Haas VMC Manual

Introduction

This procedure will guide you through the installation of a VMC

Tools required:

• Precision Machinist Level, 0.0005" Division
• Precision Spindle Test Bar, 8" Long
• 3/4 " socket and ratchet
• 1-1/2" Wrench
• Tape Measure
• 0.0005" or 1 micron indicator
• For 110V machines: 110V Electrical receptacle tester with GFCI diagnosis
• For 240V machines: 240V Electrical receptacle tester with GFCI diagnosis

Leveling Screws Hardware

Note: The washers [1] and nuts [2] are installed during shipping and should be saved for installation and not be discarded.
Note: The washer orientation [3] is important. The conical part of the washer should be against the casting, see illustration.

Removal of Rust Inhibitor

For ease of removal, first use a plastic scraper to remove most of the rust inhibitor and then use WD-40 or another PH neutral degreaser to spray all the way covers and other non-painted surfaces that have been coated with rust inhibitor. Let it soak for a few minutes before removing it. Then use shop towels to remove it. For thick applications of rust inhibitor use a plastic scraper to remove it.
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Do not use scotch-brite or metal scrapers, these will scratch the way covers. Furthermore, to avoid any contamination of the way cover seals with the sticky residue. Do not move any of the axes until all the rust inhibitor has been removed.

Air Connection

Connect the air supply at the lube panel.

Note: For air requirements refer to the decal that is located on the lube cabinet door.

Electrical Connections

WORKING WITH ELECTRICAL SERVICES REQUIRED FOR A CNC ARE EXTREMELY HAZARDOUS. ALL POWER TO CNC MUST BE TURNED OFF LOCKOUT-TAGOUT AT THE SOURCE PRIOR TO CONNECTING THE LINE WIRES TO CNC. HOWEVER, IF THIS NOT THE CASE OR ARE NOT SURE HOW TO DO THIS, CHECK WITH APPROPIATE PERSONNEL OR OBTAIN THE NECESSARY HELP BEFORE CONTINUING. ALWAYS CHECK THE INCOMING LINES WITH AN AC VOLTAGE DETECTOR TO MAKE SURE POWER HAS BEEN DISCONNECTED.

1. Initial Control Inspection
   
   At this point, there should be no electrical connection to the machine. Electrical panel must be closed and secured. When main switch is on, there is HIGH VOLTAGE throughout the electrical panel (including the circuit boards and logic circuits) and some components operate at high temperatures. Therefore, exercise extreme caution when working in the panel.
   • Set the main breaker switch at the upper right of the electrical panel on the back of the machine to OFF.
   • Using a screwdriver, unlock the two latches on the panel door, unlock the cabinet with the key and open the door.
   • Take sufficient time to check all the components and connectors associated with the circuit boards. Look for any cables that have become disconnected, look for any signs damage and loose parts in the bottom of the panel box. If there are any signs that the machine was mishandled, call the factory before proceeding.
2. 1-Phase Machines: Insert each power lead into the wire cover. Connect the two power leads to L1 and L3 terminals on top of the main circuit breaker.
   3-Phase Machines: Insert each power lead into the wire cover. Connect the three power leads to L1, L2 and L3 terminals on top of the main circuit breaker.
   Connect the separate ground line to the ground bus to the left of the terminals.
   
   Note: Make sure that the leads actually go into the terminal-block clamps. (A poor connection will cause the machine to run intermittently or have other problems, such as servo overloads.) To check, simply pull on the wires after the screws are tightened.
3. After the line voltage is connected to the machine, make sure that main circuit breaker (at top-right of rear cabinet) is OFF. Remove the Lockout / Tagout and Turn ON the power at the source. Using a digital voltmeter and appropriate safety procedures:
   1-Phase Machines: Measure the AC voltage across L1 & L3 at the main circuit breaker. The AC voltage must be between 220 - 250 volts.
   Note: Lower or higher than this voltage can generate low/high voltage alarms.
   3-Phase Machines: Measure the AC voltage between all three pair phases at the main circuit breaker. The AC voltage must be between 195 and 260 volts (360 and 480 volts for high voltage option).
   Note: Wide voltage fluctuations are common in many industrial areas; minimum and maximum voltage supplied to a machine while it is in operation must be known. 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 line voltage occur, or low line voltage is suspected, an external transformer may be used. If you suspect voltage problems, voltage should be checked every hour or two during a typical day to be sure it does not fluctuate more than +5% or -5% from an average.
   
4. 
   With the main circuit breaker turned OFF.
   Check the transformer taps at the bottom-right corner of the rear cabinet.
   1-Phase Machines: The input voltage cable must be moved to the connector which corresponds to the average voltage measured in the above step.
   3-Phase Machines: The input voltage cables labeled 74, 75, and 76 must be moved to the terminal block triple which corresponds to the average voltage measured in the above step.
   
5. Transformer T5 supplies 24VAC used to power the main contactor. There are two versions of this transformer for use on a 240 and 400V machines. The 240V transformer has two input connectors located about two inches from the transformer, which allow it to be connected to either 180-220V or 221-240V. Users that have 220V240V RMS input power should use the connector labeled 221-240V, while users with 190-220V input power should use the connector labeled 180-220V. Failure to use the correct input connector will result in either overheating of the main contactor or failure to reliably engage the main contactor.
   The 480V (option) T5 transformer has three input connectors, labeled 340-380V, 381-440V and 441-480V. Users with 340-380V 50Hz power should use the 340-380V connector while users with 380V-440V 50Hz power should use the 381-440V connector.
   
   Set the main circuit breaker to ON. Check for evidence of problems, such as the smell of overheating components or smoke. If such problems are indicated, immediately set the main circuit breaker to OFF and call the factory before proceeding.
   After the power is on, measure the voltage across the bottom terminals on the main circuit breaker. It should be the same as the measurements where the input power connects to the main breaker. If there are any problems, check the wiring.
   
6. Apply power to the control by pressing the Power-On switch on the front panel.
   Check the DC Voltage and AC Line Voltage gauges in Diagnostics. The DC Voltage gauge must read between 310 - 360V. The AC Line Voltage must be between 90 and 105 percent. If the voltage is outside these limits, turn off the power and recheck steps 2 and 3. If the voltage is still outside these limits, call the factory.
   
7. Electrical power must be phased properly to avoid damage to your equipment. The Power Supply Assembly PC board incorporates a "Phase Detect" circuit with neon indicators. When the orange neon is lit (NE5), the phasing is incorrect. If the green neon is lit (NE6), the phasing is correct. If both neon indicators are lit, you have a loose wire; check the connections. Adjust phasing by setting the source power to off and then swapping L1 and L2 of the incoming power lines at the main circuit breaker.
   
   ALL POWER TO CNC MUST BE TURNED OFF LOCKOUT-TAGOUT AT THE SOURCE PRIOR TO ADJUSTING PHASING. ALWAYS DOUBLE CHECK THE INCOMING LINES WITH AN AC VOLTAGE DETECTOR.
   Turn off the power and set the main circuit breaker to OFF. Close the door, lock the latches, and turn the power back on.
   Remove the key from the control cabinet and give it to the shop manager.
8. Activation
   When the machine is properly placed and connected to both air and electrical power, it is ready for final installation (removing shipping blocks, leveling, spindle sweep, etc.) and software activation. The HFO service technician does this. Contact the local HFO to schedule the work.

Removal of Shipping Brackets

1. • Remove the zip tie holding the chip auger in place and remove the auger [1]
   • Remove the cardboard tubing used to protect the auger. [2]
   • Remove the bracket and cardboard protecting the cable guide on top of the machine [3,4]

Note: For large VMCs There is no bracket removal needed only cardboard removal.

2. • Remove the Shipping brackets keeping the doors in place. [5,6,7,8]
   • Now that you have access, install the chip auger.

For a guide on chip auger installation please see: VF 1-5 CHIP AUGER INSTALLATION

3. • Power up the machine and jog the Z-axis upward
   • Remove the spindle bracket. [9]

Additional option brackets

• If you purchased a machine with the Wireless Intuitive Probing System (WIPS) remove the bracket attached to the table [10]
• If you purchased a machine with a Multi-Auger Chip Conveyor Remove the Shipping brackets holding it in a its vertical position [11]

Machine Leveling

1. • Adjust the four corner leveling screws to the same height to lift the base casting 3-1/2" from the ground.
   • Loosen the middle leveling screws [3, 6] so that they are not touching the pads, install jam nuts [1] on leveling screws, but do not tighten
   • Jog the table so that it is centered in the machine.
2. • Place the level on the center of the bed and position it so that the shorter vial is parallel to the Y-axis and the longer vial is parallel to the X-axis.
   • Using the shorter vial adjust the front to back level by either adjusting the front or back leveling screws.
   • Adjust the leveling screws until the Y-axis bubble is centered.
   • Using the longer vial which is parallel to the X-axis, raise the leveling screws on lower side of the machine.
   • Adjust the leveling screws accordingly until the X-axis bubble is centered
3. • Continue using the longer vial, with the table at the front of the machine look at the position of the indicating bubble
   • Jog the table through its full Y-axis travel stopping at the column, with the table at the column look to see which rear corner of the machine is lowest if any.
   • If needed adjust the leveling screws 2 and 4 until there is no twist across Y axis
   • Continue adjusting the level at the front and back of the machine until both readings are zero.
   • Lower the center leveling screws 3 and 6 until they make contact with the pads. Tighten these hand tight and then tighten them an additional 10 degrees with the ratchet.
4. • Place the level in the center of the bed and orient it so the long vial is parallel to the Y-axis
   • Look at the bubble position when the bed is at its center position and then jog the bed back in the Y direction until it reaches the column.
   • Take note of the bubble position, if the level shows that the machine is either bowed in the up or down direction, make small and even adjustments to middle leveling screws 3 and 6
   • The Tolerance for both the twist and bow is N.T.E 0.0002"/10"

For a more in depth guide on how to level your VMC including how to level machines with outriggers please see: VMC LEVELING

Spindle Sweep

Tools Required:

• Test Indicator with a magnetic mount.
• pH-neutral cleaner
• Degreaser
• Abrasive pad
• Gauge Block (optional)

1. • Clean the table surface to remove any corrosion
   • Jog the spindle down to the middle of the z-axis travel and attach the magnetic base to the spindle
   • Adjust the indicator to measure a 10" diameter circle
   • Position the table so that the indicator will remain on the table as the spindle rotates
   • Move the Z-axis so that the indicator makes contact with the table and zero the indicator
   • Sweep the spindle and take measurements every 90 degrees. Make sure the measurement locations are parallel to their respective axis
   • The total indicator for all four positions should not exceed 0.0005"
2. Spindle Sweep Adjustment
   
   Note: Only the front and back sweep values can be effectively changed by adjustment of the middle leveling screws
   • If the values from the front to back differ by more than 0.0005", make small and equal adjustments to the middle leveling screws.
   • If the spindle sweep values come back into tolerance with only small adjustments to the leveling screws then there is no need to recheck the twist and bow.

For a more in depth guide on how to perform a spindle sweep test on your VMC please see: VMC SPINDLE SWEEP

Lubrication Verification

1. • Run the spindle run-in program.
   • Examine the sight glass, make sure the correct number of drops are fall through the sight glass.
   • Examine the fittings [1,2] on top of the oil pump tank.
   • The oil collects on top of the oil pump tank [3] either behind or in front of the sight glass bracket, underneath the leaking fitting.
   • Tighten any leaking fittings.
2. Go to the Maintenance tab.
   Press [F2] to cycle an axis lubrication test.
   Inspect the gauge on the grease lubrication system. Make sure it holds pressure.

Pendant Installation

After removing the pendant from its packaging you can now install it on your machine. For a pendant installation guide please see: VMC PENDANT INSTALLATION

Option Installation Guides

Verify and test that all the options have been properly installed.
REMOTE JOG HANDLE (RJH-TOUCH)- INSTALLATION
WI-FI CAMERA OPTION INSTALLATION
VMC CONVENIENCE PACKAGE
AUXILARY COOLANT FILTER
CABCOOL INSTALLATION
PULSEJET INSTALLATION
HAAS OIL SKIMMER
TABLE WORK LIGHT
AUTO AIR GUN
TOOL AIR BLAST

1. Test Spindle Operation
   
   • Run Spindle Run in program 009221 located in the 009000 folder.
   • In the case of unusual spindle noise run a vibration test

For a guide on how to perform a spindle vibration test please see:
VIBRATION ANALYSIS - ETHERNET INTERFACE
VIBRATION ANALYSIS - RS-232 INTERFACE

2. Test Coolant Operation
   
   • Connect the Coolant pump and if your machine is came with the TSC option also connect the TSC pump
   • Test the flood coolant operation by pressing the [Coolant] button on the control [1]
   • For TSC machines test the TSC coolant operation by pressing the [AUX CLNT] button on the control [2]
3. Test Chip Auger Operation
   
   Test the chip auger by cycling between the [CHIP FWD], [CHIP STOP], and [CHIP REV] buttons
   
4. Test Remote Jog Handle (RJH-Touch)
   If your machine came with the remote jog handle option:
   • Attach the holster to the machine using the provided hardware
   • Hang RJH on holster
   • On the Control Pendant, press [MDI] and then[HAND JOG]. (Image 2)
   • Verify that the jog wheel on the Control Pendant works properly while RJH is docked
   • Remove RJH HAND UNIT from the holster. Unit should power on
   • Calibrate Touchscreen
   • Refer to Image 1 for the following
     • Press in the middle of the touch screen, an overlay should appear
     • Select the jog rate by pressing [LEFT] or[RIGHT] on the screen
     • Select an axis by pressing [-] or [+] on the screen
     • Exit the overlay by pressing the [X]
     • Jog X, Y, and Z with the jog wheel on the RJH
   • Use RJH key pad to jog X,Y, and Z axes in positive and negative directions
   • Repeat using Rapid Jog
5. Test Door Interlocks
   
   • Press [MDI]. Type in S500 M3; Press[ENTER]. Make sure the machine IS NOT in SETUP MODE by Checking the KEY SWITCH on the side of the pendant
     • With the door open, press [CYCLE START]. The machine should say to close the door and press CYCLE START
     • With the door closed, press [CYCLE START]. The INTERLOCK PIN should extend and the spindle starts rotating
       • While the locks are on try to open the doors
       • The spindle should not stop rotating but if the spindle stops, contact Haas for support
6. Test Through Spindle Air Blast (TAB)
   
   If your machine came with the TAB option:
   Note: PERFORM THIS AFTER TESTING TSC
   • Press [MDI] and type the following
     • M73;
     • S[insert max spindle speed here] M03;
     • G04 P60.;
     • M30.;
   • Press [CYCLE START]
   • Verify that full air line pressure blows out of the tool.
     • This should be similar to the air blow gun pressure.
7. Test Auto Air Gun (AAG)
   
   If your machine came with the AAG option:
   • Press [MDI] and type M83; and press [Enter]
   • Press [CYCLE START]
   • Check AAG for proper function, check solenoid for leaks in the CALM cabinet. In [MDI] type M84; then press [CYCLE START] to de-activate the AAG.
8. Test Auto Door
   
   If your machine came with the Auto Door option:
   • Verify the following:
     • Zero return U-axis
     • Setting - 131 auto door should be set to ON
   • Press [MDI] and type S300 M03; and press [CYCLE START]
   • Try to pull door open, The door gap is not to exceed 0.25".
   • If the machine alarms out, does not close properly, closes hard, or the door gap exceeds 0.25" contact Haas for support
9. Z-axis tool change offset parameter
   
   For a guide on how to check the Z-axis tool change offset parameter for either side mount tool changers or umbrella style tool changers please see:
   SMTC - Z-AXIS TOOL CHANGE OFFSET
   UTC- Z-AXIS TOOL CHANGE OFFSET
10. WIPS Calibration
    
    • If your machine includes the WIPS option perform the calibration procedure

For a guide on how to perform the WIPS calibration procedure please see: WIPS CALIBRATION NGC

11. Test Safety Features
    
    • Turn the (Run / Set-up) key switch to the Set-up mode
    • Test Memory Lock switch by verifying that in the ON position changes cannot be made to settings or programs.
    • Press [MDI] and type M03 S500;
    • Open door. Press [CYCLE START] the spindle should not start.
    • Close door. Press [CYCLE START] the spindle should start. Verify door cannot be opened when spindle is running Verify door can open when spindle is off.
    • Verify that a window latch is installed on each side window and test that they hold the windows up in their lock positions
    • Verify that the windows lock close in the down position.
    • For 110V machines conduct a GFCI Test with a 110V GFCI tester at the plug point on the side of the control
    • For 240V machines conduct a GFCI test with a 240V GFCI tester at the coolant pump connector