Haas VF Series - TECHNICAL REFERENCE

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1-15-96 96-8100

145

TABLE OF CONTENTS

ELECTRICAL SERVICE

VF-SERIES

SERVICE

MANUAL

HA AS AUTOMATION, INC.

Main Page

Troubleshooting1
Before You Begin1
General Machine Operation2
Machine Not Running2
Machine Cannot be Powered on2
Machine Can be Powered On, but Turns off by Itself2
Vibration3
Machine Vibrates While Jogging the Axis with the Hand Wheel3
The Machine Vibrates Excessively in a Cut3
Accuracy4
Machine will Not Interpolate a Round Hole4
Machine Bores Holes Out-Of-Round4
Bored Holes Are out of Round or out of Postion4
Finish5
Boring Depth Inaccurate5
Machining Yields a Poor Finish5
Spindle6
Noise6
Not Turning6
Spindle Not Turning6
Overheating7
Stalling/Low Torque7
Spindle Drive8
Orientation8
Tools Sticking in Taper8
Serv O Motors / Leadscrews9
Not Operating9
Servo Motor Noise9
Lead Screw Noise10
Noise in Z - Motion (VF-6)10
Accuracy/Backlash11
Initial Preparation11
Checking X-Axis11
Checking Y-Axis:12
Dial Indicator in Position to Check Y-Axis12
Checking Z-Axis13
Dial Indicator in Position to Check Z-Axis13
Excessive Servo Motor Vibration14
Servo Motor Overheating14
Z-Axis Motor Overcurrent (VF-6)14
Automatic Tool Changer15
Deflection15
Tool Holders Twist against Extractor Fork During Tool Change16
Tool Holders Spin at All Pockets of ATC When the ATC Shuttle Retracts16
Crashing16
Breakage17
ATC Shuttle Is Broken off of the Holding Plate17
ATC Extractor Forks Are Damaged after Breakage17
Noisy Operation18
ATC Makes Noise as the Shuttle Moves18
Spindle Orientation19
Atc will Not Run19
ATC Shuttle will Not Move; Shuttle Is Getting Power19
ATC Shuttle will Not Move; Shuttle Is Not Getting Power20
ATC Turret will Not Rotate; Turret Motor Is Getting Power20
ATC Turret will Not Rotate; Turret Motor Is Not Getting Power20
Gearbox and Spindle Motor21
Gears will Not Change21
Through the Spindle Coolant22
Low Pressure Alarm22
Coolant Overflow22
Low Coolant22
Coolant Tip Wear23
Pre-Charge Failure23
Alarms24
Head Covers Removal / Installation42
Tool Release Piston Assembly44
Tool Release Piston with Solenoid Valve45
Mounting Location for Tool Release Piston Assembly45
Installation46
Setting Pre-Charge46
Air Pressure Regulator Adjustment Knob46
Belt Assembly48
Belt Removal48
Spindle Head Casting Disconnect Points48
Belt Installation49
Head Casting Area Showing Belt Location49
Tension Adjustment50
Spindle Assembly51
Spindle Cartridge Removal51
Spindle Cartridge Installation52
Position Wood Block under Spindle52
Spindle Cartridge52
Underside View of Spindle Cartridge53
Spindle Cartridge Alignment53
Drawbar Replacement54
Spindle Sweep Adjustment55
Spindle Sweep Area56
Tool Clamp/Unclamp Switch Adjustment57
Tool Clamp/Unclamp Switch Adjustment - Initial Preparation57
Placement of Aluminum Block under Spindle57
Setting Drawbar Height58
Shim Washers58
Adjustment of Switches - Lower (Unclamp) Switch59
Upper (Clamp) Switch60
Placement of Shim before Checking Switch Adjustment60
Push Piston down to Hold Shim in Place61
Top View of Spindle Orientation Components62
VF-0 Motor with Orient Ring Location63
Setting Parameter 6464
Checking Tool Offset Reference64
Screen Showing Calculator65
Spindle Motor & Transmission66
Motor Removal66
VF-0 with Lifting Eyeholes67
Hoist Pre-Assembly67
Support Base/Mast Support Assembly68
Exploded View of Boom Modification Plate Components68
Fig. 8-4 Mounting Cable Guide and Pulley Wheel to Boom69
Transmission Removal70
View of Transmission Lift Fixture70
Solenoid Bracket with All Lines Connected71
Support Base/Mast Support Assembly Location71
Mounting Boom Assembly to Mast72
Fully Assembled Hoist in Position72
Transmission Installation73
Lifting Position for VF-1 through 473
Axis Motor Removal / Installation74
X-Axis Motor Removal74
X-Axis Motor and Components74
Motor Coupling Components75
Y-Axis Motor Removal76
Removing Oiler and Air Regulator Panel76
Lubricator/Air Regulator Panel77
Z-Axis Motor Removal78
Z-Axis Motor and Components80
Coupling Replacement82
Motor Coupling82
X-Axis Lead Screw Removal83
X-Axis Lead Screw and Components83
Lead Screw Assembly84
Install Lead Screw from Right Side85
Bearing Sleeve Mounting Location85
Y-Axis Lead Screw Removal86
Y-Axis Lead Screw and Components86
Pull Lead Screw Forward Around Bearing Support87
Z-Axis Lead Screw Removal89
Z-Axis Lead Screw and Components90
Reinstalling the Lead Screw91
Bearing Sleeve Removal and Installation92
X-Axis Bearing Sleeve Removal92
Y-Axis Bearing Sleeve Removal94
Z-Axis Bearing Sleeve Removal95
Z-Axis Bearing Sleeve96
Carriage Casting Replacement98
Roller Bolt Replacement98
Automatic Tool Changer (Atc) Alignment99
Shuttle Stroke Adjustment99
Underside Showing Centering Measurements99
Extractor Fork Replacement100
Automatic Tool Changer - Mechanical Assembly (Side View)100
Sliding Cover Replacement101
Automatic Tool Changer - Mechanical Assembly (Top View)101
Shuttle Motor Removal102
Shuttle Motor Installation102
Wiring Harness for Shuttle Motor102
Turret Motor Removal103
Front View of Holding Plate Showing FHCS Location103
Carriage Casting with Cover Removed104
Required Spacing for Geneva Driver106
Geneva Star Replacement107
Atc Trap Door Replacement107
Grid Offset Calculation108
Setting the Offset108
Enclosure Replacement109
Door Replacement109
Door Adjustments110
Roller/Roller Guide Assembly110
View of Vertical Gap between Front Doors110
Window Replacement111
Switch Adjustment111
View of Gap between Front of Door and Front Panel Flange111
Cross-Section of Window Seal111
Hydraulic Counterbalance112
Hydraulic Tank Replacement112
Hydraulic Cylinder Replacement114
Hydraulic Cylinder Rod Installation115
Through the Spindle Coolant System116
Tank Pressure Requirements116
Tool Release Piston Assembly - Tsc116
Electrical Service120
Solenoids121
Air Solenoid Assembly121
Tool Release Piston Assembly Air Solenoid122
Tool Release Piston Assembly with Air Solenoid Assembly122
Spindle Lube Air Solenoid123
Front Side of Lube/Air Panel123
Top View of Spindle Lube/Air Solenoid Assembly123
Line Voltage Adjustments125
Transformer Connections126
Transformers with 195-210V (Left) and 452-480V(Right) Range127
Fuse Replacement128
Overvoltage Fuses128
Operator's Lamp Fuse129
Power Supply Board; Fuse Locations129
Servo Driver & Sdist Fuses130
Servo Drive Assembly; Fuse Locations130
Pcb Replacement131
Microprocessor, Video, Motif & Keyboard131
Motif Board131
Video Board and Keyboard132
Motor Interface Board132
Video Board133
Processor Board133
Servo Driver & Sdist134
Sdist Board134
Servo Driver Boards135
I/O Board136
Power & Low Voltage Supply137
Low Voltage Power Supply139
Power Distribution (POWER) Board139
Rs-232 Db25140
RS-232 DB25 Board140
Front Panel141
Crt Assembly Replacement141
Jog Handle Replacement142
Interior of Control Panel (Rear)142
Switch Replacement143
Jog Handle Removal143
Spindle Load Meter Replacement144
Keypad Replacement144
Keyboard Interface145
Keypad Installation145
Spindle Encoder Replacement146
Spindle Encoder Installation (VF-1/VF-2)147
Technical Reference149
Tool Changer150
Tool Changer Lubrication151
Shuttle In/Out Motor151
Turret Rotation Motor151
Tool Clamp/Unclamp152
Tool Clamp/Unclamp Air Solenoids152
Tool Clamp/Unclamp Sense Switches152
Remote Tool Unclamp Switch152
Spindle Operation153
Spindle Orientation Lubrication153
Spindle Orientation Sequence153
Spindle Orientation Air Solenoid153
Servos Brush / Brushless154
Servo Encoders (Brush)154
Servo Characteristics (Brush)154
Servo Drive Assembly (Brush)155
160 Volt DC Power Supply (Brush)155
Servo Cooling Fan (Brush)155
Servo Distribution Pcb (Sdist)156
Servo Drive Pcb’s (Driver)156
Servo Encoders (Brushless)157
Servo Characteristics (Brushless)158
Servo Amplifiers (Brushless)158
Input/Output Assembly159
Two-Speed Gear Transmission Vf-1/2/3/4/6161
Gear Box Lubrication161
Gear Box Air Solenoids161
Gear Box Sense Switches161
Control Panel162
Jog Handle162
Power On/Off Switches162
Spindle Load Meter162
Microprocessor Assembly163
Keyboard Beeper163
Microprocessor Pcb (68Eco30)163
Memory Retention Battery164
Video Keyboard Pcb with Floppy164
CRT/VIDEO Initialization Complete. (Normally On)164
Program Signature Found in Memory.(Normally On)164
Motor Interface Pcb (Motif)165
Motor Controller (Mocon) Brushless165
Spindle Drive Assembly167
Resistor Assembly167
Spindle Drive Regen Resistor167
Servo Drive Regen Resistor167
Power Supply Assembly168
Main Circuit Breaker Cb1168
Main Contactor K1168
Power Pcb (Power)169
Power-Up Low Voltage Control Transformer (T5)169
Secondary Circuit Breakers169
Operator’s Lamp Transformer170
Power Transformer Assembly (T1)171
Primary Connection to T1171
Voltage Selection Taps171
Secondary Connection to T1171
Fuses172
Spare User M Code Interface172
M Function Relays172
M-Fin Discrete Input173
Turning M Functions on and off173
Lubrication Pump173
Low Lubrication and Low Pressure Sense Switches173
Lamp On/Off Switch174
Door Open Sense Switch174
Limit Switches174
Door Hold Switches175
Tool Changer Position Switches175
Geneva Wheel Position Mark175
What Can Go Wrong with Limit Switches?175
Tool #1 Sense Switch176
Shuttle In/Out Switches176
Transmission High/Low Gear Position Switches176
Lubrication System177
Diagnostic Data177
Power Failure Alarm177
Discrete Inputs178
Discrete Outputs178
Inputs 2179
Analog Data179
Parameters181
Parameter List181
Maintenance Schedule200
Lubrication Chart201
Pcb's Cable Locations and Board Diagrams202
Power Pcb 32-5010 Cable Connections204
Micro Processor Pcb 32-3090 Cable Connections206
I/O Pcb 32-3080 Cable Connections208
Servo Distribution (Sdist)Pcb 32-5020 Cable Connections210
SERVO DRIVER Pcb’s 32-4070 CABLE CONNECTIONS212
Motif Pcb 32-4020 Cable Connections214
Video & Keyboard Pcb 32-3201 with Floppy Drive Cable Connections216
Mocon Pcb 32-4023 C Cable Connections218
Brushless Servo Amplifier (Rev C) Cable Connections220
Cable Location Diagram221
Cable List223
Assembly Drawings233
Vf -1 Base234
Vf -1 Column235
Vf -1 Saddle236
Vf -1 Leadscrew237
Vf -3 Base238
Vf -3 Column239
Vf-3 Saddle240
Vf -3 Leadscrew241
Vf -Gearbox Assembly242
Vf -Series Spindle 7.5K / 10K243
Vf -O Spindle 10K243
Through the Spindle Coolant - Tool Release Piston244

Haas VF Series - TECHNICAL REFERENCE

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