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Haas Automation Servo Bar 300 Operator's Manual Supplement

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Servo Bar 300
Operator's Manual Supplement
96-0013
Revision BC
December 2013
English
Original Instructions
ATTENTION!
This manual contains important placement instructions.
Refer to the Installation Section, starting on page 43.
To get translated versions of this Manual:
Haas Automation Inc.
1. Go to www.HaasCNC.com
2800 Sturgis Road
2. See Owner Resources (bottom of page)
Oxnard, CA 93030-8933
3. Select Manuals and Documentation
U.S.A. | HaasCNC.com
©
2013 Haas Automation, Inc. All Rights Reserved. Copy by Permission Only. Copyright Strictly Enforced.

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Summary of Contents for Haas Automation Servo Bar 300

  • Page 1 1. Go to www.HaasCNC.com 2800 Sturgis Road 2. See Owner Resources (bottom of page) Oxnard, CA 93030-8933 3. Select Manuals and Documentation U.S.A. | HaasCNC.com © 2013 Haas Automation, Inc. All Rights Reserved. Copy by Permission Only. Copyright Strictly Enforced.
  • Page 3 Haas Automation, Inc. No patent liability is assumed with respect to the use of the information contained herein. Moreover, because Haas Automation strives constantly to improve its high-quality products, the information contained in this manual is subject to change without notice.
  • Page 5 Covering Haas Automation, Inc. CNC Equipment Effective September 1, 2010 Haas Automation Inc. (“Haas” or “Manufacturer”) provides a limited warranty on all new mills, turning centers, and rotary machines (collectively, “CNC Machines”) and their components (except those listed below under Limits and Exclusions of Warranty) (“Components”) that are manufactured by Haas and sold by Haas or its authorized...
  • Page 6 Limits and Exclusions of Warranty Components subject to wear during normal use and over time, including, but not limited to, paint, window finish and condition, light bulbs, seals, wipers, gaskets, chip removal system (e.g., augers, chip chutes), belts, filters, door rollers, tool changer fingers, etc., are excluded from this warranty.
  • Page 7 Customer has accepted the limitations and restrictions set forth in this Certificate, including, but not limited to, the restriction on its right to recover damages, as part of its bargain with Manufacturer or its Authorized Representative. Customer realizes and acknowledges that the price of the Haas Products would be higher if Manufacturer were required to be responsible for damages and claims beyond the scope of this warranty.
  • Page 8 Customer Feedback If you have concerns or questions regarding this Operator’s Manual, please contact us on our website, www.HaasCNC.com. Use the “Contact Haas” link and send your comments to the Customer Advocate. You also can find an electronic copy of this manual and other useful information on our website under the “Owner’s Resources”...
  • Page 9 Att: Customer Satisfaction Manager email: customerservice@HaasCNC.com Once you contact the Haas Automation Customer Service Center, we will make every effort to work directly with you and your HFO to quickly resolve your concerns. At Haas Automation, we know that a good Customer-Distributor-Manufacturer relationship will help ensure continued success for all concerned.
  • Page 10 viii...
  • Page 11 The Servo Bar 300, when incorporated into Haas CNC Lathes (turning centers), complies with the regulations as outlined in the CE directive for turning centers.
  • Page 12 Declaration of Incorporation USA: Haas Automation certifies this machine to be in compliance with the OSHA and ANSI design and manufacturing standards listed below. Operation of this machine will be compliant with the below-listed standards only as long as the owner and operator continue to follow the operation, maintenance, and training requirements of these standards.
  • Page 13 How to Use This Manual To get the maximum benefit of your new Haas machine, read this manual thoroughly and refer to it often. The content of this manual is also available on your machine control under the HELP function. IMPORTANT: Before you operate the machine, read and understand the Operator’s Manual Safety chapter.
  • Page 14 Text Conventions Used in this Manual Description Text Example Code Block text gives program examples. G00 G90 G54 X0. Y0.; A Control Button Reference gives the name of a Press [CYCLE START] control key or button that you are to press. A File Path describes a sequence of file system Service >...

  • Page 15: Table Of Contents

    Introduction ......5 Servo Bar 300 Overview....5 Bar Feeder Extended Push Function .
  • Page 16 Counter ......22 Machining Short Bars ..... 22 Bar Feeder as a Hard Stop .

  • Page 17: Safety

    Individuals not associated with production or who are unfamiliar with this type of equipment must be kept away. WARNING: The Bar Feeder is controlled by the lathe and may start at any time. SERVO BAR 300 DOW N Front View Left Side View A –...
  • Page 18 Electrical safety: DANGER: Lethal voltages may be present; disconnect main power before servicing this machine. • Disconnect all sources of power before maintaining, servicing, or altering setup of this machine. Operation Safety: • Do not operate or allow others to operate the Bar Feeder until receiving user and safety training.

  • Page 19: Modes Of Operation

    Safety Modes of Operation The Haas Bar Feeder has two modes of operation: setup and run. 1.3.1 Setup Mode Setup Mode allows a trained user to load and adjust the machine to feed bar. Raise the setup lid to view the path of the bars. WARNING: Never put your hands in the enclosure of the Bar Feeder unless the [EMERGENCY STOP] is pressed on the lathe.
  • Page 20 Run Mode...

  • Page 21: Introduction

    Servo Bar 300 Overview The Haas Servo Bar 300 (Bar Feeder) features a heavy-duty yet compact design, with up to 3 1/8" (79 mm) bar capacity and a footprint of only 4.5' x 8' (1.38 m x 2.43 m). Refer to the Haas web site at www.haascnc.com for Bar Feeder dimensions for your lathe.
  • Page 22 Bar Feeder Components (front view) Detail A - Transfer Tray F2.2: 1. Transfer Tray Charging Position Charging Tray Bar Feeder Components (front view) Detail B - Set-up Lid Lock F2.3: 1. Set-up Lid Lock Set-up Lid Lift Handle...

  • Page 23: Bar Feeder Extended Push Function

    Introduction Bar Feeder Components (front view) Detail C - Charging Tray Details F2.4: 1. Charging Tray Charging Tray Cover Storage Tray Charging Tray Adjustment Screw Bar Feeder Extended Push Function The bar feeder extended push kit comes as a standard feature on models BAR3010GBX and BAR3012ST.

  • Page 24: Bar Feeder Compatibility

    ST / DS Bar Feeder Compatibility Bar Feeder Compatibility This section contains compatibility tables that match lathes with the appropriate bar feeder. 2.3.1 ST / DS Bar Feeder Compatibility ST/DS Lathes and Compatible Bar Feeders T2.1: Haas Lathe Bar Feeder ST-10 / ST-10Y BAR1006ST ST-20 / ST-20Y...

  • Page 25: Gt/Sl/ Tl (Sub-Spindle) Bar Feeder Compatibility

    Introduction 2.3.2 GT/SL/ TL (Sub-Spindle) Bar Feeder Compatibility Bar Feeder Compatibility with GT/SL/TL (Sub-Spindle) T2.2: Replaced Bar Feeder (Obsolete Part New Bar Feeder and Additional Lathe Number) Parts GT-10 BARGT05B BAR1006S Alignment Plate (25-1026A) LINERGT-10 KIT (1 each) UDK5 LINER DISK KIT (1 each). Casting Level Pad (30-10798) 4 each SL-10 BAR1006B...

  • Page 26: Compatibility Notes

    Compatibility Notes Replaced Bar Feeder (Obsolete Part New Bar Feeder and Additional Lathe Number) Parts SL-30BB / BAR3015B BAR3012ST TL-25BB 4" Bar Alignment Plate (25-6516B)• Casting Level Capacity Pad (30-10798) 4 each SL-40 BAR4015B No Model Available 2.3.3 Compatibility Notes Some previous Bar Feeder models can be retrofitted to a new lathe model.

  • Page 27: Operation

    Operation Chapter 3: Operation Introduction The Bar Feeder can store a single layer of 60" long bars on its adjustable charging tray, located at the rear of the machine. A spindle liner must be installed in the lathe spindle, and the transfer tray must be aligned to it, before the machine is ready for operation.
  • Page 28 Recommendations • Use a drawback collet. The Bar Feeder push rod is held in place while the collet is closed. If the draw tube does not pull the bar stock into the push rod, length variation may occur. • Cut the end of the bar stock that contacts the push rod at 90° to prevent protrusions or length variations.

  • Page 29: Servo Bar 300 Quick Start Guide

    Operation Servo Bar 300 Quick Start Guide To prepare your Bar Feeder for operation: Install a spindle liner for the size of the bar used, and adjust the transfer table to the proper height. The bar must slide from the transfer table into the liner without interference.
  • Page 30 Recommendations • #3102 (Minimum Clamping Length): The minimum amount of stock needed to clamp safely and machine the workpiece. Example: #3100=2.150 (2.0" long workpiece + .125" cut off width + .025" to face off) #3101=2.5 (2.5" of stock pushed past face of the collet) #3102=1.0 (1.0"...

  • Page 31: Transfer Tray Adjustment

    Operation To change jobs, remove all material from the Bar Feeder and lathe, and change the spindle liners. Load the new material in the Bar Feeder tray and enter new values for variables #3100, #3101 and #3102. Transfer Tray Adjustment When you change applications to a different diameter bar stock, you must change the spindle liner and adjust the transfer tray.

  • Page 32: Bar Feeder Push Rod Clearance

    Recommendations Bar Feeder Push Rod Clearance CAUTION: Make sure that the push rod maintains 1/4" (6.4 mm) of clearance between it and the bore taper. This clearance is necessary to make sure that the push rod does not come in contact with collet clamping surfaces.

  • Page 33: Machining Small Diameter Bars

    Operation Type this test program and watch the Bar Feeder operation (you do not need to include the comments in parentheses): G105 Q9 (Load Bar Stock) ; G105 Q8 (Unload Bar Stock) ; If necessary, adjust the tray angle. Machining Small Diameter Bars The Bar Feeder comes with two push rods: 3/4"...
  • Page 34 Recommendations...

  • Page 35: Programming

    Programming Chapter 4: Programming Sample Programs This section has two sample programs. • Example 1 is a standard stock program with a procedure on how to set up and cut the parts. • Example 2 is a program for reference for a double-push on a workpiece. 4.1.1 Example 1 This example uses 2"...

  • Page 36: Example 2

    Example 2 Example 1, Part Off and Bar Feed: [A] Reference Position Macro Variable, [B] F4.1: Initial Push Length Macro Variable #310, [C] Part Length + Cutoff Macro Variable #3100, [D] Min Clamp Length Macro Variable #3102, [E] Spindle Tool Clearance, [F] Finished Part Length, [G] Face Clean Up Allowance, [H] Parting Tool Width, [1] Bar, [2} Stub, [3] Collet, [4] Cut-off Tool, [5] Facing Tool X0, Z0...
  • Page 37 Programming (I=Initial push length, J=part length + cutoff, K=min clamping length) could be added to the G105 line to make program function, regardless of the values stored in the macro variables #3101, #3100, and #3102. Study both G105 callouts on the program for programmed moves. At the start of the first G105, the part should be flush with the collet face.

  • Page 38: Counter

    Example 2 Counter The Bar Feeder can count either the numbers of bars used, the number of parts made, or the length of material run. A non-zero value set in Max # Parts (#3103), Max # Bars (#3104), or Max Length to Run (#3105) determines the active counting modes. The first non-zero value stops the cycle if more than one is present.

  • Page 39: Bar Feeder As A Hard Stop

    Programming To machine short bars: When you load short bars on the charging tray, make sure that at least to of the pick arms pick the bar up, or the bar may not load properly. Load bars at least 10" (254 mm) long, or a minimum of 2.25 times the distance from the end of the transfer tray to the start of the liner bore, whichever is longer.

  • Page 40: Macro Variables

    Example 2 Macro Variables Bar Feeder Macro Variables T4.1: Variable Name Description PART LENGTH + CUTOFF Bar feed increment (Length of #3100 bar pushed out with each G105 after the bar is loaded). Finished part length + cutoff length + face cleanup allowance.
  • Page 41 Programming Variable Name Description MIN RETRACT POSITION Adjust this to make sure the #3113 push rod retracts out of the spindle liner after each G105 push. Jog the V Axis until there is a safe gap between the end of the push rod and the spindle liner (approximately 1 inch/25 mm).
  • Page 42 Example 2...

  • Page 43: G-Codes

    G-Codes Chapter 5: G-Codes G105 Servo Bar Command This G-code is used with the Bar Feeder. For complete setup and programming, refer to the Bar Feeder Operator’s Manual. G105 [In.nnnn] [Jn.nnnn] [Kn.nnnn] [Pnnnnn] [Rn.nnnn] I - Optional Initial Push Length (macro variable #3101) Override (variable #3101 if I is not commanded) J - Optional Part Length + Cutoff (macro variable #3100) Override (variable #3100 if J is not commanded)
  • Page 44 G105 Q1 Set Bar Length Used to reset the bar length stored in control. Press [V] on the keyboard, and then [HANDLE JOG] on the control. Use the [HANDLE JOG] control to push the bar up to the reference position set during bar feed position setup. Run G105 Q1 and the current bar length is recalculated.
  • Page 45 G-Codes When executed, a new bar is loaded, measured and pushed through the spindle and halted just before the chuck face. Pushing [RESET] switches the control to V-Axis Handle Jog mode and the user can jog the bar to the Reference Position. G105 Q5 Set EOB Position Used to set end-of-bar switch position, which is used to determine bar lengths.

  • Page 47: Maintenance

    Maintenance Chapter 6: Maintenance Maintenance WARNING: Press [POWER OFF] before you do maintenance or service tasks. To ensure proper operation, the rotation control shaft and push rod require regular lubrication. Lubricate the rotation control shaft approximately once a month (or whenever it is dry), and the push rod during installation (or whenever it is dry).

  • Page 48: Push Rod Removal

    Push Rod Removal To remove the push rod: Power down the machine. Loosen the socket-head clamp screw [1] on the rotation control arm [2]. Remove the (2) socket-head screws from the push rod control bracket [2] on the control arm positioner [3]. Slide the bracket to the right and the push rod [1] to the left until it comes out of the clamp bracket.

  • Page 49: Push Rod Installation

    Maintenance Push Rod Installation To install the push rod: Slide the push rod control bracket [2] over the push rod [1], and slide the push rod into the clamp [3] on the rotation control arm [4]. Attach the push rod control bracket [2] to the control arm positioner [3] with two socket head screws.

  • Page 50: Push Rod Installation Check

    Push Rod installation Check Tighten the clamp screw [1] on the rotation control arm [2]. Press [V] on the keyboard, and then press [HANDLE JOG]. Use the jog handle to move the push rod toward the spindle until it is about 2" (51 mm) from the control bracket.
  • Page 51 Maintenance To determine the value, Press [MDI/DNC]. Key in G105 Q7 ; then press [CYCLE START] to load the push rod. Measure the distance between the end of the push rod and the spindle liner. Subtract a buffer distance 1/2" (13 mm) and enter the remainder in macro variable #3113 on the Bar Feeder Current Commands page.

  • Page 52: Push Rod Adjustment (3/8" Push Rod)

    Push Rod installation Check Push Rod Adjustment (3/8" Push Rod) Adjust the transfer table to between 10° and 15° of elevation. Place a piece of 3/8" stock approximately 1" (25 mm) from the transfer table stop [1]. Lower the push rod arms and install the push rod connector. The push rod connector should be adjusted flush with the bottom of the pusher nose by raising or lowering the set screw [1]in the rod carriage.
  • Page 53 Maintenance Raise or lower the push control bushing assembly [1] to align the push rod parallel with the charging table. Use the hand wheel to jog the push rod up to the back of the spindle, and then realign the Bar Feeder to the spindle. Return the push rod to the home position.

  • Page 54: Push Rod Adjustment (Large Bar)

    Push Rod installation Check Remove the bar hold down bracket from its storage position on the rear of the Bar Feeder. Install the bar hold down bracket. Push Rod Adjustment (Large Bar) To run 3/4" and larger bars: Use the 3/4" push rod. Install a push control 3/4"...

  • Page 55: Bar Feeder Detail Parts List

    Maintenance Bar Feeder Detail Parts List Bar Feeder Detail Parts T6.1: Part Part Number 3/8" Push rod 30-1389 3/4" Push rod 30-0804 Bar Feeder Current Parts T6.2: Part Part Number Push Rod End Clamp 20-1033 Push Rod Control Bushing Holder 3/4” 20-1034 Push Rod Control Bushing Holder 3/8”...
  • Page 56 Push Rod installation Check Part Part Number Spacer 20-1923 Switch Hold Down Assembly 30-1336 Nylon Flange Bearing 3/8" 51-0055 Push Shaft Bushing 3/4" 20-1046...
  • Page 57 Maintenance Bar Feeder Previous Parts T6.3: Part Part Number Push Rod Connector Adapter 20-6483 Push Rod Control Bushing Holder 3/4” 20-6032 Push Rod Control Bushing Holder 3/8” 20-6044...
  • Page 58 Push Rod installation Check...

  • Page 59: Installation

    Because the spindle bore of the ST-30 Big Bore is larger than the maximum bar capacity of the Servo Bar 300, a spindle liner is always required. Refer to diy.haascnc.com for spindle liner kit and installation information.
  • Page 60 ST-10 Bar Feeder Interface Plate To install and remove the plate: Align the interface plate with the liner adapter and the tabs on the coolant collector. Push the interface plate in, then slide it down so the coolant collector tabs lock it in place.

  • Page 61: Bar Feeder Installation

    Installation With the small hole on the flange at the top [1], put the bar tube into the interface plate. The mounting tabs on the tube fit into the slots on the plate. For clarity, inset view [2] illustrates this from the other side of the plate. To remove the interface plate, remove any bar between the lathe and the Bar Feeder, turn the bar tube counter-clockwise to remove the tube, then pull the interface plate up and out of the coolant collector.
  • Page 62 ST-10 Bar Feeder Interface Plate Install the spindle liner adapter kit before you position the Bar Feeder. Refer to the Haas Customer Service Center (diy.haascnc.com) for information on all spindle liner kits, including installation and part reorder information. ST-10/20 Bar Feeder Height Configuration F7.2: ST-30/DS-30 series Bar Feeder Height Configuration F7.3:...

  • Page 63: Uncrating And Assembly

    Installation 7.2.1 Uncrating and Assembly Carefully remove the alignment plate from the charging table, and the accessories from the Bar Feeder and pallet. Remove the four lag bolts holding the base to the pallet and lift the machine off of the pallet.
  • Page 64 Bar Feeder Height Adjustment Sheet metal is cut out around SHCS. Do not remove this screw [1] or the screw F7.4: on the left rear corner leg. NOTE: The studs on the rear of the Bar Feeder hold together the base and rear support bracket.
  • Page 65 Installation properly position the forks. Caution: Damage to the front sheet metal will occur if the forks are inserted too far. Bar Feeder Height Adjustment with a Forklift. [1] SHCS, [2] Mounting Studs. Lift F7.5: with the forks level and even under the bar feed mechanism.
  • Page 66 Bar Feeder Height Adjustment Method 2: Height Adjustment - Lifting Straps To adjust the bar feeder height with lifting straps: Carefully route the lifting straps under the Bar Feeder. Use caution and keep the straps away from the sheet metal edges. Lifting Strap Routing Example F7.6: If you need a third strap for balance, wrap it around the base assembly.
  • Page 67 Installation Method 3: Height Adjustment - Jack Screws NOTE: Jack screws are not shipped with the Bar Feeder. You can contact your dealer to purchase the Haas lifting kit, or purchase jack screws at a local industrial supply house. The bolt dimensions are 3/4 - 10 x 10" long, and the spacer is 5"...
  • Page 68 Bar Feeder Height Adjustment NOTE: The length of the jack screw allows the Bar Feeder to be raised only one position at a time; for example, from the ST/SL-20 to the ST/SL-30 position. In order to raise the Bar Feeder (ST/SL-20) to SL-40 position, you must use an additional spacer.
  • Page 69 Installation Position the height of the Bar Feeder here for SL-30 and TL-25 lathes. SL-30 TL-25...
  • Page 70 Bar Feeder Height Adjustment Position the Bar Feeder as shown in the illustration for SL-40 lathes. SL-40 Position the Bar Feeder as shown in the illustration for the GT-10 and GT-20 lathes. GT-10 GT-20...

  • Page 71: Positioning The Bar Feeder To St/Ds Lathes

    Installation 7.2.3 Positioning the Bar Feeder to ST/DS Lathes ST/DS Lathe Alignment Plate: [1] Bar Feeder side, [2] Lathe Side, F7.8: [3] Big Bore, Gearbox, Extended Push, [4] Lathes with Coolant Collector Extension, [5] Standard Lathes, [6] Bar Feeder, [7] Leveling Screw, [8] Alignment Plate, [9] Leveling Pad ST-10 DS-30 ST-20/30...

  • Page 72: Positioning The Bar Feeder To Sl Lathes

    Positioning the Bar Feeder to SL Lathes 7.2.4 Positioning the Bar Feeder to SL Lathes SL/TL/GT Alignment Plates F7.9: SL / TL / GT Alignment Plate GT-10 GT-20 SL-10 25-1026A 25-6516B SL-10 GT-20 GT-10/SL-10B SL-10/GT -10/GT -20 SL-20/30, TL15/25 25-61 14 Standard Bore SL-40...
  • Page 73 Installation Tighten the left rear leveling screw of the lathe against its leveling pad. Lift the Bar Feeder with a pallet jack or forklift. Align the right side leveling screws to the appropriate holes in the alignment plate. Please make sure to follow the alignment instructions provided in the following illustration.

  • Page 74: End Enclosure Panel

    End Enclosure Panel 7.2.5 End Enclosure Panel The factory-installed end enclosure panel is a hinged piece attached to the right end hinge panel. You can attach the end enclosure panel to the bar feeder door so that they open together for extra clearance. Remove the socket head cap screw (SHCS) that secures the end enclosure panel to the right end hinge panel.

  • Page 75: Parameter Change

    Installation Make sure the door and the end enclosure panel open freely, without any obstruction. 7.2.6 Parameter Change WARNING: Parameters define machine operations in very specific ways. Never change a parameter, except under explicit factory instructions. Incorrectly set parameters can cause severe damage to your machine and void the warranty.
  • Page 76 Parameter Change Repeat steps 3 through 7 for any other parameters that you need to change. Reset [EMERGENCY STOP]. Press [RESET]. Change Setting 7 back to ON. Change Bar Feeder Parameters To change Bar Feeder specific parameters on the Lathe: Power on the lathe, update these parameters and check for alarms.

  • Page 77: Bar Feeder Leveling

    Installation The following Parameters are written on a decal at the left end of the Bar Feeder. Enter these values into the lathe control at set-up. Parameters on Bar Feeder Decal T7.2: PARAMETER NAME VALUE V Max Travel (52267232 to 5332768) Grid Offset (+/- 32000) V Tool Change Offset...

  • Page 78: Verify Alignment

    Verify Alignment 7.2.8 Verify Alignment To verify bar feeder alignment: Install a 1 inch liner and push by hand at least a 3 ft bar stock to ensure there is no binding through the liner. Hand jog the push rod. Make sure that the push rod does not interfere with the rear of the spindle or liner.
  • Page 79 Installation Raise the charging tray to its highest position. Remove the storage tray to access the bar feeder bracket and cable routing.
  • Page 80 Cable Routing Feed cable P/N 32-1579A through the opening in the lathe side of the Bar Feeder and down through the alignment plate trough. Do not route cables over the side of the Bar Feeder. This will result in pinched or broken cables.

  • Page 81: Interface Installation

    Installation For Y-Axis lathes, connect the Bar Feeder signal cable to (P6) on the Maincon board II. Connect the BF MOTOR AMP end of cable P/N 32-1579A to the amp and ground. Plug one end of cable P/N 33-0610 into the amp Servo Drive Current Commands port.

  • Page 82: Establish End-Of-Bar Position

    Establish End-of-Bar Position Remove the cable channel covers. Attach the jumpers between the High Voltage Power connection of the closest amp and Bar Feeder amp. 7.2.11 Establish End-of-Bar Position To establish the end-of-bar position: Place the 12" gauge bar supplied with the machine in the charging tray. To load the bar properly, make sure the bar is picked up by at least two of the pick arms.

  • Page 83: Index

    ........end-of-bar position ......extended push function operation ........introduction ......... Haas Servo Bar 300 hard stop ........parameters bar feeder as ....changing bar feeder values height adjustment ................changing values forklift ........
  • Page 84 recommendations ......drawtube cover plate ..........general ........ hexagonal stock ........recover a bar feed reference positions ..........setup safety ......modes of operation ......read before operating ........warning labels ........sample programs ........example 1 ........example 2 ..........

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