Haas VF-SERIES, Service Manual

Page 1: ...aim hole mis positioning if you don t first center drill the hole FIND THE PROBLEM FIRST Many mechanics tear into things before they understand the problem hoping that it will appear as they go We know this from the fact that more than half of all warranty returned parts are in good working order If the spindle doesn t turn remember that the spindle is connected to the gear box which is connected ...

Page 2: ...y for OVERVOLTAGE or OVERHEAT shutdown l Check AC power supply lines for intermittent supply l Check wiring to POWER OFF button on front control panel l Replace IOPCB see Electrical Service l Check Parameter 57 for Power Off at E STOP l Replace MOTIF PCB see Electrical Service Machine turns on keyboard beeps but no CRT display l Check for green POWER LED at front of CRT l Check for power connectio...

Page 3: ...d machining practices are being observed These symptoms will not occur individually Ex A machine with backlash may vibrate heavily yielding a bad finish Put all of the symptoms together to arrive at an accurate picture of the problem Machine vibrates while jogging the axis with the hand wheel l The HAAS control uses very high gain accelerations curves This vibration as you jog is simply the servos...

Page 4: ...d as the source of the problem determine specifically what the machine is doing wrong Machine will not interpolate a round hole l Check the levelness of the machine See the Installation Manual l Check for backlash Servo Motors Leadscrews section Bored holes do not go straight through the workpiece l Check the levelness of the machine See the Installation Manual l Check for squareness in the Z axis...

Page 5: ... bad regulator l bad check valve l air cylinder bad l bound cylinder l surge tank leak 1 4 FINISH Machining yields a poor finish l Check for gearbox vibration This is the most common cause of a poor finish l Check for backlash Accuracy Backlash section l Check the condition of the tooling and the spindle l Check for spindle failure l Check the condition of the servo motors l Check the machine leve...

Page 6: ...t of the machine Isolate the sources of noise as follows Excessive noise coming from the spindle head area On VF 1 through 6 models first determine if the noise is related to the RPM of the motor or the RPM of the spindle For example If the noise appears at 2000 RPM in high gear listen for a similar noise at 500 RPM in low gear If the same noise persists the problem lies with the gearbox If the no...

Page 7: ... N600 S5000 M03 G04 P900 M05 G04 P900 M99 G04 P900 M05 G04 P900 G04 P900 N400 S3000 M03 G04 P900 NOTE This program will step the spindle speed from 300 RPM up to either 5000 or 7500 RPM at regular intervals of time stop the spindle and allow it to cool to room temperature then restart it so the temperature can be monitored l If at any time during this procedure the spindle temperature rises above ...

Page 8: ...cing holes Ø If there are cracks replace the ring l Check the shot pin on the gearbox for binding damage and proper operation Replace it if it is damaged l Check the switch on the shot pin against the Diagnostic display Replace the switch if it is found to be faulty 2 7 TOOLS STICKING IN TAPER Tool sticking in the taper causes ATC to be pulled up accompanied by a popping noise as the tool holder p...

Page 9: ...or Removal Installation l Check for broken or loose coupling between the servo motor and the lead screw Replace or repair the coupling Axis Motor Removal Installation l Check for a broken lead screw If cracked or broken replace Lead Screw Removal and Installation section NOTE If a lead screw fails it is most often due to a failed bearing sleeve When replacing the lead screw in an older machine alw...

Page 10: ...st be replaced When replacing the lead screw in an older machine always replace the bearing sleeve with the current angular contact design bearing sleeve l Check the lead screw for misalignment If incorrect perform alignment procedure l 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 M...

Page 11: ...d Y directions Move the spindle head to approximate center of the Z axis travel also CHECKING X AXIS 1 Set up a dial indicator and base on the mill table as shown in Fig 3 1 Fig 3 1 Dial indicator in position to check X axis 2 Set dial indicator and the Distance to go display in the HANDLE JOG mode to zero as follows Zero the dial indicator Press the MDI button on the control panel Press the HANDL...

Page 12: ...ws Zero the dial indicator Press the MDI button on the control panel Press the HANDLE JOG button on the control panel The Distance to go display on the lower right hand corner should read X 0 Y 0 Z 0 3 Set the rate of travel to 001 on the control panel and jog the machine 010 in the positive Y direction Jog back to zero 0 on the display The dial indicator should read zero 0 0001 4 Repeat step thre...

Page 13: ...saddle depending on the axis Tighten the SHCS as described in Mechanical Service l Loose clamp nut on the bearing sleeve Tighten the SHCS on the clamp nut l Loose motor coupling Tighten as described in Mechanical Service l Broken or loose flex plates on the motor coupling NOTE The coupling cannot be serviced in the field and must be replaced as a unit if it is found to be defective l Loosen SHCS a...

Page 14: ...LARMS 135 138 check the Parameters for an incorrect setting Axis flags in Parameters 1 15 or 29 can invert the overheat switch OVER TEMP NC l If the motor is actually getting hot to the touch there is excessive load on the motor Check the user s application for ex cessive load or high duty cycle Check the lead screw for binding Accuracy Backlash section If the motor is binding by itself replace in...

Page 15: ...popping noise as the tool holder pops out of the spindle taper NOTE This problem may occur after loading a cold tool into a hot spindle a result of thermal expansion of the tool holder inside the spindle taper It may also occur in cuts with heavy vibration If sticking occurs only during these circumstances no service is necessary l Check the condition of the customer s tooling verifying the taper ...

Page 16: ...certain pockets of the ATC when the ATC shuttle retracts l Check all the extractor forks to ensure they are centered in the pocket of the ATC Also see above See Extractor Fork Replacement section if necessary NOTE If the ATC shows the problem as described here each extractor fork must be checked and centered to eliminate the possibility of the ATC being aligned against an incorrectly centered fork...

Page 17: ...rt or fixture on the mill table crashes into long tooling or into the ATC itself when machining l Either reposition the tools to remove the interference or program the carousel to rotate long tooling out of the way of the part USE THIS ONLY AS A LAST RESORT CAUTION If the carousel has to be programmed to rotate long tools clear of the part the correct carousel position must be programmed back in b...

Page 18: ...emoval section If the Geneva driver is found to be loose check for damage to the Geneva star Any roughness in the slots will require that it be replaced Geneva Star Replacement section l Check the adjustment of the Geneva driver in relation to the Geneva star Geneva Star Replacement section If the adjustment is too loose the carousel will vibrate heavily and make a loud clanking noise during carou...

Page 19: ...oves Alarm 113 will be generated l Check the orientation of the machine ATC WILL NOT RUN l In all cases where the tool changer will not run an alarm is generated to indicate either a shuttle in out problem or a turret rotation problem These alarms will occur either on an attempt to change tools ATC FWD or ZERO RETURN the machine AUTO ALL AXES Use the appropriate alarm to select one of the problems...

Page 20: ...to the turret motor l If power is applied but the output shaft on the motor does not turn check for binding between the turret motor assembly and the Geneva star Automatic Tool Changer section Check for damage to the Geneva star or the Geneva driver Check for a broken turret motor Turret Motor Removal section NOTE Do not attempt to repair the motor or to further isolate the problem in the motor AT...

Page 21: ... If the noise persists the gearbox is damaged and must be replaced Spindle Motor Transmission sec tion Ø With the drive belt disconnected run the machine at 1000 RPM in high gear Command a change of direction and listen for a banging noise in the gearbox as the machine slows to zero RPM and speeds back up to 1000 RPM in reverse If the noise occurs the motor has failed and the gearbox must be repla...

Page 22: ...oolant to dump into the spindle head l Ensure the coolant pump relief valve has not been tampered with yellow paint band is intact Check the coolant pump pressure should be 140 psi with a standard tool holder in spindle If pump pressure is above 140 psi reset the pump relief valve in accordance with the Setting TSC Pump Relief Valve section Excessive coolant flow out of drain line Pulsating flow t...

Page 23: ... and needs frequent replacement l Check the filtration system and that the coolant is not contaminated l Check pre charge pressure refer to the TSC Pressure Regulator Adjustment section Heavy wear will occur if this pressure is too high 6 4 PRE CHARGE FAILURE Alarm 198 Precharge Failure NOTE This alarm can only applies to the TSC system l Check for broken or disconnected pre charge air line and re...

Page 24: ... off and the spindle motor is stopped Caused by EMERGENCY 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 resta...

Page 25: ... Fault For Vertical Mills only Gearbox did not shift into high gear During a change to high gear the spindle is rotated slowly while air pressure is used to move the gears but the high gear sensor was not detected in time Parameters 67 70 and 75 can adjust the time out times Check the air pressure the solenoids circuit breaker CB4 and the spindle drive 118 Spindle Low Gear Fault For Vertical Mills...

Page 26: ...ton will correct this but be sure that the pocket facing the spindle after wards does not contain a tool 128 Tool In Turret Pocket opposite spindle has tool in it Future option not yet implemented 129 M Fin Fault M Fin was active at power on Check the wiring to your M code interfaces This test is only performed at power on 130 Tool Unclamped Tool release piston is energized at power up This is a p...

Page 27: ...Y Limit Switch same as 145 147 Z Limit Switch same as 145 148 A Limit Switch Normally disabled for rotary axis 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 150 Z and Tool Tool changer not at home and Z is not either at machine home or above If RESET...

Page 28: ...8 volts 161 X axis Over Current Current in X servo motor beyond limit Possibly caused by a stalled or or Drive Fault 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 162 Y axis Over Current same as 161 or Drive Fault 163 Z axis Over Current same as 16...

Page 29: ...n any of the servo motors the tool change motors the fans or the oil pump 176 Over heat Shutdown An overheat condition persisted for 4 5 minutes and caused an automatic shutdown 177 Over voltage Shutdown An overvoltage condition persisted for 4 5 minutes and caused an automatic shutdown 178 Divide by Zero Software Error Call your dealer 179 Low Pressure Spindle coolant oil is low or low pressure c...

Page 30: ...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 Software Error Call your dealer 207 Queue Advance Error Software Error Call your dealer 208 Queue Allocation Error Software Error Call your dealer 20...

Page 31: ...e as above 225 Z Transition Fault Same as above 226 A Transition Fault Same as above 227 B Transition Fault Same as above 228 C Transition Fault Same as above 231 Jog Handle Transition Same as 223 Fault 232 Spindle Transition Fault Same as above 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 d...

Page 32: ... compensation tables have no CRC when loading from floppy or RS 232 264 Rotary CRC Missing Rotary table parameters have no CRC when loading from floppy or RS 232 302 Invalid R In G02 or G03 Check your geometry with the HELP page R must be less than or equal to half the distance from start to end within an accuracy of 0 0010 inches 303 Invalid X Y or Z In Check your geometry with the HELP page G02 ...

Page 33: ...nctions 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 over 1000 0 or over 9999 325 Queue Full Control problem call your dealer 326 G04 Without P Code Put a Pn n for seconds or a Pn for milliseconds 327 No Loop For M L code not ...

Page 34: ...2 or G03 342 Cutter Comp Path Geometry not possible Check your geometry with the HELP page 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 345 Diff Step Ratio Parameters 5 and 19 must be same value On G17 Plane 346 Diff Step Ratio Parameters 5 and 33 must be sa...

Page 35: ...359 Invalid I J or K In G12 Check your geometry with the HELP page or G13 360 Tool Changer Disabled Check Parameter 57 Not a normal condition for VF Series CNC Mill 361 Gear Change Disabled Check Parameter 57 Not a normal condition for VF Series CNC Mill 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 Lo...

Page 36: ...der to store the measured tool diameter 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 386 Invalid Address Format An address A Z was used improperly 387 Cutter Comp Not If block bu...

Page 37: ...a User was loading settings or parameters and something was wrong with the data 411 RS 232 Empty Program Check your program Between and there was no program found 412 RS 232 Unexpected Check Your Program An ASCII EOF code was found in the input data End of Input before program receive was complete This is a decimal code 26 413 RS 232 Insufficient Program received doesn t fit Check the space availa...

Page 38: ...possibly delete some programs 435 Floppy Abort Could not read disk 436 Floppy File Not Found Could not find floppy file 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 va...

Page 39: ...h 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 ...

Page 40: ... 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 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 s...

Page 41: ...1 15 96 96 8100 HAAS AUTOMATION INC 41 MECHANICAL SERVICE S E R V I C E M A N U A L VF SERIES MECHANICAL SERVICE ...

Page 42: ...ace with a piece of cardboard 4 Loosen the four SHCS that attach top cover to side covers and remove 5 Loosen the six SHCS that attach rear cover to side covers and remove 6 Loosen the eight SHCS that attach front cover to side covers then carefully remove front cover from the bottom until you can disconnect the tool release cable quick disconnect 7 Loosen the seven SHCS that attach each side cove...

Page 43: ...rom the top side with seven SHCS Jog Z axis as necessary to make access to screws easier CAUTION Be careful not to run the head covers into the enclosure 3 Reconnect tool release cable if equipped then replace front cover from the bottom and attach with eight SHCS 4 Replace rear cover and attach to side covers with six SHCS 5 Replace top cover and attach to side covers with four SHCS ...

Page 44: ...move cover panels from the headstock area in accordance with Head Covers Removal and Installation 2 Remove the four 3 8 16 x 1 SHCS holding the tool release piston assembly to the head casting 3 Disconnect the air line at the lube air panel 4 Disconnect the clamp unclamp cables quick disconnect and the assembly s solenoid wiring located on the sole noid bracket 5 Remove the tool release air hose a...

Page 45: ...1 15 96 96 8100 HAAS AUTOMATION INC 45 MECHANICAL SERVICE S E R V I C E M A N U A L VF SERIES Fig 2 2 Tool release piston with solenoid valve Fig 2 3 Mounting location for tool release piston assembly ...

Page 46: ... air hoses at the applicable fittings on the tool release piston assembly 5 Reconnect the clamp unclamp cables to the sides of the solenoid bracket 6 Continue with the reassembly and adjustments described later in this manual 2 3 SETTING PRE CHARGE 1 Remove the cover panels in accordance with Head Covers Removal and Installation It will not be necessary to remove the rear or right side panels for ...

Page 47: ...e drawbar 5 Turn the air pressure regulator turn in Execute a tool change and listen for the noise described previously If it is heard repeat this step until no noise is heard There should be no noise with or without a tool in the spindle CAUTION Only increase the pressure to the point where tool changes become obviously quiet Any further pressure increases are not beneficial Excessive pressure to...

Page 48: ...moval and Installation Fig 3 1 Spindle head casting disconnect points 2 Remove tool release piston assembly in accordance with Tool Release Piston Assembly Removal 3 For all VMC s except VF 0 remove the six SHCS holding the transmission to the head casting and pull the transmis sion forward enough to max to allow the drive belt to be pulled upward over the spindle pulley 4 For the VF 0 remove the ...

Page 49: ...e replacement belt s under the sump tank and onto the pulley NOTE DO NOT bend or kink the belt in any way damage to the fibers in the belt may result and the belt will fail soon after installation 2 Ensuring the belt is properly seated push the transmission back tightening the belt Pull belt forward from rear of head casting Pull belt over spindle pulley 3 Tighten the drive belt in accordance with...

Page 50: ...ng the transmission to the spindle head casting 6 Place the pry bar between the transmission and the bolt in the spindle head and force the transmission back until the belt tension is set The belt tension should be set moderately tight If it is set too tight the belt will whine when the assembly is at speed and if it is set too loose if will vibrate during accelerations and decelerations 7 Tighten...

Page 51: ...e 2 Remove cover panels from head stock area as described in Head Covers Removal section 3 Remove the tool release piston assembly in accordance with appropriate section 4 Remove the spindle drive belt from the spindle pulley as shown in previous section It is not possible to completely remove the belt at this time 5 First disconnect the oil line from the fitting at the oil injection cover then re...

Page 52: ... in the negative direction until the spindle rests on the block then remove the screws that were previously loosened step 7 10 Jog Z axis in the positive direction until spindle is half way out of the head casting 11 Grasp spindle with one hand and continue to jog in Z in the positive direction until it is completely free of the casting 4 2 SPINDLE CARTRIDGE INSTALLATION Fig 4 2 Spindle cartridge ...

Page 53: ...e direction until threaded portion of spindle is inside of head casting At this point align spindle to spindle bore While performing this operation you must make sure the spindle cartridge is straight to the spindle bore Fig 4 4 Spindle cartridge alignment 4 If the spindle moves to one side use a rubber mallet and or jog in the X or Y directions to straighten it The spindle must go in easy If it d...

Page 54: ...shown in Head Covers Removal 3 Remove the tool release piston in accordance with appropriate section 4 Remove the snap ring from the top of the spindle shaft 5 Reinstall the tool release piston 6 Remove the tool holder from the spindle 7 Remove the spindle as described earlier in this section 8 Remove the drawbar and distance tube from the spindle assembly INSTALLATION 9 Thoroughly coat the replac...

Page 55: ...st be followed or damage to the ATC will result 19 Refer to Spindle Orientation and set the spindle orientation 20 Reinstall the head covers 21 Test run the machine and perform the necessary ATC adjustments in the Automatic Tool Changer section 4 4 SPINDLE SWEEP ADJUSTMENT NOTE The machine must be properly leveled for the spindle sweep adjustment to be accurate 1 To check spindle sweep place a 000...

Page 56: ...e spindle if necessary to correct the spindle sweep to specifications 4 Recheck sweep It must be within 0005 in both X Z and Y Z planes as stated in the inspection report supplied with the VMC 5 Replace the Tool Release Piston Assembly in accordance with the Tool Release Piston Assembly Installation and Setting Pre Charge sections ...

Page 57: ...l 2 Place a sheet of paper under the spindle for table protection then place a machined block of aluminum approxi mately 2 x 4 x 4 on the paper Fig 5 1 Placement of aluminum block under spindle 3 Power on the VMC 4 Insert a tool holder WITHOUT ANY TYPE OF CUTTER into the spindle taper 5 Go to the HANDLE JOG mode Choose Z axis and set jog increments to 01 6 Jog Z axis in the negative direction unti...

Page 58: ... at 110 If block does move at 100 jog Z axis in the negative direction one increment at a time Push tool release button and check for movement between increments until block is tight The increments jogged in the Z negative direction are the amount of shim washers that must be added to the tool release bolt Refer to Shim Washers section 4 If block is tight at 110 move Z axis in the positive directi...

Page 59: ...o A 1 means that particular switch is being tripped A 0 means it is not being tripped 2 With the tool holder resting on the block and set at zero Setting Drawbar Height section jog Z axis in the positive direction 06 3 Press the tool release button and hold it DB OPN should change from a 0 to a 1 If it does not slightly loosen the two 20 x SHCS holding the unclamp switch bracket switch on right to...

Page 60: ...release piston down so the shim is pressed against the drawbar This can be done in one of the two following ways Ø Using the pipe as a lever push down on the piston until it contacts the draw bar and the shim is held in place For the VF 0 wedge a large flat tip screwdriver under the cooling fins of the motor and push the piston down Ø If machine is equipped with the macros option set macro variabl...

Page 61: ...ck the switch several times This is done by by moving the piston up and down to ensure that the Tool Unclmp status appears when the piston makes contact with the shim and drawbar and does not appear DB OPN 0 DB CLS 1 when it is in the retracted position Fig 5 5 Push piston down to hold shim in place ...

Page 62: ...move two of these bolts and insert them into the two threaded holes on the ring Evenly tighten these two bolts until the taper lock is broken 4 Remove the two 1 4 20 bolts and place them into their original holes Tighten them finger tight then 1 2 of a turn more Ensure that the orientation ring is snug but not tight 5 Set up a magnetic base with a 0 0005 indicator on the table Zero the indicator o...

Page 63: ...ry difficult to rotate STOP and return to Step 5 9 Disconnect the main air line to the machine 10 Manually turn the orientation ring and push the shot pin until it drops into the orient ring detent 11 Tighten the orient screws evenly to 15 ft lbs Verify that spindle alignment has not changed NOTE It is vital that the orient screws be tightened evenly If not the top of the orientation ring will run...

Page 64: ...to bottom right edge B of tool holder Any difference between these edges should be equally divided For example if a difference of 002 from left side to right side edge adjust indicator dial so that indicator reads 001 when it is on either edge This gives you the tool offset reference Fig 7 1 Checking tool offset reference 3 Carefully so as not to disturb relative position move the indicator to one...

Page 65: ...egative add the number to the number that you calculated to Parameter 64 If the number is positive subtract it from Parameter 64 8 To insert the calculated new number place the cursor at Parameter 64 type in new number and push write key ZERO RET Z axis to initialize the new Parameter 64 9 Recheck the offset with the indicator Steps 1 5 10 Insert tool holder in spindle in spindle taper and initiat...

Page 66: ...k it out 5 Disconnect the air supply from the back panel of the machine 6 Disconnect all of the electrical and pneumatic lines from the solenoid bracket on top of the spindle motor assembly Mark any connections that have not been previously labeled for reassembly 7 Remove the two SHCS holding the cable carrier to the solenoid bracket and position the cable carrier so as to not interfere with remov...

Page 67: ...te section and set the spindle orientation 5 Check for proper orientation of the machine and be aware of any unusual noises or vibration that may occur because of incorrect belt tension 6 Reattach the cable carrier to the solenoid bracket and reconnect all electrical and fluid lines Replace any leaking or damaged lines at this time if necessary NOTE Ensure the orient ring has an adequate layer of ...

Page 68: ...e to the through hole and the side surface of the pulley wheel 2 Wipe a thin coat of oil on the entire cable 3 Lubricate all clevis pins with a thin layer of grease 4 Oil all bearings on the winch and apply grease to the gear teeth B Place the pulley wheel inside the cable guide and place this subassembly into the end of the boom Ensure the clevis pin through hole is toward the top of the boom and...

Page 69: ...sp carriage bolt and hex nut The cable must be underwound on the winch drum 2 FOR RIGHT HAND OPERATION Pass the cable between the frame rod and the countershaft of the winch over the winch drum and through the hole in the drum flange Form a loop of cable and securely anchor it in place using the tie down clasp carriage bolt and hex nut The cable must be overwound on the winch drum F Ensure all hex...

Page 70: ...bracket from the old transmission so they can be installed later on the new transmission 4 Remove the tool release piston assembly Tool Release Piston section 5 Remove the six SHCS holding the transmission to the head casting Slide the transmission forward enough to release the drive belt from the transmission and spindle pulleys 6 Press the POWER OFF button on the control panel and turn the main ...

Page 71: ...back to the Z axis motor to keep it in place 9 Remove the protective cardboard from the mill table and install the support base assembly on the table using the four SHCS four flat washers and the four T nuts CAUTION Ensure the protective rubber pads on the bottom of the mounting base are in place and in good condition or damage to the mill table may result Fig 8 7 Support base mast support assembl...

Page 72: ... mast 11 Place the hoist directly over the transmission and attach the hook to the cradle s eye bolt Fig 8 9 Fully assembled hoist in position 12 Raise the transmission ensuring the hoist is being lifted in the locking position clearing the enclosures Swing the boom toward the front of the machine and lower onto the wood blocks ...

Page 73: ...e Spindle Coolant option reinstall the pressure regulator check valve assembly and bracket Install two cable ties on the replacement transmission as follows Ø Place one cable tie around the limit switch cable Ø Place the second cable tie through the first one forming a loop Ø Tighten the first cable tie NOTE The loop of the second cable tie must allow the drain line to slip through 2 Place cradle ...

Page 74: ...tely 8 Reattach the cable carrier to the solenoid bracket and reconnect all electrical and fluid lines Replace any leaking lines at this time if necessary NOTE The hoist must be disassembled before removing from the mill table Break down the hoist by removing the boom assembly then the mast It will not be necessary to completely break down the hoist after the first assembly NOTE On shot pin assemb...

Page 75: ...isconnect all wiring from the motor INSTALLATION 1 Slide motor into motor housing inserting the end of the lead screw in the motor coupling Fig 9 2 Motor coupling components 2 Reinstall and tighten down the four SHCS that hold the motor to the housing 3 Visually inspect the flex plates to ensure they are parallel to the coupling halves and the slits in the coupling and clamp ring are in alignment ...

Page 76: ...the base Pull the way cover forward and off of the base 4 If the bearings are to be serviced move the table to the rear of its travel and remove the SHCS holding the front way covers to the saddle Slide the way cover to the forward position Fig 9 3 Y axis motor and components REMOVING OILER AND AIR REGULATOR PANEL 5 Turn the machine off and disconnect the compressed air 6 Using a 3 8 open end hex ...

Page 77: ...move the motor from the housing Fig 9 4 Lubricator air regulator panel INSTALLATION 1 Slide motor into motor housing inserting the end of the lead screw in the motor coupling 2 Replace and tighten down the four SHCS that hold the motor to the housing 3 Visually inspect the flex plates to ensure they are parallel to the coupling halves and the slits in the coupling and clamp ring are in alignment T...

Page 78: ...ULIC CYLINDER WITH SHAFT STOP BLOCK BEFORE SERVICING ANY Z AXIS COMPONENTS 1 Turn the machine power ON Zero return ZERO RET all axes and put the machine in HANDLE JOG mode 2 Loosen the six SHCS that attach the rear cover to the side covers and remove from the spindle head NOTE If machine is equipped with a hydraulic counterbalance remove entire spindle head cover for VF 0 OE 1 2 VCE 500 550 700 75...

Page 79: ...1 15 96 96 8100 HAAS AUTOMATION INC 79 MECHANICAL SERVICE S E R V I C E M A N U A L VF SERIES 6 Disconnect the electrical power 7 On the motor housing loosen the four BHCS and remove the cover plate ...

Page 80: ...96 8100 1 15 96 80 MECHANICAL SERVICE HAAS AUTOMATION INC S E R V I C E M A N U A L VF SERIES Fig 9 5 Z axis motor and components ...

Page 81: ... four 5 16 18 x 1 SHCS that hold the motor to the housing 3 Visually inspect the flex plates to ensure that they are parallel to the coupling halves and that the slits in the coupling and clamp ring are in alignment See Fig 10 2 Tighten the 10 32 x SHCS on the motor coupling at the lead screw Place a drop of blue Loctite on the screw before inserting 4 Replace the cover plate and fasten with the f...

Page 82: ...etely remove the motor Do not disconnect the electrical compo nents 2 Completely loosen the 10 32 x SHCS on the two coupling rings and remove the coupling 3 For installation Slide the new coupling onto the motor shaft until the coupling half is flush to the end of the shaft NOTE Make sure that the collar split and coupling half split do not line up Otherwise the coupling will not be locked tightly...

Page 83: ... older bearing sleeves TOOLS REQUIRED SPANNER WRENCH 2 x 4 WOOD BLOCK 21 23 L PRE LOAD FIXTURE BLUE LOCTITE 10 1 X AXIS LEAD SCREW REMOVAL 1 Turn the VMC ON ZERO RETURN all axes and put the machine in HANDLE JOG mode 2 Remove the side enclosures 3 Loosen the SHCS and remove the chip tray from the mill table 4 Move the table to the far right position Loosen the SHCS and remove the left way cover 5 ...

Page 84: ...or housing Push on the mill table or the opposite end of the lead screw to loosen CAUTION DO NOT PRY THE BEARING SLEEVE AWAY FROM THE HOUSING DAMAGE TO THE SLEEVE BEARING OR LEAD SCREW WILL RESULT 12 Loosen the six SHCS and remove the lead screw from the nut housing by pushing on the lead screw at the motor end INSTALLATION 1 Center the mill table on the saddle 2 Ensure all mating surfaces on the ...

Page 85: ...w at the end opposite the motor housing Screw on two or three turns but do not tighten down 7 Move mill table as far right as possible leaving room to insert two of the six 20 x 1 or 20 x SHCS one on either side attaching the ball nut to the nut housing Place a drop of blue Loctite on each of the SHCS before inserting Tighten down completely CAUTION DO NOT RUN MILL TABLE PADS PAST THE END OF THE L...

Page 86: ...he clamp nut on the motor housing end of the lead screw to 15 foot pounds Ø Tighten the SHCS on the clamp nut Ø Tighten the clamp nut on the support bearing end of the lead screw until it contacts the bearing then tighten further approximately 1 8 of a turn Ø Tighten the SHCS on the clamp nut 13 Reinstall the motor 14 Reinstall the way covers and chip tray 15 Check for backlash in the lead screw A...

Page 87: ...he opposite end of the lead screw to loosen CAUTION DO NOT PRY THE BEARING SLEEVE AWAY FROM THE HOUSING DAMAGE TO THE SLEEVE BEARING OR LEAD SCREW WILL RESULT 7 Disconnect the oil line at the ball nut 8 Loosen and remove the six SHCS attaching the ball nut to the nut housing 9 Hand turn the lead screw toward the rear of the machine until the front end of the lead screw clears the bearing by approx...

Page 88: ...o align the bearings in the sleeve to facilitate mounting on the lead screw 5 Screw the clamp nut on the motor end of the lead screw two or three turns Do not tighten 6 Pull the lead screw through the lead screw support bearing and loosely install the clamp nut as on the opposite end NOTE DO NOT SKIP STEPS 7 10 THESE STEPS ENSURE THE LEAD SCREW IS INSTALLED AND RUNS PARALLEL AND FLAT TO THE LINEAR...

Page 89: ...E DURING LEAD SCREW SERVICE 1 Remove the axis motor in accordance with Z Axis Motor Removal making sure to follow all warnings included in that procedure 2 Remove the bearing sleeve in accordance with Z Axis Bearing Sleeve Removal 3 Hand turn the lead screw to move the screw up until the bottom end clears the support bearing by approximately six inches 6 4 Disconnect the oil line at the ball nut 5...

Page 90: ...SERVICE HAAS AUTOMATION INC S E R V I C E M A N U A L VF SERIES Fig 10 7 Z axis lead screw and components INSTALLATION 1 Ensure all mating surfaces on the bearing sleeve motor housing nut housing and ball nut are free of dirt burrs ...

Page 91: ...until it comes into contact with the nut housing mounting surface If necessary turn the leadscrew to correctly position lube fitting of the ball nut 6 Install and tighten down the two outer 20 x 1 or SHCS attaching the ball nut to the nut housing Place a drop of blue Loctite on each of the SHCS before inserting Tighten down completely 7 Loosen but do not remove the six 20 x 1 SHCS attaching the be...

Page 92: ...Ø Tighten the SHCS on the clamp nut Ø Tighten the clamp nut on the support bearing end of the lead screw until it contacts the bearing then tighten further approximately 1 8 of a turn Ø Tighten the SHCS on the clamp nut 14 Reinstall cylinder shaft stop by hand turning the lead screw 15 Reinstall the axis motor in accordance with Z Axis Motor Installation 16 Check for backlash in the Z axis lead sc...

Page 93: ...g 5 Loosen the six 20 x 1 SHCS and remove the bearing sleeve from the motor housing Push on the mill table or the opposite end of the lead screw to loosen CAUTION DO NOT PRY THE BEARING SLEEVE AWAY FROM THE HOUSING DAMAGE TO THE SLEEVE BEARING OR LEAD SCREW WILL RESULT INSTALLATION 1 Ensure all mating surfaces on the bearing sleeve motor housing nut housing and ball nut are free of dirt burrs grea...

Page 94: ...runs parallel and flat to the linear guides and the saddle NOTE For the angular contact design bearing no pre load is necessary Do the following Ø Tighten the clamp nut on the motor housing to 15 foot pounds Ø Tighten the SHCS on the clamp nut Ø Tighten the clamp nut on the support bearing end of the lead screw until it contacts the bearing then tighten further approximately 1 8 of a turn Ø Tighte...

Page 95: ...contaminants CAUTION MATING SURFACES MUST BE CLEAN OR MISALIGNMENT MAY OCCUR SERIOUSLY AFFECTING THE PROPER OPERATION OF THE MACHINE 2 Slide the bearing sleeve into the motor housing and start all six 20 x 1 SHCS into the motor housing Place a drop of blue Loctite on each of the SHCS before inserting 3 Move the table to the rear of its travel 4 Tighten the six 20 x 1 SHCS that attach the bearing s...

Page 96: ...cover to the bottom position 4 Remove the hard stop from the bearing housing on the lead screw 5 Loosen the 10 32 x SHCS and remove the clamp nut from the bearing support end of the lead screw 6 Raise the spindle head until the bottom edge is approximately sixteen inches 16 above the mill table 7 Install cylinder shaft stop PN 99 7562 HANDLE JOG Z axis up until shaft stop block axis 8 Place the wo...

Page 97: ...HINE 2 Slide the bearing sleeve into the motor housing and start all six 20 x 1 SHCS into the motor housing Place a drop of blue Loctite on each of the SHCS before inserting 3 Tighten the six 20 x 1 SHCS that attach the bearing sleeve to the motor housing 4 Loosely install the clamp nut on the lead screw at the motor housing end 5 Reinstall the hard stop on the bearing housing end of the lead scre...

Page 98: ...g any further 6 Remove any damaged roller bolts from the carriage casting Replace with new bolts 7 With a lifting device carefully lift the ATC assembly up and onto the holding plate NOTE Ensure the cam follower on the slip clutch engages the slot on the carriage casting 8 With the ATC assembly securely supported install the lower roller bolts and adjust in accordance with Roller Bolt Replacement ...

Page 99: ...dog and alignment key do not line up loosen the four HHB that hold the ATC holding arm to the column Fig 12 1 Underside showing centering measurements 4 Move the entire tool changer until the tool alignment key lines up with the spindle dog Tighten the four HHB NOTE Parameter 64 must be checked and adjusted if necessary when the ATC is aligned 5 Make at least 50 tool changes after the alignment is...

Page 100: ... must be replaced Damage to the ATC will result if not replaced 1 With no tool holders in the spindle or in the ATC command ATC FWD until the extractor fork needing replacement is facing the spindle 2 Command ATC FWD again but press the EMERGENCY STOP after the spindle head lifts up off the carousel NOTE At this point the shuttle should be in and the spindle should be about 4 above the carousel 3 ...

Page 101: ...m the edge of the extractor fork to the edge of the pocket in the carousel is the same on both sides in accordance with the following section 6 Test run the ATC to ensure proper operation 12 6 SLIDING COVER REPLACEMENT NOTE If any of the sliding covers on the ATC do not slide freely or are bent in a crash they must bereplaced 1 Loosen the four screws that attach the sliding panel cover to the caro...

Page 102: ...ip clutch assembly to the shuttle motor see Fig 12 3 6 Using a small two jaw puller pull the slip clutch assembly see Fig 12 3 off the shuttle motor shaft 7 Remove the SHCS attaching the cover to the holding arm casting on the tool changer 8 Remove the cover from the wire channel inside the holding arm casting and unplug the shuttle motor from the wiring harness Fig 12 4 Wiring harness for shuttle...

Page 103: ...tuating arm on the slip clutch assembly contacts the shuttle IN and OUT limit switches 7 Ensure the hub of the slip clutch assembly does not interfere with the face plate on the shuttle motor 8 Start the VMC and go through a performance check consisting of at least 30 tool changes assuring correct opera tion 12 9 TURRET MOTOR REMOVAL 1 Power on the VMC and put it in MDI mode 2 Zero Return all axes...

Page 104: ...carriage casting NOTE The gear motor should never be disassembled and is not field serviceable All gear motors should be returned to Haas for evaluation and rebuilding INSTALLATION 1 Grease the locking element and drive pin on the Geneva driver Also grease the teeth on the Geneva star on the ATC 2 Rotate the Geneva driver until the cam depresses the limit switch on the turret motor assembly 3 Plac...

Page 105: ...1 15 96 96 8100 HAAS AUTOMATION INC 105 MECHANICAL SERVICE S E R V I C E M A N U A L VF SERIES acting as a shim ...

Page 106: ...M A N U A L VF SERIES Fig 12 7 Required spacing for Geneva driver 4 Attach the turret motor assembly to the carriage casting with the four SHCS 5 Reconnect the power and limit switch lines to the turret motor 6 Power on the VMC and ZERO RETURN all axes ZERO RET AUTO ALL AXES ...

Page 107: ... the center of the carousel 5 Loosen the nut inside the carriage casting that attaches the ATC carousel assembly to the casting There is a socket head in the top of the shaft to hold it stationary while loosening the nut 6 Place the cardboard over the mill table and carefully lower the carousel until it rests on the table 7 Remove the six SHCS that attach the Geneva star to the bearing housing on ...

Page 108: ...hers where the shutter pivots The position of the ATC may need to be readjusted after installation 13 GRID OFFSET CALCULATION 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 released If DISTANCE TO GO is less than 1 8 0295 or greater than 7 8 2065 of a revo...

Page 109: ...ts at the top and bottom of the door 4 Slide the door to the fully closed position Loosen the two upper roller hex nuts and disengage the upper swivel roller brackets from the top roller guide 5 Lift the door from the bottom roller guide and remove INSTALLATION 6 Ensure that the lower roller hex fasteners are wrench tight and the upper roller fasteners are finger tight in the middle of their adjus...

Page 110: ...at the vertical gap between them is uniform If it is not Ø Determine which door must be adjusted Ø Loosen the door s outer lower roller attachment and pivot the door on the inner lower roller wheel Ø When the door is in the desired position the vertical gap is uniform tighten the lower outer roller fastener Fig 14 2 View of vertical gap between front doors 11 Check the gap between the door and the...

Page 111: ...racket to the top of the door NOTE It is possible to access this bracket from the side window Ø Move the bracket in its slot to the proper position and tighten the SHCS 14 2 WINDOW REPLACEMENT REMOVAL 1 Turn the machine power off 2 Move the door to the fully closed position so the window is accessible Use a trim installation tool to pull the locking tab out of the inside of the window seal the tab...

Page 112: ... to 14 5 above table Insert wood block and lower head casting onto it EMER GENCY STOP the machine Head should rest securely on table block Power OFF VMC NOTE DO NOT LOWER SPINDLE ONTO BLOCK 2 Disconnect the two pin end of the pressure sensor cable s to the pressure sensor s if tank is equipped with sensor 3 Remove cap to Schrader filler valve attach discharging hose and release any remaining press...

Page 113: ...the cable 11 Rout the section of cable in the control cabinet inside the wire channels 12 Connect the charging system to the Schrader filling valve Pressurize system with dry nitrogen gas welding grade acceptable NOTE Ø Do not use compressed air oxygen or flammable gas Ø Refer to the table below and verify pressure according to machine and spindle head position Ø Verify cylinder is seated in count...

Page 114: ... three SHCS holding the Z axis way cover to the spindle head 3 Remove the cotter pin and lock nuts from the threaded end of the cylinder rod 4 Loosen the two SHCS holding the cylinder clamp to the column and the bracket screw and remove both 5 Remove the hydraulic cylinder from the top of the column NOTE Do not disassemble unit Keep the hose attached to the cylinder 6 Return complete assembly to H...

Page 115: ...replace valve cap 12 Install cylinder clamp with two SHCS and bracket at top of column with bracket screw Fig 15 2 Hydraulic Cylinder Rod Installation 13 Zero return ZERO RET machine HANDLE JOG Z axis in 0 1 increments Verify full Z travel 14 Cycle Z axis using the following program for five minutes and check for oil leaking at top of cylinder and cylinder rod G28 G54 Z 14 M99 50 Rapid 15 If Z axi...

Page 116: ...stallation 3 Disconnect the air line at the lube air panel 4 Disconnect the clamp unclamp cables quick disconnect and the assembly s solenoid wiring located on the sole noid bracket 5 Remove the tool release air hose at the fitting as shown in Figure 2 2 the precharge air hose and the coolant hose 6 Remove the four SHCS holding the tool release piston assembly to the head casting 7 Lift up the ent...

Page 117: ...m the following l Place a tool holder in the spindle l Remove the Tool Release Piston l Run the spindle at 1000 2000 RPM NOTE New spindle must be run at 300 RPM for two hours before running at 1000 2000 RPM Polish the sides and top surface of the drawbar using 600 grit sandpaper The sides of the drawbar must be mirror smooth for the first 1 8 Round off the corner of the chamfer so the seal can rid...

Page 118: ...96 8100 1 15 96 118 MECHANICAL SERVICE HAAS AUTOMATION INC S E R V I C E M A N U A L VF SERIES ...

Page 119: ...1 15 96 96 8100 HAAS AUTOMATION INC 119 MECHANICAL SERVICE S E R V I C E M A N U A L VF SERIES ...

Page 120: ...1 15 96 96 8100 117 TABLE OF CONTENTS ELECTRICAL SERVICE VF SERIES S E R V I C E M A N U A L HAAS AUTOMATION INC ELECTRICAL SERVICE ...

Page 121: ...ead covers Mechanical Service 3 Remove air supply from machine 4 Disconnect all air lines going to and from the air solenoid assembly on the bottom rear of the solenoid bracket Do not remove the fittings remove the lines from the fittings 5 Disconnect the two leads to the low air pressure sensor 6 Unplug the wiring leading to the plug marked on the solenoid bracket as 880 FROM I O PCB TO SOLENOID ...

Page 122: ...he plugs on the solenoid bracket See step 6 12 Reconnect air supply to the machine 1 2 TOOL RELEASE PISTON ASSEMBLY AIR SOLENOID 1 Turn machine power on and raise spindle head to uppermost position Turn power off 2 Remove spindle head covers Mechanical Service 3 Remove air supply from machine 4 Remove the tool release piston assembly Mechanical Service 5 Unscrew the air solenoid assembly from the ...

Page 123: ...the tool release piston assembly Mechanical Service 9 Ensure all air lines are reconnected to their proper fitting 1 3 SPINDLE LUBE AIR SOLENOID 1 Turn the machine power off and remove the air supply from the machine Fig 1 3 Front side of lube air panel 2 Disconnect the air lines from the spindle lube air solenoid assembly 3 Unplug the electrical leads at the quick disconnect You will have to slid...

Page 124: ...rom the T fitting Fig 1 5 Top view of spindle lube air solenoid assembly 5 Replace the assembly ensuring it is approximately horizontal to the floor and tighten fittings securely 6 Reconnect all air lines 7 Reconnect wiring leads at the quick disconnect in the wiring channel Slide cover back into place 8 Restore air supply to the machine ...

Page 125: ...er 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...

Page 126: ... volts 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 t...

Page 127: ...n 2 above There are four positions for the input power to this transformer The input voltage range for each terminal block is as follows Fig 2 3 Transformers with 195 210V left and 452 480V right range 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 c...

Page 128: ...ght of electrical cabinet to the off position Fig 3 1 Unscrew the three screws to open the cabinet door Newer control cabninets may require a key 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 Wait until at least the red CHARGE light on the servo drive assembly goes out before beginning any work ...

Page 129: ...y 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 3 The Operator s Lamp Fuse is located at the lower left of the Power Supply Board An orange light will be on to indicate the blown fuse Fig 3 3 Power supply board fuse locations 4 Using a flat tip screwdriver turn the fuse counterclock...

Page 130: ...Y there are three fuses on the SDIST panel and three individual fuses on each of the SERVO DRIVE boards See Fig 3 4 the F3 fuses are not shown 4 On the SDIST panel use a flat tip screwdriver to turn the fuse s counterclockwise to remove Replace the blown fuse s with ones having the same type and rating FU1 FU2 amp type AGC 250V FU3 5 amp type ABC 250V 5 On each of the SERVO DRIVER boards the fuses...

Page 131: ...rous voltages in the assembly EVEN WHEN POWER IS SHUT OFF MOTIF BOARD 1 Turn machine power off 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 Wait until at least the red CHARGE light on the servo drive assembly goes out ...

Page 132: ... DRIVE LOAD SP TEMP VOLTAGE MON 0 5V MOTIF INPUTS I O OUTPUTS JOG INFO X ENCODER OUTPUT Y ENCODER OUTPUT Z ENCODER OUTPUT A ENCODER OUTPUT HOME SENSORS SP ENCODER OUTPUT P24 P17 P21 P22 Fig 4 1 Motor Interface board VIDEO BOARD AND KEYBOARD 8 Remove the MOTIF board as described in steps 1 5 9 Disconnect all leads to the Video board and Keyboard Ensure all cables are properly labeled for reconnecti...

Page 133: ... Reconnect all leads previously removed to their proper connections refer to Fig 4 2 PROCESSOR BOARD 13 Remove the MOTIF board as described in steps 1 5 and the Video and Keyboard as described in steps 8 9 14 Disconnect all leads to the Processor 68020 board Ensure all cables are properly labeled for reconnecting later The following illustration shows all cable numbers and the locations on the 680...

Page 134: ...e center of the assembly Until this light goes out there are dangerous voltages in the assembly EVEN WHEN POWER IS SHUT OFF 1 Turn machine power off 2 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 Wait until at least the ...

Page 135: ...n some SDIST boards there may be cables attached to the capacitors with a plastic strap This will have to be cut off and the cables moved aside in order to remove the board It will be necessary to replace this strap after the board is replaced 5 After all cables have been disconnected remove the eight screws attaching the board to the cabinet Take care to hold the board in place until all screws h...

Page 136: ...cting later Figure 4 6 shows all cable numbers and the locations on the DRIVER boards X Y Z A NOTE When replacing any DRIVER board it will be necessary to disconnect all leads on all DRIVER boards in order to remove or replace the board 5 Remove the board by first removing the two screws that fasten it to the cabinet Take care to hold the board in place until both screws have been removed 6 Replac...

Page 137: ...820 P13 900 P14 770 P16 770A P40 1050 P38 100 P22 970 P18 950 P19 960 P17 830 P20 890 P15 780 P21 540 P3 550 P4 530 P51 520 P2 510 P1 R41 R86 R45 810A P30 T C STAT LOW COOL SP HD STAT 230VAC FROM CB3 E STOP DOOR M FIN OV V LO AIR OIL LO LUB OVERH SP DR STAT SP DR COMDS SERVO POW SP HD SOLENOID A BRAKE 115VAC FROM CB4 115VAC TO CB4 115V HTX 115V CRT 115V FROM T1 SHUTTLE MOTOR T C MOTOR 160VDC GND F...

Page 138: ...rly labeled for reconnecting later The illustration on the following page shows all cable numbers and the locations on the POWER board 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 boar...

Page 139: ...ACTORS 115VAC OUT 115VAC IN K1 COIL POWER ON OFF AUTO OFF 230VAC T4 190 260VAC INPUT PRI SEC T5 LOW VOLTAGE LOW VOLTAGE SERIAL PORT 1 12V SERIAL PORT 2 12V SOLENOID COOLANT PUMP MAIN TRANSFORMER FROM LVPS P16 TO LVPS P20 Fig 4 7 Power Distribution POWER board LOW VOLTAGE POWER SUPPLY 8 Remove the Power Distribution POWER board as described in steps 1 5 9 Disconnect all leads to the Low Voltage Pow...

Page 140: ...p ladder high enough to allow you to work from the top of the electrical cabinet It will be necessary when replacing the RS 232 DB25 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 Fig 4 8 RS 232 DB...

Page 141: ... 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 ...

Page 142: ...n 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 Parameter 57 can be used to reverse the direction of operation of the handle 1 Turn the machine power off 2 Remove the screws holding the cover panel on the ba...

Page 143: ...rews holding the jog handle encoder to the control panel and remove 6 Replacement is reverse of removal Keep in mind the important notice in step three 5 3 SWITCH REPLACEMENT NOTE This section is applicable for the POWER ON POWER OFF EMERGENCY STOP CYCLE START and FEED HOLD switches 1 Turn the machine power off 2 Remove the four screws holding the cover panel on the back of the control panel Take ...

Page 144: ...e 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 5 Installation is reverse of removal Ensure leads go the correct location 5 5 KEYPAD REPLACEMENT 1 Turn the power off and ...

Page 145: ...BOARD INTERFACE 1 Follow all precautions noted previously before working in the control cabinet See warning at beginning of Section 5 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 Key...

Page 146: ...730 P4 1010 P3 P5 SPEAKER METER START HOLD METER ADJUST 700 P1 TO VIDEO KEYBOARD PCB Fig 5 5 Keyboard Interface 6 SPINDLE ENCODER REPLACEMENT PLEASE READ THIS SECTION IN ITS ENTIRETY BEFORE ATTEMPTING TO REMOVE OR REPLACE ENCODER REMOVAL 1 Turn machine power on Raise or lower spindle head to a position that will allow you to easily work on the encoder must be above the enclosures Turn machine off ...

Page 147: ... some blue Loctite on the threads of the four set screws and screw approximately halfway into the standoffs Screw the hex end of the set screws into the standoffs 6 Screw the standoffs into the four holes located at the rear of the transmission s top plate 7 For the VF 0 place the mounting bracket in place Fasten to the top plate with the four screws and four lock washers 8 Place the 18 tooth pull...

Page 148: ...1 15 96 96 8100 145 TABLE OF CONTENTS ELECTRICAL SERVICE VF SERIES S E R V I C E M A N U A L HAAS AUTOMATION INC ...

Page 149: ...96 8100 1 15 96 146 TECHNICAL REFERENCE SERVICE M A N U A L VF SERIES TECHNICAL REFERENCE SECTION ...

Page 150: ...ximately 07 This is an indication that the pull stud is correctly touching the release mechanism Low air pressure or insufficient volume will reduce the pressure applied to the tool unclamp piston and will slow down tool change time or will not release the tool If the shuttle should become jammed the control will automatically come to an alarm state To correct this push the EMERGENCY STOP button a...

Page 151: ...d away from the spindle This is called the shuttle The motor is geared down to a low RPM and then connected to an arm that rotates through 180o and pushes the shuttle in and out NOTE This motor should never be disassembled 1 3 TURRET ROTATION MOTOR A DC brush motor is used to rotate the tool turret between tool changes This motor is geared down to a low RPM and connected to a Geneva mechanism One ...

Page 152: ...ere are two switches used to sense the position of the tool clamping mechanism They are both normallyclosed and one will activate at the end of travel during unclamping and the other during clamping When both switches are closed it indicates that the draw bar is between positions A tool change operation will wait until the unclamped switch is sensed before the Z axis pulls up from the tool This pr...

Page 153: ...indle motor and above the gear box If the spindle is oriented and locked commanding spindle forward or reverse will release the lock 3 2 SPINDLE ORIENTATION LUBRICATION The spindle orientation mechanism does not require regular lubrication 3 3 SPINDLE ORIENTATION AIR SOLENOID A solenoid controls the air valve supplying pressure to the orientation lock pin The diagnostic display can be used to disp...

Page 154: ...signal pairs A cable test is performed on these signals to ensure the differential pair are always present 4 2 SERVO CHARACTERISTICS BRUSH This machine is not capable of instantly changing speed That is it takes some non zero time to accelerate and decelerate Acceleration and deceleration in this machine have both a constant accel decel mode and an exponential mode Constant acceleration is used at...

Page 155: ...ve assembly until the small red CHARGE light goes out 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 This assembly contains four servo drive cards a Servo Distribution card and a fan 4 4 160 VOLT DC POWER SUPPLY BRUSH The Servo Distribution card contains a DC power supply ...

Page 156: ...er to X drive card 570 P2 Low voltage AC power to Y drive card 580 P3 Low voltage AC power to Z drive card 590 P4 Low voltage AC power to A drive card 600 P5 12V DC from power supply 860A P7 115V AC to fan P8 160V DC supply to tool changer 80 P9 Voltage monitor to A D 980 P10 Regen load resistor 920 P11 Relay 1 contacts from IOPCB 110 P12 Overvoltage status to IOPCB 970 P13 Ground fault detect sig...

Page 157: ...rformance differences these machines differ from brush type machines which have already been dis cussed 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 are also affected by brushle...

Page 158: ... is a PWM based current source The PWM outputs control the current to a three phase brushless motor The PWM frequency is 16 KHz The amplifiers are current limited to 30 amps peak 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...

Page 159: ...ontrolling the tool changer The Input Output Assembly consists of a single printer circuit board called the IOPCB The connectors on the IOPCB are P1 16 pin relay drivers from MOCON 1 to 8 510 P2 16 pin relay drivers from MOCON 9 to 16 520 P3 16 pin relay drivers from MOCON 17 to 24 M21 M24 540 P4 34 pin inputs to MOCON 550 P5 Servo power on relay 1 1 110 P6 230V AC from CB3 930 P7 230V AC to coola...

Page 160: ...Tool changer turret motor output 810 P40 770A A B P43 Ground fault sense signal input 1060 Axis Brake P44 5TH axis brake 319 P45 HTC Shuttle P46 Chip Conveyor 140 P47 Skip input signal 1070 P48 spare 1 P49 spare 2 P50 Spigot Motor 200 P51 16 PIN Relay drivers 17 24 530 P52 spare 1 P53 Spigot Sense 180 P54 Servo Brake 350 P55 Red green lights 280 P56 Thru spindle coolant pump 940A P57 115V spare P5...

Page 161: ...nterrupt power to these solenoids Power is left on the solenoid which is commanded last 6 3 GEAR BOX SENSE SWITCHES On the VF 1 thru VF 6 there are two switches in the gear box used to sense the position of the gears One switch indicates HIGH by opening and the other indicates LOW by opening Between gears both switches are closed indicating a between gear condition The diagnostic display shows the...

Page 162: ...agnostic 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 7 4 EMERGENCY STOP SWITCH The EMERGENCY STOP switch is normally closed If the switch opens o...

Page 163: ... the 68ECO30 processor running at 40 MHz one 128K EPROM between 256K and 8MB of CMOS RAM and betwen 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 LED s Two ports on this board are used to set the point at which an NMI is generated during power down and the point at which RESET is generated ...

Page 164: ...f Switch S2 1 is used to enable FLASH If it is disabled it will not be possible to write to FLASH The processor connectors are J1 Address buss J2 Data buss J4 Serial port 1 for upload download DNC 850 J5 Serial port 2 for auxiliary 5th axis 850A J3 Power connector J6 Battery 8 2 MEMORY RETENTION BATTERY The memory retention battery is initially soldered into the processor PCB This is a 3 3V Lithiu...

Page 165: ...ss P20 Spindle encoder inputs 1000 P21 A to D input for spindle temperature 1020 P22 A to D input for spindle load monitor 730B P24 Home switch inputs X Y Z 990 8 5 MOTOR CONTROLLER MOCON BRUSHLESS NOTE REFER TO PCB AND CABLE LOCATION SECTION FOR BOARD DIAGRAMS The brushless machining centers are equipped with a microprocessor based brushless motor controller board MOCON that replaces the motor in...

Page 166: ...input 690 P30 B encoder input 690B P31 C encoder input 690C P18 Jog encoder input 750 P20 Spindle encoder input 1000 P10 Inputs from I O board 550 P11 I O relays K1 8 510 P12 I O relays K9 16 520 P13 I O relays K17 24 530 P14 I O relays K25 32 540 P15 Low Voltage Power 860 P16 Spindle command output 720 P19 Address bus P24 Axis home switches 990 ...

Page 167: ...t In addition if the line voltage into the control is above 255V this resistor will begin to heat This resistor is overtemp protected at 1000 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 10 2 SERVO DRIVE REGEN RESIS...

Page 168: ...115VAC IN K1 COIL POWER ON OFF AUTO OFF 230VAC T4 190 260VAC INPUT PRI SEC T5 LOW VOLTAGE LOW VOLTAGE SERIAL PORT 1 12V SERIAL PORT 2 12V SOLENOID COOLANT PUMP MAIN TRANSFORMER FROM LVPS P19 TO LVPS P20 Figure 11 1 Power Supply PCB 11 2 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 auxilia...

Page 169: ...s lamp 800A P15 230V AC from contactor K1 for coolant pump 70 P16 Low voltage power from power supply P17 12V DC to IOPCB 860A P18 Not used P19 Connector to op lamp transformer T4 290 P20 115V AC to low voltage supply P21 12V DC to processor PCB P22 12V DC to MOTIF PCB P26 12V DC option connector P27 5 12 Gnd form low volt supply to logic boards 860 P30 12V AC OP Lamp 800 P31 12V 860A For older in...

Page 170: ... 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 11 7 OPERATOR S LAMP TRANSFORMER Transformer T4 supplies low voltage to the operator s lamp The primary is 115V AC and the secondary is 10V AC The primary is protected at amp by F6...

Page 171: ...s other 240V applications Fig 12 1 Polyphase bank transformer 12 1 PRIMARY CONNECTION TO T1 Input power to T1 is supplied through CB1 the 40 amp three phase main circuit breaker Three phase 230 to T1 is connected to the first three terminals of TB10 12 2 VOLTAGE SELECTION TAPS There are four labeled plastic terminal blocks Each block has three connections for wires labeled 74 75 and 76 Follow the ...

Page 172: ...ight FU2 AGC 250V FU3 AGC 250V LAMP AGC 250V lower left FU1 AGC 250V SDIST pcb right center FU2 AGC 250V FU3 AGC 5 250V top center F1 ABC 20 250V SDRIVER pcb s X Y Z A F2 ABC 20 250V F3 ABC 10 250V FU1 ABC 5 250V I O PCB FU2 ABC 5 250V I O PCB FU3 ABC 5 250V I O PCB FU4 ABC 5 250V I O PCB 14 SPARE USER M CODE INTERFACE The M code interface uses outputs M21 24 and one discrete input circuit M codes...

Page 173: ...to M54 will turn on one of the eight relays and M61 to M64 will turn the relays off M51 and M61correspond to M21 etc 15 LUBRICATION PUMP The lubrication pump is powered whenever the spindle is on or any axes are in motion It operates from 115V AC On a cyclic basis it will pump oil to the screws and guides It cycles at least once every 30 minutes and pumps 2 8cc 3 8cc of lubrication 15 1 LOW LUBRIC...

Page 174: ...ith Setting 51 but this setting will return to OFF when the control is turned off 16 3 LIMIT SWITCHES NOTE There are fourteen 14 limit switches located on the VMC and some are difficult to reach Ensure the problem is the switch before beginning removal procedures The following is a list of all switches their general location and a functional description CLAMP UNCLAMP SWITCHES Tool Release Piston A...

Page 175: ...to search for zero in the Z axis is followed by a rapid move from the limit switch position down to the tool change position This makes the Z axis a little different from the other axes The position found with the limit switch is not machine zero but is the position used to pull tools out of the spindle Machine zero for Z is below this by Parameter 64 Be careful during the Z zero search and stay c...

Page 176: ...rd These switches are normally closed so that both will be closed between in and out The diagnostic display will show this status of this input switch A 1 indicates the associated switch is activated or open TRANSMISSION HIGH LOW GEAR POSITION SWITCHES Bottom of Gearbox Assembly 2 On the VF 1 VF 2 VF 3 and VF 4 there are two switches in the gear box used to sense the position of the gears One swit...

Page 177: ...t any time after the machine completes its power up sequence it will either perform a requested function or stop with an alarm Refer to Section 2 5 for a complete list of alarms 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 ...

Page 178: ...d 32 CNVEYR DISCRETE OUTPUTS Name Description Name Description 1 SRV PO Servo Power On 17 SPGCW Spigot clockwise 2 SP FOR Spindle Forward 18 SPGCCW Spigot counter clockwise 3 SP REV Spindle Reverse 19 Spare 4 SP RST Spindle Reset 20 Spare 5 4TH BK 4th Axis Brk Rel 21 PRE CH Pre charge 6 COOLNT Coolant Pump 22 HTC SH Horizontal T C shuttle 7 AUT OF Auto Turn Off 23 5TH BK 5th Axis Brake 8 SP FAN Sp...

Page 179: ... T Self Test Input X OVRH X Motor OverTemp X CABL Broken cable to X encoder Y OVRH Y Motor OverTemp Y CABL Broken cable to Y encoder Z OVRH Z Motor OverTemp Z CABL Broken cable to Z encoder A OVRH A Motor OverTemp A CABL Broken cable to A encoder OVC X X Drive Overcurrent spare OVC Y Y Drive Overcurrent spare OVC Z Z Drive Overcurrent spare OVC A A Drive Overcurrent AD EOC A to D End of Conversion...

Page 180: ...1 15 96 96 8100 177 TABLEOFCONTENTS TECHNICAL REFERENCE SERVICE M A N U A L VF SERIES ...

Page 181: ...e left and right cursor arrows are used to select the function being changed All values are 0 or 1 only The function names are REV ENCODER Used to reverse the direction of encoder data REV POWER Used to reverse direction of power to motor REV PHASING Used to reverse motor phasing DISABLED Used to disable any axis Z CH ONLY With A only indicates that no home switch AIR BRAKE With A only indicates t...

Page 182: ...N Integral gain in servo loop Parameter 5 X RATIO STEPS UNIT The number of steps of the encoder per unit of travel Encoder steps supply four times their line count per revolution Thus a 2000 line en coder and a 6mm pitch screw give 2000 x 4 x 25 4 6 33867 Parameter 6 X MAX TRAVEL STEPS Max negative direction of travel from machine zero in encoder steps Does not apply to A axis Thus a 20 inch trave...

Page 183: ...ee 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 19 Y RATIO STEPS UNIT See Parameter 5 for description Parameter 20 Y MAX TRAVEL STEPS See Parameter 6 for description Parameter 21 Y ACCELERATION See Parameter 7 for description Parameter 22 Y MAX ...

Page 184: ...escription Parameter 33 Z RATIO STEPS UNIT See Parameter 5 for description Parameter 34 Z MAX TRAVEL STEPS See Parameter 6 for description Parameter 35 Z ACCELERATION See Parameter 7 for description Parameter 36 Z MAX SPEED See Parameter 8 for description Parameter 37 Z MAX ERROR See Parameter 9 for description Parameter 38 Z FUSE LEVEL See Parameter 10 for description Parameter 39 Z BACK EMF See ...

Page 185: ...7 for description Parameter 50 A MAX SPEED See Parameter 8 for description Parameter 51 A MAX ERROR See Parameter 9 for description Parameter 52 A FUSE LEVEL See Parameter 10 for description Parameter 53 A BACK EMF See Parameter 11 for description Parameter 54 A STEPS REVOLUTION See Parameter 12 for description Parameter 55 A BACKLASH See Parameter 13 for description Parameter 56 A DEAD ZONE See P...

Page 186: ...les BACKGROUND EDIT mode ENA GRND FLT Enables ground fault detector KEYBD SHIFT Enables use of keyboard with shift functions ENABLE MACRO Enables macro functions SPIN COOLANT Enables spindle low oil pressure detection INVERT SKIP Invert sense of skip to active low closed HANDLE CURSR Enable use of jog handle to move cursor NEG WORK OFS Selects use of work offsets in negative direction ENA CONVERSE...

Page 187: ... Parameter 67 GEAR CHANGE DELAY Maximum delay allowed when changing gears Units are milliseconds After this time an alarm is generated Parameter 68 DRAW BAR MAX DELAY Maximum delay allowed when clamping and unclamping tool Units are milliseconds After this time an alarm is generated Parameter 69 A AIR BRAKE DELAY Delay provided for air to release from brake on A axis prior to moving Units are mill...

Page 188: ...s only to rigid tapping option Parameter 80 MAX SPIN DELAY TIME The maximum delay time control will wait for spindle to get to commanded speed or to get to zero speed Units are milliseconds Parameter 81 M MACRO CALL O9000 M code that will call O9000 Zero causes no call Parameter 82 M MACRO CALL O9001 same as 81 Parameter 83 M MACRO CALL O9002 same as 81 Parameter 84 M MACRO CALL O9003 same as 81 P...

Page 189: ... MAX CURRENT Same definition as Parameter 105 Parameter 109 D D GAIN FOR X Second derivative gain in servo loop Parameter 110 D D GAIN FOR Y Second derivative gain in servo loop Parameter 111 D D GAIN FOR Z Second derivative gain in servo loop Parameter 112 D D GAIN FOR A Second derivative gain in servo loop Parameter 113 X ACC DEC T CONST Exponential acceleration time constant Units are 1 10000 s...

Page 190: ...CC DECEL Accel decel time constant in steps ms ms for spindle motor Parameter 121 X PHASE OFFSET The motor phase offset for X motor This is arbitrary units Parameter 122 Y PHASE OFFSET See Parameter 121 for description Parameter 123 Z PHASE OFFSET See Parameter 121 for description Parameter 124 A PHASE OFFSET See Parameter 121 for description Parameter 125 X GRID OFFSET This parameter shifts the e...

Page 191: ...meter 137 A EXACT STOP DIST These parameters control how close each axis must be to its end point when exact stop is programmed They apply only in G09 and G64 They are in units of encoder steps A value of 34 would give 34 33867 0 001 inch Parameter 138 X FRICTION FACTOR Parameter 139 Y FRICTION FACTOR Parameter 140 Z FRICTION FACTOR Parameter 141 A FRICTION FACTOR These parameters compensate for f...

Page 192: ...ameter 151 B SWITCHES See Parameter 1 for description Parameter 152 B P GAIN See Parameter 2 for description Parameter 153 B D GAIN See Parameter 3 for description Parameter 154 B I GAIN See Parameter 4 for description Parameter 155 B RATIO STEPS UNIT See Parameter 5 for description Parameter 156 B MAX TRAVEL STEPS See Parameter 6 for description Parameter 157 B ACCELERATION See Parameter 7 for de...

Page 193: ...meter 170 B GRID OFFSET See Parameter 125 for description Parameter 171 B EXACT STOP DIST See Parameters 134 for description Parameter 172 B FRICTION FACTOR See Parameter 138 for description Parameter 173 B ACCEL FEED FORWARD Same description as Parameter 145 Parameter 174 SPINDLE B TEMP COEF This parameter controls the amount of correction to the B axis in response to heating of the spindle head ...

Page 194: ...on being changed All values are 0 or 1 only The function names are HORZ T C Enables tool changer for horizontal machining centers HS models only RST STOPS T C Tool changer can be stopped with RESET button M21 28 540 When enabled 1 M21 M28 is installed at cable 540 ENA CONVEYOR Enables chip conveyor if machine is so equipped 50 RPD KBD When 1 the control will support the new style keyboards with th...

Page 195: ...oor is open but will resume when the door is closed For safety it is recommended that the bit be set to 0 DSBL CLNT IN If set to 1 low coolant input will not be used DSC INP PR Discrete pallet rotate part ready inputs enabled if set to 1 RMT TOOLS RLS If set to 1 allows use of remote tool release button on spindle head FLOPPY ENABL If set to 1 enables the optional floppy drive TCR KEYPAD If set to...

Page 196: ...FSET Parameter used to align tool 1 of tool changing carousel precisely Units are encoder steps Parameter 216 CNVYR RELAY DELAY Delay time in 1 50 seconds required on conveyor relays before another action can be commanded Default is 5 Parameter 217 CNVYR IGNORE OC TIM Amount of time in 1 50 seconds before overcurrent is checked after conveyor motor is turned on Default is 50 Parameter 218 CONVYR R...

Page 197: ...ore stopping at front door Parameter 226 RESERVED Parameter 227 FLOPPY DIR NAME This parameter sets the program numbers to store in the floppy directory Parameter 228 QUICKCODE FILE This parameter set the program numbers to store in the Quickcode definition Parameter 229 X LEAD COMP 10E9 This parameter sets the X axis lead screw compensation signed parts per billion Parameter 230 Y LEAD COMP 10E9 ...

Page 198: ...direction scaled by the default axis Parameter 241 U AXIS MAX TRAVEL This parameter sets the U axis maximum travel in the positive direction scaled by the default axis Parameter 242 V AXIS MAX TRAVEL This parameter sets the V axis maximum travel in the positive direction scaled by the default axis Parameter 243 W AXIS MAX TRAVEL This parameter sets the W axis maximum travel in the positive directi...

Page 199: ... a resolution of 0 0001 inch The operator entered values are used to interpolate into a table of 256 entries The spacing between two entries in the table of 256 is defined by Parameter 58 The entered values are limited to 127 encoder steps so the limit in inches is dependent on Parameters 5 19 and 33 Note that the first entry corresponds to machine position zero and subsequent entries are for incr...

Page 200: ...draulic counterbalance pressure according to the machine s specifications MONTHLY 3 Inspect way covers for proper operation and lubricate with light oil if necessary 3 Dump the oil drain bucket 3 Place a dab of grease on the outside edge of the Geneva wheel star and guide rails of the tool changer and run through all tools SIX MONTHS 3 Replace coolant and thoroughly clean the coolant tank 3 Check ...

Page 201: ... panel at the rear of Above the spindle head Side of machine the machine DESCRIPTION Piston pump with 30 minute cycle time Pump is only on when spindle is turning or when axis is moving LUBRICATES Linear guides and ball nuts Transmission only QUANTITY 1 QT Tank 2 QT Tank 40 gallons LUBRICANT Mobil Vactra 2 Mobil DTE 25 Water soluble synthetic ...

Page 202: ...1 15 96 96 8100 HAAS AUTOMATION INC 199 TABLE OF CONTENTS CABLE LOCATIONS S E R V I C E M A N U A L VF SERIES PCB S CABLE LOCATIONS AND BOARD DIAGRAMS ...

Page 203: ...2 860 P27 860 P11 P26 860 P10 P9 P21 P22 FU6 CB2 CB3 CB4 12V 12V 5V LOW VOLTAGE LOW VOLTAGE LOW VOLTAGE LOW VOLTAGE LOW VOLTAGE I O 12V 12V SPARE 115VAC T1 115VAC CB SOLENOID 12VAC OP LAMP OP LAMP TO SWITCH 230VAC COOLANT PUMP 230VAC K1 CONTACTORS 115VAC OUT 115VAC IN K1 COIL POWER ON OFF AUTO OFF 230VAC T4 190 260VAC INPUT PRI SEC T5 LOW VOLTAGE LOW VOLTAGE SERIAL PORT 1 12V SERIAL PORT 2 12V SOL...

Page 204: ...B P36 P9 860 LOW VOLTAGE èTO POWER P10 860 LOW VOLTAGE èTO POWER P11 860 LOW VOLTAGE èTO POWER P12 860 LOW VOLTAGE èTO POWER P13 860 LOW VOLTAGE èTO POWER P14 800A OP LAMP TO SWITCH èTO OP LAMP SWITCH P15 70 230VAC K1 CONTACTORS èTO K1 CONTACTOR P17 860A I O 12VDC èTO POWER P19 290 230VAC T4 èTO T4 P21 PORT 1 2 12VDC PORT 1 2 èTO PROCESSOR PCB P3 P22 12VDC èTO P24 SPARE SPARE èTO SPARE N A P26 860...

Page 205: ...TIONS HAAS AUTOMATION INC S E R V I C E M A N U A L VF SERIES MICRO PROCESSOR PCB 32 3090 B A T T E R Y EXT BAT RUN PGM CRT MSG SIO POR HALT 5V S1 850A 850 P3 ADDRESS BUSS DATA BUSS JUMPER J6 SERIAL PORT 2 SERIAL PORT 1 LOW VOLTAGE ...

Page 206: ...RO PROCESSOR PCB 32 3090 CABLE CONNECTIONS PROC PLUG CABLE SIGNAL NAME èTO LOCATION PLUG ADDRESS ADDRESS BUSS èTO VIDEO PCB DATA DATA BUSS MOTIF PCB P3 860 LOW VOLTAGE èTO POWER SUPPLY PCB P6 N A EXTERNAL BATTERY èTO EXT BATTERY PORT 1 850 SERIAL PORT 1 èTO SERIAL PORT 1 PORT 2 850A SERIAL PORT 2 èTO SERIAL PORT 2 ...

Page 207: ... CB3 E STOP DOOR M FIN OV V LO AIR OIL LO LUB OVERH SP DR STAT SP DR COMDS SERVO POW SP HD SOLENOID A BRAKE 115VAC FROM CB4 115VAC TO CB4 115V HTX 115V CRT 115V FROM T1 SHUTTLE MOTOR T C MOTOR 160VDC GND FAULT MOTIF INPUTS I O RELAYS K25 32 I O RELAYS I O RELAYS K1 8 I O RELAYS K17 24 I O OUTPUTS SPIGOT SW COOLANT SPIGOT MOTOR CHIP CONVEYOR MOTOR A161 P52 790 P24 190 P23 1070 P47 180 P53 UNCLAMP S...

Page 208: ...9 950 èTO AIR OIL P20 830 èTO REGEN RESISTORS P21 780 èTO SPINDLE DRIVE P22 100 èTO EXTERNAL P23 190 èTO SHOT PIN P24 790 èTO SPARE N A P25 SPARE èTO SPARE N A P26 M21 24 èTO EXTERNAL P28 910 èTO POWER PCB P7 P27 Y160 èTO PT RDY SW P29 390 èTO EXTERNAL P30 810A èTO SHUTTLE MOTOR P31 160 èTO 230VAC P32 80 èTO SDIST PCB P8 P33 90 èTO T1 P34 90A èTO CRT P35 90B èTO FANS P36 90C èTO POWER PCB P8 P37 1...

Page 209: ...60A P5 80 P8 920 P10 FAN P7 570 P1 580 P2 590 P3 600 P4 R11 R15 R2 FU2 FU1 NE2 NE1 LE1 FU3 NE3 TB2 TB1 93W 92V 910 REGEN X DRIVER LOW VOLTAGE Y DRIVER LOW VOLTAGE Z DRIVER LOW VOLTAGE A DRIVER LOW VOLTAGE DRIVERS 160VDC 160VDC 115VAC T1 SERVO POWER VOLTAGE MON OV V GND FAULT 12VDC RESISTORS FAN SERVO DISTRIBUTION PCB 32 5020 ...

Page 210: ... èTO Y SERVO DRIVER P1 P3 590 Z DRIVER LOW VOLTAGE èTO Z SERVO DRIVER P1 P4 600 A DRIVER LOW VOLTAGE èTO A SERVO DRIVER P1 P5 860A 12VDC èTO POWER SUPPLY PCB P7 FAN FAN VOLTAGE èTO FAN SERVO P8 80 160VDC èTO I O PCB P32 P9 980 VOLTAGE MONITOR èTO MOTIF PCB P17 P10 920 REGEN RESISTORS èTO REGEN RESISTORS P11 110 SERVO POWER èTO I O PCB P5 P12 970 OV V èTO I O PCB P18 P13 1060 GND FAULT èTO I O PCB ...

Page 211: ...ION INC S E R V I C E M A N U A L VF SERIES SERVO DRIVER PCB s 32 4070 160VDC GRD F3 F1 F2 MOTOR X 570 P1 Y 580 P1 Z 590 P1 A 600 P1 X 610 P3 Y 620 P3 Z 630 P3 A 640 P3 X Y Z A AXIS AXIS AXIS AXIS P8 160VDC DRIVE SIGNAL DRIVE P2 SIDE VIEW LOW VOLTAGE ...

Page 212: ...SIGNAL èTO MOTIF PCB P2 P8 160VDC èTO SDIST PCB TB2 Y AXIS P1 580 LOW VOLTAGE èTO SDIST PCB P2 P2 MOTOR DRIVE èTO Y SERVO MOTOR P3 620 X DRIVE SIGNAL èTO MOTIF PCB P3 P8 160VDC èTO SDIST PCB TB2 Z AXIS P1 590 LOW VOLTAGE èTO SDIST PCB P3 P2 MOTOR DRIVE èTO Z SERVO MOTOR P3 630 X DRIVE SIGNAL èTO MOTIF PCB P4 P8 160VDC èTO SDIST PCB TB2 A AXIS P1 600 LOW VOLTAGE èTO SDIST PCB P4 P2 MOTOR DRIVE èTO ...

Page 213: ...630 P4 640 P5 720 P16 540 P14 530 P13 520 P12 510 P11 LOW VOLTAGE X DRIVE SIGNAL Y DRIVE SIGNAL Z DRIVE SIGNAL A DRIVE SIGNAL SP SPEED CMD I O RELAYS K25 32 I O RELAYS K17 24 I O RELAYS K9 16 I O RELAYS K1 8 SP DRIVE LOAD SP TEMP VOLTAGE MON 0 5V MOTIF INPUTS I O OUTPUTS JOG INFO X ENCODER OUTPUT Y ENCODER OUTPUT Z ENCODER OUTPUT A ENCODER OUTPUT HOME SENSORS SP ENCODER OUTPUT P24 P17 P21 P22 MOTI...

Page 214: ...O X ENCODER P7 670 Y ENCODER OUTPUT èTO Y ENCODER P8 680 Z ENCODER OUTPUT èTO Z ENCODER P9 690 A ENCODER OUTPUT èTO A ENCODER P10 550 MOTIF INPUTS I O OUTPUTS èTO I O PCB P4 P11 510 I O RELAYS 1 8 èTO I O PCB P1 P12 520 I O RELAYS 9 16 èTO I O PCB P2 P13 530 I O RELAYS 17 24 èTO I O PCB P51 P14 540 I O RELAYS 25 32 èTO I O PCB P3 P15 860 LOW VOLTAGE èTO POWER SUPPLY PCB P16 720 SP SPEED COMMAND èT...

Page 215: ...S AUTOMATION INC S E R V I C E M A N U A L VF SERIES ADDRESS BUSS P4 DATA BUSS P5 P1 760 P13 700 P3 KEYBOARD INFO VIDEO LOW VOLTAGE S1 2 1 D3 D2 D1 A B RS422 A B P14 P15 FLOPPY DRIVE FLOPPY POWER SPARE P11 P10 P12 VIDEO KEYBOARD PCB 32 3201 ...

Page 216: ...LE CONNECTIONS VIDEO CABLE èTO LOCATION PLUG PLUG P1 860 LOW VOLTAGE èTO POWER SUPPLY PCB P3 700 KEYBOARD INFO èTO KEYBOARD INT P4 ADDRESS BUSS èTO MICRO PROC PCB P5 DATA BUSS MOTIF PCB P10 FLOPPY DR POWER èTO FLOPPY DRIVE P11 SPARE èTO N A N A P12 FLOPPY DR SIGNAL èTO FLOPPY DRIVE P13 760 VIDEO SIGNAL èTO CRT P14 RS422 B èTO N A N A P15 RS422 A èTO N A N A ...

Page 217: ... 520 P12 510 P11 LOW VOLTAGE X DRIVE SIGNAL Y DRIVE SIGNAL Z DRIVE SIGNAL A DRIVE SIGNAL 720 P16 SP SPEED CMD I O RELAYS K25 32 I O RELAYS K17 24 I O RELAYS K9 16 I O RELAYS K1 8 SP DRIVE LOAD VOLTAGE MON 0 5V MOTIF INPUTS I O OUTPUTS JOG INFO X ENCODER OUTPUT Y ENCODER OUTPUT Z ENCODER OUTPUT A ENCODER OUTPUT P24 990 HOME SENSORS D1 5V D2 HALT B DRIVE SIGNAL 640B 1000 P20 SP ENCODER OUTPUT B ENCO...

Page 218: ...TO X ENCODER P7 670 Y ENCODER OUTPUT èTO Y ENCODER P8 680 Z ENCODER OUTPUT èTO Z ENCODER P9 690 A ENCODER OUTPUT èTO A ENCODER 690B B ENCODER OUTPUT èTO B ENCODER P10 550 MOTIF INPUTS I O OUTPUTS èTO I O PCB P4 P11 510 I O RELAYS 1 8 èTO I O PCB P1 P12 520 I O RELAYS 9 16 èTO I O PCB P2 P13 530 I O RELAYS 17 24 èTO I O PCB P51 P14 540 I O RELAYS 25 32 èTO I O PCB P3 P15 860 LOW VOLTAGE èTO POWER S...

Page 219: ...C S E R V I C E M A N U A L VF SERIES CAUTION HIGH VOLTAGE HAAS BRUSHLESS SERVO AMPLIFIER FUSE OPEN A B C HV HV 12V FAIL FAULT PWR ON 320VDC FROM SPINDLE DRIVE TO SERVO MOTOR LOW VOLTAGE INPUT SERVO DRIVE SIGNAL FROM MOCON BRUSHLESS SERVO AMPLIFIER 32 5550 ...

Page 220: ... MOCON PCB P2 TB HV HV 320VDC èTO SPINDLE DRIVE Y AXIS AMP P 580 LOW VOLTAGE èTO L V POWER SUPPLY TB A B C MOTOR DRIVE èTO X SERVO MOTOR P 620 X DRIVE SIGNAL èTO MOCON PCB P3 TB HV HV 320VDC èTO SPINDLE DRIVE Z AXIS AMP P 590 LOW VOLTAGE èTO L V POWER SUPPLY TB A B C MOTOR DRIVE èTO X SERVO MOTOR P 630 X DRIVE SIGNAL èTO MOCON PCB P4 TB HV HV 320VDC èTO SPINDLE DRIVE A AXIS AMP P 600 LOW VOLTAGE è...

Page 221: ...96 8100 1 15 96 218 CABLE LOCATIONS HAAS AUTOMATION INC S E R V I C E M A N U A L VF SERIES CABLE LOCATION DIAGRAM ...

Page 222: ...1 15 96 96 8100 HAAS AUTOMATION INC 219 TABLE OF CONTENTS CABLE LOCATIONS S E R V I C E M A N U A L VF SERIES ...

Page 223: ...PINDLE DRIVE PHASE 1 10 S L8 230VAC FROM K1 TO SPINDLE DRIVE PHASE 2 10 T L9 230VAC FROM K1 TO SPINDLE DRIVE PHASE 3 10 71 L4 FUSED 230 VAC FROM MAIN CB1 4 TO K1 1 10 72 L5 FUSED 230 VAC FROM MAIN CB1 5 TO K1 2 10 73 L6 FUSED 230 VAC FROM MAIN CB1 6 TO K1 3 10 74 R 230 VAC FROM MAIN CONTACTOR K1 4 12 75 S 230 VAC FROM MAIN CONTACTOR K1 5 12 76 T 230 VAC FROM MAIN CONTACTOR K1 6 12 77 230VAC FUSED ...

Page 224: ... J IOPCB 130 OVERCURRENT SENSE FROM CHIP CONVEYOR REMOVED IN REV J IOPCB 140 230VAC 3PH POWER TO CHIP CONVEYOR MOTOR 5 SHIELD 141 PHASE A 230VAC 142 PHASE B 230VAC 143 PHASE C 230VAC 144 STARTING WINDING 230VAC 145 STARTING WINDING 230VAC 140A 230VAC 3PH POWER IN CONDUIT TO CHIP CONVEYOR 150 12VDC TO CHIP CONVEYOR CONTROL PCB REMOVED IN REV J IOPCB 160 3PH 230VAC TO CHIP CONVEYOR CONTROLLER 161 PH...

Page 225: ... 243 SPARE 4 250 HORIZONTAL TOOL CHANGER SHUTTLE VALVE SHIELD 2 251 COMMON 115VAC 252 SWITCHED 115VAC 260 K210 CABLING FOR EC 270 K111 CABLING FOR EC 280 RED GREEN STATUS LIGHT WIRING 281 RED LAMP 115VAC 282 GREEN LAMP 115VAC 283 COMMON 115VAC 290 230VAC TO TRANSFORMER T2 deleted 1 Aug 90 300 115VAC TO SPINDLE MOTOR FAN OIL PUMP OILER 301 LEG 1 115VAC FUSED AT 3 A 18 302 LEG 2 115VAC FUSED AT 3 A ...

Page 226: ...RAKE LATHE PART DOOR SHIELD 2 391 LEG 1 18 392 LEG 2 SWITCHED 18 400 SPINDLE DRIVE COAST COMMAND SHIELD 2 401 LOGIC COMMON 20 402 SPINDLE COAST COMMAND 20 410 483 reserved 490 ALL WIRES CARRYING SERVO MOTOR DRIVE POWER all 14 491 X AXIS FUSED MOTOR POWER P1 E 492 X AXIS FUSED MOTOR POWER P1 F 493 Y AXIS FUSED MOTOR POWER P2 E LATHE T S 494 Y AXIS FUSED MOTOR POWER P2 F LATHE T S 495 Z AXIS FUSED M...

Page 227: ...RIVER P2 4 24 575 CHASSIS GROUND DRIVER P2 5 24 576 CHASSIS GROUND DRIVER P2 6 24 580 Y AXIS DRIVER LOW VOLTAGE POWER LATHE T S SAME AS 571 to 576 590 Z AXIS DRIVER LOW VOLTAGE POWER SAME AS 571 to 576 600 A AXIS DRIVER LOW VOLTAGE POWER SAME AS 571 to 576 610 X AXIS DRIVER CONTROL CABLE SHIELD 6 611 LOW ENABLE MOTIF P2 1 24 612 HIGH ENABLE MOTIF P2 2 24 613 DRIVE DIRECTION MOTIF P2 3 24 614 5 VDC...

Page 228: ...ORWARD COMMAND SP DR CN1 18 TO IO P9 4 24 712 REVERSE COMMAND CN1 19 TO IO P9 3 24 713 RESET COMMAND CN1 21 TO IO P9 2 24 714 COMMON CN1 14 TO IO P9 1 24 720 ANALOG SPEED COMMAND TO SPINDLE SHIELD 2 721 0 TO 10 VOLTS SPEED COMMAND SPINDLE DRIVE CN1 1 24 722 SPEED COMMAND REFERENCE A GROUND CN1 17 24 730 POWER METER FROM SPINDLE DRIVE TO KBIF SHIELD 2 731 METER SPINDLE DRIVE CN1 5 TO KBIF 24 732 ME...

Page 229: ...INPUT 19 TO CN1 22 24 790 SPARE INPUTS FROM IOPCB P24 791 SPARE 1 792 SPARE 2 793 COMMON 800 12VAC TO LAMP SHIELD 2 801 UNSWITCHED LEG 1 20 802 SWITCHED LEG 2 20 800A CABLE FOR LAMP SWITCH SHIELD 2 800B CABLE WITH 10VAC FROM TRANSFORMER T2 SHIELD 2 810 TOOL CHANGER MOTORS SHIELD 2 20 811 TURRET MOTOR IO P30 2 TO P6 J 14 812 TURRET MOTOR IO P30 1 TO P6 I 14 810A TOOL CHANGER MOTORS SHIELD 2 20 813 ...

Page 230: ...C POWER RETURN D GROUND 860B 5 POWER TO 3 FLOPPY DRIVE 860C 5 12 12 POWER TO 68030 870 115VAC TO OILER SHIELD 2 871 115VAC LEG 1 18 872 115VAC LEG 2 18 880A HIGH LOW GEAR UNCLAMP LOCK SOLENOID POWER SHIELD 6 881 115 VAC SOLENOID COMMON IO P12 5 18 882 HIGH GEAR SOLENOID IO P12 4 18 883 LOW GEAR SOLENOID IO P12 3 18 884 TOOL UNCLAMP SOLENOID IO P12 2 18 885 SPINDLE LOCK SOLENOID IO P12 1 18 886 PRE...

Page 231: ...0A LOW HYDRAULIC PRESSURE SWITCH FOR LATHE SHIELD 2 952 LOW HYDRAULIC RETURN D GROUND 65 20 953 LOW HYD PRESSURE SWITCH FOR VERTICAL TRANSMISSION 20 960 LOW LUB DOOR OPEN SENSORS SHIELD 4 961 LOW LUB SIGNAL INPUT 13 24 962 LOW LUB RETURN D GROUND 65 24 963 DOOR OPEN SIGNAL INPUT 9 24 OBSOLETE OPTION 964 DOOR OPEN RETURN D GROUND 65 24 OBSOLETE OPTION 970 LOW VOLTAGE SENSOR SHIELD 2 971 LOW VOL SIG...

Page 232: ... ROT COMMON 1020 SPINDLE TEMPERATURE SENSOR CABLE SHIELD 3 1021 SIGNAL 1022 ANALOG RETURN 1023 5 VOLTS TO SENSOR 1024 SHIELD GROUND 1030 SPINDLE LOAD RESISTOR SHIELD 2 1031 REGEN LOAD RESISTOR FOR SPINDLE DRIVE B1 18 1032 REGEN LOAD RESISTOR FOR SPINDLE DRIVE B2 18 1040 Y160 MIKRON DOOR LOCK OR HORIZONTAL PART READY LAMP 1041 SWITCHED RELAY CONTACT 1042 SWITCHED RELAY CONTACT 1050 DOOR SWITCH WIRI...

Page 233: ...96 8100 1 15 96 230 VF SERIES S E R V I C E M A N U A L ASSEMBLY DRAWINGS CHAPTER 25 ASSEMBLY DRAWINGS ...

Page 234: ...1 15 96 96 8100 231 TABLE OF CONTENTS VF SERIES S E R V I C E M A N U A L ASSEMBLY DRAWINGS VF 1 BASE ...

Page 235: ...96 8100 1 15 96 232 VF SERIES S E R V I C E M A N U A L ASSEMBLY DRAWINGS VF 1 COLUMN ...

Page 236: ...1 15 96 96 8100 233 TABLE OF CONTENTS VF SERIES S E R V I C E M A N U A L ASSEMBLY DRAWINGS VF 1 SADDLE ...

Page 237: ...96 8100 1 15 96 234 VF SERIES S E R V I C E M A N U A L ASSEMBLY DRAWINGS VF 1 LEADSCREW ...

Page 238: ...1 15 96 96 8100 235 TABLE OF CONTENTS VF SERIES S E R V I C E M A N U A L ASSEMBLY DRAWINGS VF 3 BASE ...

Page 239: ...96 8100 1 15 96 236 VF SERIES S E R V I C E M A N U A L ASSEMBLY DRAWINGS VF 3 COLUMN ...

Page 240: ...1 15 96 96 8100 237 TABLE OF CONTENTS VF SERIES S E R V I C E M A N U A L ASSEMBLY DRAWINGS VF 3 SADDLE ...

Page 241: ...96 8100 1 15 96 238 VF SERIES S E R V I C E M A N U A L ASSEMBLY DRAWINGS VF 3 LEADSCREW ...

Page 242: ...1 15 96 96 8100 239 TABLE OF CONTENTS VF SERIES S E R V I C E M A N U A L ASSEMBLY DRAWINGS VF GEARBOX ASSEMBLY ...

Page 243: ...96 8100 1 15 96 240 VF SERIES S E R V I C E M A N U A L ASSEMBLY DRAWINGS VF SERIES SPINDLE 7 5K 10K VF O SPINDLE 10K ...

Page 244: ...1 15 96 96 8100 241 TABLE OF CONTENTS VF SERIES S E R V I C E M A N U A L ASSEMBLY DRAWINGS THROUGH THE SPINDLE COOLANT TOOL RELEASE PISTON ...

Page 245: ...96 8100 1 15 96 242 VF SERIES S E R V I C E M A N U A L ASSEMBLY DRAWINGS 3 4 2 1 ...

Page 246: ...sy VF 3 4 1 30 3170A Hydraulic Cylinder Assy VF 0 1 2 1 30 3970A Hydraulic Cylinder Assy VF 3 4 1 30 3980A Hydraulic Cylinder Assy VF 6 8 2 58 1730A 90 Hydraulic Hose 1 1 58 1729A 138 Hydraulic Hose 2 25 7560B Hydraulic Fluid Tank Mount 1 2 33 0771 Hydraulic Pressure Sensor Cable VF 0 thru 4 1 1 33 6771 Hydraulic Pressure Sensor Cable VF 6 8 1 59 4016 Hydraulic Hose Clamp 1 1 equipped 4 2 1 3 ...