLACEMENT
2. Remove the 16 screws holding the rear cover panel to the back of the control panel. Take care to hold
the cover panel in place until all screws have been removed.
3. Remove all switches, spindle load meter, and the jog handle as described in the previous sections.
4. Unplug the keypad's 24-pin ribbon cable from the Serial Keyboard Interface board.
5. Remove the screws from the front of the control panel. Take care to hold the front cover panel and bezel
spacer in place until all screws have been removed. Remove the two pieces and set aside in a safe place.
6. Using a flat, blunt tool, such as putty knife, pry the keypad away from the control panel. Pull the ribbon
cable through the opening in the control to remove.
7. To replace, first put the bezel spacer in place and fasten temporarily with screws in the top corners.
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8. Insert the ribbon cable through the opening in the control panel and place the keypad in the upper right
corner of the lower opening and press to the control panel to mount. Plug the ribbon cable into the
Keyboard Interface board, taking care to not bend the pins on the board.
9. While holding the bezel spacer in place, remove the two screws holding the spacer, put the front cover
panel in place, and fasten with all screws previously removed.
10. Reinstall all switches, spindle load meter, and the jog handle as described in the previous sections.
11. Replace the rear cover panel and fasten with the screws that were previously removed.
1. Follow all precautions noted previously before working in the control cabinet (See warning at beginning
of "Front Panel" section).
2. Turn the main switch (upper right of electrical cabinet) to the off position.
3. Remove the four screws on the back of the control box, then remove the cover panel. Take care to hold
the panel in place until all screws have been removed.
4. Disconnect all leads to the Serial Keyboard Interface (KBIF) board. Ensure all cables are properly labeled
for reconnecting later.
5. After all cables have been disconnected, unscrew the four screws holding the Serial KBIF board to the
control box. Take care to hold the board in place until all screws have been removed. Place the screws
and standoffs aside for later use.
6. Replace the Serial KBIF board, using the four screws previously removed, starting at the top right. Attach
the screw and standoff loosely, then all other screws and standoffs, until all are mounted. Tighten down
completely.
7. Reconnect all cables to the Serial KBIF board at their proper locations.
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Please read this section in its entirety before attempting to remove or replace encoder.
REMOVAL -
1. Loosen the eight motor fan panel mounting bolts (on left end of machine), then remove the panel.
2. Loosen the two encoder mounting bolts and slide the encoder up until there is slack in the belt.
4. Inspect the encoder belt for any damage. If replacement is necessary, refer to the "Spindle" section for
removal.
INSTALLATION -
5. Place the belt onto the pulley.
Note: When tightening the bolts, ensure the belt remains loose around the pulleys. If
the belt is too tight, it could damage the encoder.
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5. TECHNICAL REFERENCE
5.1 SPINDLE
Spindle speed functions are controlled primarily by the S address code. The S address specifies RPM in integer
values from 1 to maximum spindle speed (Parameter 131). NOT TO BE CHANGED BY USER!
Two M codes, M41 (Low Gear) and M42 (High Gear), can be used for gear selection. Spindle speed accuracy
is best at the higher speeds and in low gear.
The spindle is hardened and ground with a A2-6, A2-8, A2-11 spindle nose.
The spindle head contains a two-speed gear transmission. The spindle motor is directly coupled to the
transmission and the transmission is cog belt-coupled to the spindle pulley. An electric motor drives the
gearbox shifter into high or low gear.
LUBRICATION
OPERATION
High gear and low gear are selected by programming an M41 (Low Gear) or M42 (High Gear). The spindle
will not change gears automatically. The spindle will come to a complete stop when changing gears.
The machine will remain in it's current gear (until changed with an M41 or M42) even after the machine is
powered off. When the machine is powered up, it will be in the same gear (or between gears) as when it was
powered off.
The current gear status is monitored by discrete outputs SP HIG (Spindle High) and SP LOW (Spindle Low).
A "0" (zero) in either of these outputs indicates it is the current gear. If the outputs are the same, neither gear
is selected. If the gearbox remains in this condition (between gears) for a certain amount of time, Alarm 126,
"Gear Fault", is generated. The only way to reset this alarm is to press the POWER UP/RESTART key. The current
gear can also be monitored by pressing the CURNT COMDS key. This display will show whether the machine
is currently in "HIGH GEAR", "LOW GEAR", or "NO GEAR".
There are a number of parameters related to the gearbox. Their values should not be changed by the operator.
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Haas machines are equipped with brushless motors, which provide for better performance, and no mainte-
nance. In addition to the performance differences, these machines differ from brush type machines, which
have already been discussed, in the following areas:
The brushless motors have 8192 line encoders built in, which result in differences in acceleration parameters
7, 21,35,49 and 157. The exponential accel/decel time is set by parameters 115, 116 and 168.
"In Position" parameters 101, 102, 103, 104 and 165 also affect brushless motors.
The motor controller board has a dedicated processor which does all the servo control algorithm.
There is no servo distribution board anymore, therefore there is no CHARGE light present. Care should still
be taken however, since there are high voltages present on the amplifiers, even when power is shut off. The
high voltage comes from the vector drive, which does have a CHARGE light.
The servo drive cards are replaced by Brushless Servo Amplifiers, and are controlled differently.
A low voltage power supply card is added to the servo drive assembly to supply the low voltage requirement
to the amplifiers.
The user interface and motion profiling have not changed however, and the user should not see any functional
differences between a brush type machine and a brushless machine.
Servo characteristics are explained in detail in the previous section. The following is an example of how to
achieve 130 inches/minute.
The exponential accel/decel time constant is set by Parameters 113, 114, 115, 116 and 168. It has units of
0.0001 seconds. The speed limit at which exponential accel/decel is not available is defined by the
relationship between Parameters 7 and 113 (for the X-axis). Thus if Parameter 7 is 8000000 steps/sec/sec
and Parameter 113 is 375 (0.0375 seconds); the maximum velocity for accurate interpolation should be:
The brushless servo amplifier is a PWM based current source. The PWM outputs control the current to a three
phase brushless motor. The PWM frequency is either 12.5 KHz or 16 KHz. The amplifiers are current limited
to 30 amps peak (45A peak for a medium amplifier. However there are fuse limits both in hardware and software
to protect the amplifiers and motors from over current. The nominal voltage for these amplifiers is 320 volts.
Therefore the peak power is about 9600 watts or 13 H.P. The amplifiers also have short circuit, over
temperature and over voltage protection.
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There is a 10 amp (20A for a medium amplifier) supply fuse for failure protection. This fuse is relatively slow,
therefore it can handle the 30 amp peak. Actual continues current limit to the motor is controlled by software.
Commands to the amplifier are +/-5 volts current in two legs of the motor and a digital enable signal. A signal
from the amplifier indicates drive fault or sustained high current in stalled motor.
The IOPCB contains a circuit for electronically turning the tool changer power on and off. This prevents any
arcing of the tool changer relays and increases their life tremendously. This includes an adjustable current
limit to the tool changer. Potentiometer R45 adjusts the current limit to the tool changer motors. R45 should
be set to limit current to between four and six amps.
The IOPCB also contains a circuit for sensing a ground fault condition of the servo power supply. If more
than 0.5 amps is detected flowing through the grounding connection of the 160V DC buss, a ground fault
alarm is generated and the control will turn off servos and stop.
Relay K6 is for the coolant pump 230V AC It is a plug-in type and is double-pole. Relays K9 through K12 are
also plug in types for controlling the tool changer.
The Input/Output Assembly consists of a single printed circuit board called the IOPCB.
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JOG HANDLE
The JOG handle is actually a 100-line-per-revolution encoder. We use 100 steps per revolution to move one
of the servo axes. If no axis is selected for jogging, turning of the crank has no effect. When the axis being
moved reaches its travel limits, the handle inputs will be ignored in the direction that would exceed the travel
limits.
The POWER ON switch engages the main contactor. The on switch applies power to the contactor coil and
the contactor thereafter maintains power to its coil. The POWER OFF switch interrupts power to the contactor
coil and will always turn power off. POWER ON is a normally open switch and POWER OFF is normally closed.
The maximum voltage on the POWER ON and POWER OFF switches is 24V AC and this voltage is present any
time the main circuit breaker is on.
The Load meter measures the load on the spindle motor as a percentage of the rated continuous power of
the motor. There is a slight delay between a load and the actual reflection of the meter. The eighth A-to-D
input also provides a measure of the spindle load for cutter wear detection. The second page of diagnostic
data will display % of spindle load. The meter should agree with this display within 5%. The spindle drive
display #7 should also agree with the load meter within 5%.
There are different types of spindle drive that are used in the control. They are all equivalent in performance
but are adjusted differently.
The EMERGENCY STOP switch is normally closed. If the switch opens or is broken, power to the servos will
be removed instantly. This will also shut off the turret, spindle drive, and coolant pump. The EMERGENCY
STOP switch will shut down motion even if the switch opens for as little 0.005 seconds.
Be careful of the fact that Parameter 57 contains a status switch that, if set, will cause the control to be
powered down when EMERGENCY STOP is pressed.
You should not normally stop a tool change with EMERGENCY STOP as this will leave the tool changer in an
abnormal position that takes special action to correct.
Note that tool changer alarms can be easily corrected by first correcting any mechanical problem, pressing
RESET until the alarms are clear, selecting ZERO RETURN mode, and selecting AUTO ALL AXES.
If the turret should become jammed, the control will automatically come to an alarm state. To correct this,
push the EMERGENCY STOP button and remove the cause of the jam. Push the RESET key to clear any alarms.
Push the ZERO RETURN and the AUTO ALL AXES keys to reset the Z-axis and turret. Never put your
hands near the turret when powered unless the EMERGENCY STOP button is pressed.
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KEYBOARD BEEPER
There is a speaker inside the control panel that is used as an audible response to pressing keyboard buttons
and as a warning beeper. The beeper is a one kHz signal that sounds for about 0.1 seconds when any keypad
key, CYCLE START, or FEED HOLD is pressed. The beeper also sounds for longer periods when an auto-
shutdown is about to occur and when the BEEP AT M30 setting is selected.
If the beeper is not audible when buttons are pressed, the problem could be in the keypad, keyboard interface
PCB or in the speaker. Check that the problem occurs with more than one button and check that the speaker
volume is not turned down.
CONTROL CABINET
The following illustration shows the connectors on the side of the control cabinet.
The microprocessor assembly is in the rear cabinet at the top left position. It contains three large boards.
They are: microprocessor, the keyboard and the MOCON. All three boards of the processor assembly receive
power from the low voltage power supply. The three PCBs are interconnected by a local buss on dual 50-
pin connectors. At power-on of the control, some diagnostic tests are performed on the processor assembly
and any problems found will generate alarms 157 or 158. In addition, while the control is operating, it
continually tests itself and a self test failure will generate Alarm 152.
The Microprocessor PCB contains the 68ECO30 processor running at 40 MHz, one 128K EPROM; between
256K and 8MB of CMOS RAM and between 512K and 1MB of FAST STATIC RAM. It also contains a dual serial
port, a five year battery to backup RAM, buffering to the system buss, and eight system status LEDs.
Two ports on this board are used to set the point at which an NMI* is generated during power down and the
point at which RESET* is generated during power down.
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The eight LEDs are used to diagnose internal processor problems. As the system completes power up testing,
the lights are turned on sequentially to indicate the completion of a step. The lights and meanings are:
There is a two-position DIP switch on the processor PCB labled S1. Switch S1-1 must be
ON to auto-start the CNC operational program. If S1-1 is OFF, the PGM light will remain off.
Switch S2-1 is used to enable FLASH. If it is disabled it will not be possible to write to FLASH.
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The memory retention battery is placed into the battery holder soldered into the process board. This is a 3.3V
Lithium battery that maintains the contents of CMOS RAM during power off periods. Prior to this battery being
unusable, an alarm will be generated indicating low battery. If the battery is replaced within 30 days, no data
will be lost. The battery is not needed when the machine is powered on. Connector J6 on the processor PCB
can be used to connect an external battery.
The VIDEO and KB PCB generates the video data signals for the monitor and the scanning signals for the
keyboard. In addition, the keyboard beeper is generated on this board. There is a single jumper on this board
used to select inverse video. The video PCB connectors are:
The brushless machining centers are equipped with a microprocessor based brushless motor controller board
(MOCON)that replaces the motor interface in the brush type controls. It runs in parallel with the main
processor, receiving servo commands and closing the servo loop around the servo motors.
In addition to controlling the servos and detecting servo faults, the motor controller board, (MOCON), is also
in charge of processing discrete inputs, driving the I/O board relays, commanding the spindle and processing
the jog handle input. Another significant feature is that it controls 6 axes, so there is no need for an additional
board for a 5 axis machine.
P1 Data Buss
P2 X amplifier control and fault sensing (610)
P3 Y amplifier control and fault sensing (620)
P4 Z amplifier control and fault sensing (630)
P5 A amplifier control and fault sensing (640)
P32 B amplifier control and fault sensing (640B)
P33 C amplifier control and fault sensing (640C)
P6 X encoder input (660)
P7 Y encoder input (670)
P8 Z encoder input (680)
P9 A encoder input (690)
P30 B encoder input (690B)
P31 C encoder input (690C)
P18 Jog encoder input (750)
P20 Spindle encoder output (1000)
P10 Inputs from I/O board (550)
P11 I/O relays K1-8 (510)
P12 I/O relays K9-16 (520)
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The spindle drive is located in the main cabinet on the right side and halfway down. It operates from three-
phase 200 to 240V AC. It has a 10 H.P. (20 H.P. for SL-30 and 40) continuous rating, and a 15 H.P. (30 H.P.
for SL-30 and 40) one-minute rating. The spindle drive is protected by CB1 at 40 amps (20 for High Voltage
option). Never work on the spindle drive until the small red CHARGE light goes out. Until this light goes out,
there are dangerous voltages inside the drive, even when power is shut off.
For all other data on the spindle drive, refer to the supplied documentation for your drive.
The Haas vector drive is a current amplifier controlled by the MOCON software, using the C axis output. The
vector drive parameters are a part of the machine parameters and are accessible through the Haas front panel.
The spindle encoder is used for the closed loop control and spindle orientation, as well as rigid tapping if
the option is available. Spindle speed is very accurate since this is a closed loop control, and the torque output
at low speeds is superior to non vector drive spindles.
The Resistor Assembly is located on top of the control cabinet. It contains the servo and spindle drive regen
load resistors.
A 8.6-ohm (6-ohm for SL-30 and 40), 300-watt resistor bank is used by the vector drive to dissipate excess
power caused by the regenerative effects of decelerating the spindle motor. If the spindle motor is accelerated
and decelerated again in rapid succession repeatedly, this resistor will get hot. In addition, if the line voltage
into the control is above 255V, this resistor will begin to heat. This resistor is overtemp protected at 100 0
C. At that temperature, an alarm is generated and the control will begin an automatic shutdown. If the resistor
is removed from the circuit, an alarm may subsequently occur because of an overvoltage condition inside the
spindle drive.
There is an overtemperature sense switch mounted near the above-mentioned regen resistors. This sensor
is a normally-closed switch that opens at about 100 0 C. It will generate an alarm and all motion will stop. After
four minutes of an overheat condition, an automatic shutdown will occur in the control.
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All power to the control passes through the power supply assembly. It is located on the upper right corner
of the control cabinet.
Circuit breaker CB1 is rated at 40 amps (20 amps for High Voltage option, 80 amps for SL-30 and 40) and is
used to protect the vector drive and to shut off all power to the control. The locking On/Off handle on the
outside of the control cabinet will shut this breaker off when it is unlocked. A trip of this breaker indicates
a SERIOUS overload problem and should not be reset without investigating the cause of the trip. The full
circuit breaker rating corresponds to as much as 15 horsepower.
MAIN CONTACTOR K1
Main contactor K1 is used to turn the control on and off. The POWER ON switch applies power to the coil
of K1 and after it is energized, an auxiliary switch on K1 continues to apply power to the coil. The POWER
OFF switch on the front panel will always remove power from this contactor.
When the main contactor is off, the only power used by the control is supplied through two ½ amp fuses to
the circuit that activates the contactor. An overvoltage or lightning strike will blow these fuses and shut off
the main contactor.
The power to operate the main contactor is supplied from a 24V AC control transformer that is primary fused
at ½ amp. This ensures that the only circuit powered when the machine is turned off is this transformer and
only low voltage is present at the front panel on/off switches.
The low voltage power supply provides +5V DC, +12V DC, and -12V DC to all of the logic sections of the control.
It operates from 115V AC nominal input power. It will continue to operate correctly over a 90V AC to 133V
AC range.
The low voltage power distribution and high voltage fuses and circuit breakers are mounted on a circuit board
called the POWER PCB. The following connectors are on it:
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The low voltage control transformer, T5, supplies power to the coil of the main contactor K1. It guarantees
that the maximum voltage leaving the Power Supply assembly when power is off is 12V AC to earth ground.
It is connected via P5 to the POWER PCB.
The following circuit breakers are located on the Power supply assembly.
CB2 controls the 115volt power from the main transformer to the servo transformers and, if tripped, will turn
off the servo motors and air solenoids. CB2 could be blown by a severe servo overload.
CB3 controls the power to coolant pump only. It can be blown by an overload of the coolant pump motor
or a short in the wiring to the motor.
CB4 controls the 115V AC to the air solenoids, 4th axis brake, and the oiler. It is never expected to trip. If
it does trip, it is likely caused by a short circuit in the wiring on the I/O assembly or the wiring to the solenoids
on the spindle head.
OPERATOR'S LAMP
The operator's lamp is using 115 VAC taken from P19 on the main power distribution.
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The power transformer assembly is used to convert three-phase input power (50/60Hz) to three phase 230V
and 115V power. Two different transformers are used depending on the input voltage range. The low voltage
transformer has four different input connections to allow for a range of voltages from 195 V RMS to 260 V
RMS. The high voltage transformer has five different input connections and will accept a range of voltages
from 354V RMS to 488 V RMS.
The 230 V is used to power the spindle drive, which also develops the 325 VDC power for the axis servo
amplifiers. The 115 V is used by the video monitor, solenoids, fans and pumps, in addition to supplying power
to the main LVPS used by the control electronics.
The transformer assembly is located in the lower right hand corner of the main cabinet. Besides the high/low
voltage variations, two different power levels are available depending on the spindle motor used. The small
and large transformers have power ratings of 14 KVA and 28 KVA, respectively. They are protected by the main
circuit breaker to the levels shown in the preceding table.
Fig. 5-2a Transformer with 354-488V range Fig 5-2b Transformer with 195-260V range
PRIMARY CONNECTION TO T1
Input power to T1 is supplied through CB1, the 40 amp or 80 amp three-phase main circuit breaker. Three-
phase 230 to T1 is connected to the first three terminals of TB10.
There are four labeled plastic terminal blocks. Each block has three connections for wires labeled 74, 75, and
76. Follow the instructions printed on the transformer.
SECONDARY CONNECTION TO T1
The secondary output from T1 is 115V AC three-phase CB2 protects the secondary of transformer T1 and is
rated at 25 amps.
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Right to left:
354 to 376
377 to 402
403 to 428
429 to 457
458 to 488*
5.11 FUSES
The brushless amplifier has one fuse, F1 15 amps. This fuse protects the amplifier itself from drastic damage.
If this fuse is ever blown, the associated motor will stop. This will only happen if there is a failure of the
amplifier card and the user should never attempt to replace these fuses.
The POWER PCB contains three ½-amp fuses located at the top right (FU1, FU2, FU3). If the machine is subject
to a severe overvoltage or a lightning strike, these fuses will blow and turn off all of the power. Replace these
fuses only with the same type and ratings. The other two fuses protect the turret (FU5) and the operator's
lamp (FU4).
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TECHNICAL REFERENCE January 1999
The M code interface uses outputs M21-24 and one discrete input circuit. M codes M21 through M24 will
activate relays labeled M21-24. These relay contacts are isolated from all other circuits and may switch up
to 120V AC at three amps. The relays are SPDT. WARNING! Power circuits and inductive loads must have
snubber protection.
Note: If the optional Mcode relay board is installed relays M21-M28 become available on
the secondary board. These relays willl be controlled by outputs M21-M28.
The M-FIN circuit is a normally open circuit that is made active by bringing it to ground. The one M-FIN applies
to all three of the user M codes.
The timing of a user M function must begin with all circuits inactive, that is, all circuits open. The timing is
as follows:
The Diagnostic Data display page may be used to observe the state of these signals.
M FUNCTION RELAYS
The IOPCB contains position for four relays (M21-M24) and the optional M code relay board contains eight
(M21-M28), either one of these groups of relays may be available to the user. M21 is already wired out to P12
at the side of the control cabinet. This is a four-pin DIN connector and includes the M-FIN signal.
Note: If the optional M code relay board is installed, the relays on the IOPCB are to be left
unused.
The M-FIN discrete input is a low voltage circuit. When the circuit is open, there is +12V DC at this signal.
When this line is brought to ground, there will be about 10 milliamps of current. M-FIN is discrete input #10
and is wired from input #10 on the Inputs PCB on the Input/Output Assembly. The return line for grounding
the circuit should also be picked up from that PCB. For reliability, these two wires should be routed in a
shielded cable where the shield is grounded at one end only. The diagnostic display will show this signal
a 1 when the circuit is open and a 0 when this circuit is grounded.
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The three optional M code relays can also be separately turned on and off using M codes M51-M54 and M61-
M64. M51 to M54 will turn on one of the relays and M61 to M63 will turn the relays off. M51 and M61
correspond to M21, etc.
Note: If the M code relay board is installed then M51 - M58 will turn on the relays and
M61-M68 will turn off the relays. M51 and M61 correspond to M21, etc. on the M code
relay board.
The relays are marked on both the IOPCB and the M code relay board, with their respective terminals forward
of them. If the optional M code relay board is installed then the connections on the IOPCB are to be left unused
as they are replaced by the relays on the optional board. Refer to the figures below, and the Probe Option figure
in the Electrical Diagrams section for the terminal labeling. Maximum voltage for the relays is 125 VAC with
a maximum amperage of 3 amps.
WARNING! Power circuits and inductive loads must have snubber protection.
CAUTION! If a screw terminal is already in use DO NOT connect anything else to it. Call you
dealer.
The lubrication system is a resistance type system which forces oil through metering units at each of the 16
lubricating points within the machine. The system uses one metering unit at each of the lubricating points:
one for each linear guide pad, one for each lead screw and one for spindle lubrication. A single oil pump is
used to lubricate the system. The pump is powered only when the spindle and/or an axis moves. Once powered
the pump cycles approximately 3.0 cc of oil every 30 minutes throughout the oil lines to the lube points. Every
lube point receives approximately 1/16 of oil. The control monitors this system through an internal level
switch in the reservoir and external pressure switch on the lube panel.
There is a low lube sense switch in the oil tank. When the oil is low, an alarm will be generated. This alarm
will not occur until the end of a program is reached. There is also an lube pressure switch that senses the
lube pressure. Parameter 117 controls the lube pressure check. If Parameter 117 is not zero, the lube pressure
is checked for cycling high within that period. Parameter 117 has units of , 1/50 seconds; so 30 minutes gives
a value of 90000. Parameter 57, bit "Oiler on/off", indicates the lube pump is only powered when the spindle
fan is powered. The lube pressure is only checked when the pump is on.
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5.14 SWITCHES
An on/off switch is supplied for the operator's lamp. It is located on the side of the control cabinet below
all of the motor connectors.
The DOOR OPEN switch is in the open position when the door is open and closed when the door is fully closed.
When the doors open, one or both of these switches will open and the machine will stop with a Door Hold
function. When the door is closed again, operation will continue normally.
If the doors are open, you will not be able to start a program. Door Hold will not stop a tool change operation
or a tapping operation, and will not turn off the coolant pump. Also, if the doors are open, the spindle speed
will be limited to 500 RPM.
The Door Hold function can be temporarily disabled with by turning Setting 51 on, if Parameter 57 bits DOOR
STOP SP and SAFETY CIRC are set to zero, but this setting will return to OFF when the control is turned off.
LIMIT SWITCHES
The diagnostic display can be used to display the status of the relay outputs and the switch inputs.
If the door is open, you will not be able to start a program. Door hold will not stop a tool change operation,
will not turn off the spindle, and will not turn off the coolant pump.
The door hold function can be temporarily disabled with Setting 51, but this setting will return to OFF when
the control is turned off.
The limit switches are normally closed. When a search for zero operation is being performed, the X and Z axes
will move towards the limit switch unless it is already active (open); then they will move away from the switch
until it closes again; then they will continue to move until the encoder Z channel is found. This position is
machine zero.
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If the switch is damaged and permanently open, the zero search for that axis will move in the negative direction
at about 0.5 in/min until it reaches the physical travel stops at the opposite end of travel.
If the switch is damaged and permanently closed, the zero search for that axis will move at about 10 in/min
in the positive direction until it reaches the physical stops.
If the switch opens or a wire breaks after the zero search completes, an alarm is generated, the servos are
turned off, and all motion stops. The control will operate as though the zero search was never performed. The
RESET can be used to turn servos on but you can jog that axis only slowly.
The ALARM MSGS display is the most important source of diagnostic data. At any time after the machine
completes its power-up sequence, it will either perform a requested function or stop with an alarm. Refer to
the alarms list for , their possible causes, and some corrective action.
If there is an electronics problem, the controller may not complete the power-up sequence and the CRT will
remain blank. In this case, there are two sources of diagnostic data; these are the audible beeper and the LEDs
on the processor PCB. If the audible beeper is alternating a ½ second beep, there is a problem with the main
control program stored in EPROMs on the processor PCB. If any of the processor electronics cannot be
accessed correctly, the LEDs on the processor PCB will or will not be lit.
If the machine powers up but has a fault in one of its power supplies, it may not be possible to flag an alarm
condition. If this happens, all motors will be kept off and the top left corner of the CRT will have the message:
When the machine is operating normally, a second push of the PARAM/DGNOS key will select the diagnostics
display page. The PAGE UP and PAGE DOWN keys are then used to select one of two different displays. These
are for diagnostic purposes only and the user will not normally need them. The diagnostic data consists of
32 discrete input signals, 32 discrete output relays and several internal control signals. Each can have the
value of 0 or 1. In addition, there are up to three analog data displays and an optional spindle RPM display.
Their number and functions are:
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DISCRETE INPUTS
# Name # Description
1000 Tool Turret Unlock 1016 Spindle Lock (Vector Drive: Spare)
1001 Tool Turret Lock 1017 Spindle Fault (Vector Drive: Spare)
1002 spare 1018 Spindle Stopped (Vector Drive: Spare)
1003 Low Coolant 1019 Spindle At Speed (Vector Drive: Spare)
1004 Automatic door 1020 Low hyd pressure
1005 Spindle In Hi Gear 1021 T.S. Foot Switch
1006 Spindle In Low Gear 1022 Probe not home
1007 Emergency Stop 1023 spare 2b
1008 Door Switch 1024 Tool Unclamp Rmt*
1009 M Code Finish 1025 Low phasing 115V
1010 Over voltage 1026 B F End of Bar
1011 Low Air Pressure 1027 Bar Feeder Fault
1012 Low Lube Press. 1028 Ground fault
1013 Regen Overheat 1029 G31 Block Skip
1014 spare 1030 B F Spindle Intlk
1015 spare 1031 Conveyr Overcrnts
DISCRETE OUTPUTS
The 32 inputs are numbered the same as the 32 connections on the inputs printed circuit board. The last eight
outputs are reserved for expansion by HAAS.
The second page of diagnostic data is displayed using the PAGE UP and PAGE DOWN keys. It contains:
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INPUTS 2
Name Name
The following inputs and outputs pertain to the Haas Vector Drive. If it is not enabled, these will display a
value of *. Otherwise, it will display a 1 or 0.
Description
Spindle Forward
Spindle Reverse
Spindle Lock
Spindle At Speed
Spindle Stopped
Speed Fault
Spindle Locked
Spindle Overheat
Spindle Cable Fault
ANALOG DATA
Name Description
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6. PARAMETERS
Parameters are seldom-modified values that change the operation of the machine. These include servo motor
types, gear ratios, speeds, stored stroke limits, lead screw compensations, motor control delays and macro
call selections. These are all rarely changed by the user and should be protected from being changed by the
parameter lock setting. If you need to change parameters, contact HAAS or your dealer. Parameters are
protected from being changed by Setting 7.
The Settings page lists some parameters that the user may need to change during normal operation and these
are simply called "Settings". Under normal conditions, the parameter displays should not be modified. A
complete list of the parameters is provided here.
The PAGE UP, PAGE DOWN, up and down cursor keys , and the jog handle can be used to scroll through the
parameter display screens in the control. The left and right cursor keys are used to scroll through the bits
in a single parameter.
PARAMETER LIST
Parameter 1 X SWITCHES
Parameter 1 is a collection of single-bit flags used to turn servo related
functions on and off. The left and right cursor arrows are used to select the
function being changed. All values are 0 or 1 only. The function names are:
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HI LO
0 0 3
0 1 5
1 0 7
1 1 9
Parameter 2 X P GAIN
Proportional gain in servo loop.
Parameter 3 X D GAIN
Derivative gain in servo loop.
Parameter 4 X I GAIN
Integral gain in servo loop.
Parameter 7 X ACCELERATION
Maximum acceleration of axis in steps per second per second.
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Parameter 12 X STEPS/REVOLUTION
Encoder steps per revolution of motor. Thus, an 8192 line encoder gives:
8192 x 4 = 32768
Parameter 13 X BACKLASH
Backlash correction in encoder steps.
Parameter 15 Y SWITCHES
See Parameter 1 for description.
Parameter 16 Y P GAIN
See Parameter 2 for description.
Parameter 17 Y D GAIN
See Parameter 3 for description.
Parameter 18 Y I GAIN
See Parameter 4 for description.
Parameter 21 Y ACCELERATION
See Parameter 7 for description.
Parameter 26 Y STEPS/REVOLUTION
See Parameter 12 for description.
Parameter 27 Y BACKLASH
See Parameter 13 for description.
Parameter 29 Z SWITCHES
See Parameter 1 for description.
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Parameter 30 Z P GAIN
See Parameter 2 for description.
Parameter 31 Z D GAIN
See Parameter 3 for description.
Parameter 32 Z I GAIN
See Parameter 4 for description.
Parameter 35 Z ACCELERATION
See Parameter 7 for description.
Parameter 40 Z STEPS/REVOLUTION
See Parameter 12 for description.
Parameter 41 Z BACKLASH
See Parameter 13 for description.
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Parameters 57 through 128 are used to control other machine dependent functions. They are:
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Note: To change the values of parameters 134-137 permanently the machine must be
rebooted.
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50% RPD KBD When (1) the control will support the new style keyboards with the 50% rapid
traverse key. For controls without a 50% rapid keypad set this bit to (0).
FRONT DOOR When enabled the control will look for an additional door switch and will
generate an operator message.
RESERVED
RESERVED
RESERVED
UNUSED Not presently used.
T SUBROUTINE Reserved for future use.
SPIN Y ENCDR For lathe only. When enabled, spindle encoder input is to the Y-axis.
REV CONVEYOR Reverses the direction of the chip conveyor.
M27-M28 CONVYR Usually the chip conveyor motor and direction relays are attached to the user
relays M21 M22. When this bit is set, the control expects to see the conveyor
hooked up to M27 and M28.
RESERVED
GREEN BEACON When (1) user relay M25 is used to flash a beacon. If the control is in a reset
state, the beacon will be off. If the control is running normally, the beacon will
be steadily on. If the control is in a M00, M01, M02, M30 feedhold, or single
block state, then the beacon will flash.
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RED BEACON When (1) user relay M26 is used to flash a beacon. The beacon flashes if the
control is experiencing an alarm or emergency stop condition.
CONVY DR OVRD When (1) the conveyor will continue to run with the door open. When (0) the
conveyor will stop when the door is open, but will resume when the door is
closed. For safety it is recommended that the bit be set to (0).
TC FWD CW Determines the direction that the turret moves as viewed from the spindle, when
the turret is commanded forward. When (1), the turret will rotate clockwise for
a forward command, and when (0), it will rotate counterclockwise. The default
is 1.
RAPID EXSTOP Default is 1. When this bit is set to 1, the control will execute an exact stop after
all rapid motions, regardless of the next motion. When set to zero, the control
will exact stop after a rapid only if the next motion is not a rapid move.
HYDRAULICS This bit must be set to 1 if a lathe has the hydraulic chuck clamping option.
STALL DETECT Enables detection of spindle stall. If spindle stalls, the spindle motor is stopped and an
alarm is generated.
SPNDL NOWAIT When (1), the machine will not wait for the spindle to come up to speed
immediately after an M03 or M04 command. Instead, it will check and/or wait
for the spindle to come up to speed immediately before the next interpolated
motion is initiated. This bit does not affect rigid tapping.
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INVERT G.B. Default is 0. When this bit is set to 1, the sense of the discrete inputs for SP HIG
and SP LOW (high and low gear) are inverted.
RESERVED Not used.
DPR SERIAL Causes the main serial inputs/outputs to go through the floppy video board.
DISPLAY ACT When set to 1, displays the actual spindle speed on the Current Commands
display page.
HYDRAULIC TS This bit enables the hydraulic tailstock
SPND DRV LCK This bit must be set to 0 if machine is equipped with a Haas vector spindle
drive.
CHUCK OPN CS When set to 1, the user can press CYCLE START and run a program with the
chuck unclamped. If the spindle is commanded with this bit set to 1, the spindle
will not exceed the CHUCK UNCLAMP RPM (Parameter 248). The default for this
bit is 0. This feature is ineffective when the CE safety circuit is enabled.
CNCR SPINDLE When set to 0, spindle start occurs at the end of a block, as in normal M code
operation. When set to 1, spindle start occurs at the beginning of a block and
concurrent with axis motion.
TL SET PROBE This bit must be set to 1 in order to enable the Tool Pre-Setter.
HAAS VECT DR (Haas Vector Drive) This bit must be set to 1 if machine is equipped with a HAAS
vector spindle drive. When set to 1, voltage to the Haas vector drive is
displayed in the diagnostics display as DC BUSS.
HAAS RJH Haas remote jog handle. This bit must be set to 1 if the machine is equipped with
a Haas 5-axis Remote jog handle.
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SPIN TEMP NC Spindle temperature normally closed. This bit specifies the type (normally open
normally closed) of the spindle temperature sensor. This bit should be set to 1
for machines with a Haas Vector Drive, and 0 for machines without a Vector Drive.
D:Y SW ENABL Delta Wye switch enable, this is used for machine with a Vector Drive. If this
switch is set, but bit 19 is not, then winding switching will only be done when
the spindle is at rest, depending on the target speed of the spindle
DY SW ON FLY Delta Wye switch enable, this is used for machine with a Vector Drive. This
parameter enables switching on the fly, as the spindle motor is accelerating or
decelerating through the switch point.
CK BF STATUS This bit has been added for the improved Bar Feeder interface. When this bit is
set to 1, the control will constantly check the Bar Feeder Status on discrete input
1027. If this input goes high, alarm 450 BAR FEEDER FAULT will be generated
and the servos and spindle will be turned off. Note that the spindle will simply
coast to a stop.
CK BF SP ILK This bit has been added for the improved Bar Feeder interface. When this bit is
set to 1, the control will constantly check the Bar Feeder Spindle Interlock on
discrete input 1030. If this input goes high, and the spindle is being com
manded to turn, or coasting or being manually turned at 10rpm or more, alarm
451 BAR FEEDER SPINDLE INTERLOCK will be generated and the servos and
spindle will be turned off. Note that the spindle will simply coast to a stop.
SAFETY INVERT This bit supports the CE door interlock that locks when power is turned off. For
machines that have the regular door lock that locks when power is applied, this
bit must be set to 0. For machines that have the inverted door lock, this bit must
be set to 1.
LIVE TOOLING Lathes fitted with the Live Tooling drive this bit must be set to 1. For all other
lathes, this bit is set to 0.
INV SPD DCEL Inverse spindle speed deceleration. When this parameter is set to 1, the spindle
decelerates faster at lower speeds, resulting in a shorter deceleration time.
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NOTES: When tapping, the feed and spindle overrides will be locked out, so the
AUTOFEED feature will be ineffective (although the display will appear to respond to the
override buttons.)
The last commanded feed rate will be restored at the end of the program execution, or when the
operator presses RESET or turns off the AUTOFEED feature.
The operator may use the feed rate override buttons while the AUTOFEED feature is active. As
long as tool load limit is not exceeded, these buttons will have the expected effect and the
overridden feed rate will be recognized as the new commanded feed rate by the AUTOFEED
feature. However, if the tool load limit has already been exceeded, the control will ignore the feed
rate override buttons and the commanded feed rate will remain unchanged.
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January 1999 MAINTENANCE
MAINTENANCE SCHEDULE
MONTHLY ü Inspect way covers for proper operation and lubricate with light oil, if necessary.
ü Remove coolant pump form the coolant tank. Clean sediment from inside the tank.
Reinstall the pump.CAUTION! Be careful to disconnect the coolant pump from the
controller and to POWER OFF the control before working on the coolant tank.
ü Dump the oil drain bucket.
ü Check gearbox oil level (if applicable). If oil is not visible at the bottom edge of
the sight gauge, remove the end panel and add DTE-25 through the top filler hole
until it is visible in the sight gauge.
SIX MONTHS ü Replace coolant and thoroughly clean the coolant tank.
ü Replace hydraulic unit oil filter.
ü Check all hoses and lubrication lines for cracking.
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LUBRICATION CHART
COOLANT 30 gallons (40 for SL-30) Water soluble, synthetic, or cutting oil.
LUBRICATION REQUIREMENTS:
CHUCK MAINTENANCE
CHUCK MAINTENANCE
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BOARD DIAGRAMS
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X AXIS AMP
P 570 LOW VOLTAGE L. V. POWER SUPPLY -
TB A, B, C - MOTOR DRIVE X SERVO MOTOR -
P 610 X DRIVE SIGNAL MOCON PCB P2
TB -HV +HV 490 320VDC SPINDLE DRIVE -
Y AXIS AMP
P 570 LOW VOLTAGE L. V. POWER SUPPLY -
TB A, B, C - MOTOR DRIVE X SERVO MOTOR -
P 620 X DRIVE SIGNAL MOCON PCB P3
TB -HV +HV 490 320VDC SPINDLE DRIVE -
Z AXIS AMP
P 570 LOW VOLTAGE L. V. POWER SUPPLY -
TB A, B, C - MOTOR DRIVE X SERVO MOTOR -
P 630 X DRIVE SIGNAL MOCON PCB P4
TB -HV +HV 490 320VDC SPINDLE DRIVE -
A AXIS AMP
P 570 LOW VOLTAGE L. V. POWER SUPPLY -
TB A, B, C - MOTOR DRIVE X SERVO MOTOR -
P 640 X DRIVE SIGNAL MOCON PCB P5
TB -HV +HV 490 320VDC SPINDLE DRIVE -
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9. CABLE LIST
THE FOLLOWING IS A SUMMARY OF THE CABLES USED IN THE WIRING OF THIS CONTROL:
WIRE/
TERMINAL FUNCTION NAME:
NUMBER
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180 SPARE
181 SIGNAL
182 COMMON
200 SPARE
201 +12VDC
202 RETURN
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January 1999 ELECTRICAL DIAGRAMS
ELECTRICAL
WIRING DIAGRAMS
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January 1999 ASSEMBLY DRAWINGS
ASSEMBLY DRAWINGS
AND
PARTS LISTS
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96-8710 219
ASSEMBLY DRAWINGS January 1999
220 96-8710
January 1999 ASSEMBLY DRAWINGS
96-8710 221
ASSEMBLY DRAWINGS January 1999
222 96-8710
January 1999 ASSEMBLY DRAWINGS
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ASSEMBLY DRAWINGS January 1999
224 96-8710
January 1999 ASSEMBLY DRAWINGS
96-8710 225
ASSEMBLY DRAWINGS January 1999
226 96-8710
January 1999 ASSEMBLY DRAWINGS
96-8710 227
ASSEMBLY DRAWINGS January 1999
228 96-8710
January 1999 ASSEMBLY DRAWINGS
96-8710 229
ASSEMBLY DRAWINGS January 1999
230 96-8710
January 1999 ASSEMBLY DRAWINGS
96-8710 231
ASSEMBLY DRAWINGS January 1999
232 96-8710
January 1999 ASSEMBLY DRAWINGS
96-8710 233
ASSEMBLY DRAWINGS January 1999
234 96-8710
January 1999 ASSEMBLY DRAWINGS
96-8710 235
ASSEMBLY DRAWINGS January 1999
236 96-8710
January 1999 ASSEMBLY DRAWINGS
96-8710 237
ASSEMBLY DRAWINGS January 1999
238 96-8710
January 1999 ASSEMBLY DRAWINGS
96-8710 239
ASSEMBLY DRAWINGS January 1999
240 96-8710
January 1999 ASSEMBLY DRAWINGS
96-8710 241
ASSEMBLY DRAWINGS January 1999
242 96-8710
January 1999 ASSEMBLY DRAWINGS
96-8710 243