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G
r
eneral
equirements
Operating Temperature Range
Storage Temperature Range
Ambient Humidity: 20% – 95% relative humidity, non-condensing
Altitude: 0-7000 ft.
e
r
lectricity
equirements
IMPORTANT! REFER TO LOCAL CODE REQUIREMENTS BEFORE WIRING MACHINES.
ALL MACHINES REQUIRE:
Three phase 50 or 60Hz power supply.
Line voltage that does not fluctuate more than +/-5%
40-30 HP System
Power Supply
Haas Circuit Breaker
If service run from elec.panel
is less than 100' use:
If service run from elec. panel
is more than 100' use:
TSC-1000 Machines: Refer to the TSC-1000 installation procedure in this document for electrical require-
ments.
WARNING!
A separate earth ground wire of the same conductor size as the input power is required to be connected to
the chassis of the machine. This ground wire is required for operator safety and for proper operation. This
ground must be supplied from the main plant ground at the service entrance, and should be routed in the
same conduit as the input power to the machine. A local cold water pipe, or ground rod adjacent to the ma-
chine cannot be used for this purpose.
Input power to the machine must be grounded. For wye power, the neutral must be grounded. For delta
power, a central leg ground or one leg ground should be used. The machine will not function properly on
ungrounded power.
The rated horsepower of the machine may not be achieved if the imbalance of the incoming voltage is beyond
an acceptable limit. The machine may function properly, yet may not deliver the advertised power. This is
noticed more often when using phase converters. A phase converter should only be used if all other methods
cannot be used.
The maximum voltage leg-to-leg or leg-to-ground should not exceed 260 volts.
The high voltage requirements shown reflect the Internal 400V option which is available only in Europe. Do-
mestic and all other users must use the External 480V option.
The current requirements shown in the table reflect the circuit breaker size internal to the machine. This
breaker has an extremely slow trip time. It may be necessary to size the external service breaker up by 20-
25%, as indicated by "power supply", for proper operation.
HS-3/4/6/7 VS-1/3
INSTALLATION INSTRUCTIONS
41°F to 104°F (5 to 40°C)
-4°F to 158°F (-20 to 70°C)
Voltage Requirements
(195-260V)
125 AMP
100 AMP
2 GA. WIRE
0 GA. WIRE
ES0755 rev A
1/11
1

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Summary of Contents for Haas HS-4

  • Page 1 HS-3/4/6/7 VS-1/3 INSTALLATION INSTRUCTIONS eneral equirements Operating Temperature Range 41°F to 104°F (5 to 40°C) Storage Temperature Range -4°F to 158°F (-20 to 70°C) Ambient Humidity: 20% – 95% relative humidity, non-condensing Altitude: 0-7000 ft. lectricity equirements IMPORTANT! REFER TO LOCAL CODE REQUIREMENTS BEFORE WIRING MACHINES.
  • Page 2 equirements The VMC requires a minimum of 100 PSI at 4 scfm at the input to the pressure regulator on the back of the machine. This should be supplied by at least a two horsepower compressor, with a minimum 20-gallon tank, that turns on when the pressure drops to 100 PSI.
  • Page 3 while in use. The anchoring bolts (in accordance with the anchoring instructions) should be installed prior to the machine being set in place. The X-axis auger trough must be removed before mating the column base to the table base. The auger trough will remain off the table base until the leveling and squaring procedures are completed.
  • Page 4 mating surfaces. Prepare the column base for mating • Stone and clean thoroughly the mating flange surface. This is an extremely important step that must be well and properly done before the bases are moved into position with respect to each other. (Failure to properly prepare the surfaces and preserve their cleanliness may require separation of the main components for corrective action).
  • Page 5 Main Switch Take sufficient time to check all the components and connectors associated with the circuit boards. With the power off, push on them gently to make sure that they are seated in their sock- ets. Look for any cables that have become disconnected, look for any signs of damage and loose parts in the bottom of the panel box.
  • Page 6 CAUTION! NEVER push down on the primer handle! It gradually returns to the down position by itself, and the corresponding pressure increase can be seen on the pressure gauge. NOTE: Depending on the position of the cam that drives it, the lubrication system may not activate until a few minutes after the machine is started.
  • Page 7 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 Elec- trical Code specifies that machines should operate with a variation of +5% to -5% around an average supply voltage.
  • Page 8 T5Transf o rmer Mai n Ci r cui t HI G HVOLT LOWVOLT Breaker HI G HVOLT 488- 4 58V 457- 4 29V 428- 4 03V 402- 3 77V 376- 3 54V WARNING! Through the Spindle Coolant (TSC) pump is a three phase pump and must be phased correctly! Im- proper phasing will cause damage to the TSC pump and void the warranty.
  • Page 9: Installation

    10. Remove the key from the control cabinet and give it to the shop manager. 480v 60h nstallation rocedure for xternal ransformer Introduction The external transformer adds to overall machine reliability and performance, however it does require extra wiring and a place to locate it. The external transformer provides electrostatically shielded isolation. This type of transformer acts to isolate all common mode line transients and improve EMI conducted emissions.
  • Page 10 Place the flat washer on the rod and thread both nuts onto the end of the rod. Before jamming the nuts together, be certain they are both high enough to allow the insertion of the cotter pin into the hole on the end of the cylinder rod. When the nuts are in place, jam the nuts together. Insert the cotter pin into the hole on the end of the rod.
  • Page 11 Column Axis Ballscrew Cover Remove the cover from around the colum axis ballscrew. There are two parts to the cover, a long section above the ballnut and a short section below the ballnut. Be certain to completely remove the cover from the ballscrew to prevent contamination after the column axis is later enabled.
  • Page 12 X-axis motor cable is disconnected at the control. Linear Scale Cable, Limit Switch and Disconnect at Lube Line Junction Interpolation box a) Route the X-axis motor and encoder cable and connect. b) If this is a machine with a rotary axis, route the A-axis motor, home switch, and rotary encoder cables.
  • Page 13 Remove the two shipping blocks and hardware completely from the column base. Raise the spindle head to the full up position and support the bellows. While ensuring the lower bellows do not fall, handle jog (without zero return) the Z-axis (HS) / Y-axis (VS) toward the rear of the machine until access to the bolts holding the forward shipping blocks are accessible.
  • Page 14 • The table base will be leveled to earth • The column base will be leveled to earth • The X-Y axes will be checked for perpendicularity • The table will be swept for parallel to the X-Y plane of the machine •...
  • Page 15 evelinG the olumn Check that the mating flange screws are still free to turn so the following steps do not affect the level of the table base primary datum. Allow only the four leveling screws on the corners on the column base are to be in contact with the leveling pads at this time.
  • Page 16 / z-a weePinG the Before continuing to the final attachment of the column base to the table base the Y-axis (VS) / Z-axis (HS) needs to be swept. Until now we have assumed that the geometry of the column is perfectly perpendicular to the plane of the column base, but that may not be close enough to maintain the required machine geometry.
  • Page 17 be within tolerance, there almost certainly is contamination or damage between the mating flange surfaces that is creating this error. The unit will have to be completely separated, the surfaces re-stoned and recleaned thoroughly, and the entire leveling/squaring process will have to be repeated up to this point.
  • Page 18 level. When the end of travel is reached, the leveling screws on the end of the table base can be slightly adjusted. Return the table to the center of travel. Verify that earth level still applies to the table at that posi- tion.
  • Page 19 Trough Cable (To X-Axis Auger Motor) Cable X-Axis Auger Trough condition exists, please contact Haas factory service. hanGer nstallation liGnment Installing the Hydraulic Power Unit (HPU) Before placing the Tool Changer, position the HPU behind the machine. This must be done before the tool changer is installed, otherwise there may not be room to maneuver the HPU between the tool changer and any obstacles.
  • Page 20 4. Connect the power cord from the hydraulic power unit’s motor to the power connection located on the side of the milling machine’s control box. 5. Check the rotation direction of the hydraulic power unit motor using the following procedure: a.
  • Page 21 Attach the alignment bracket to the base of the tool changer using three M16 X 60mm metric socket head cap screws (Haas P/N 40-0039). Install, but do not tighten screws at this time. In addition, it may be necessary to move the tool changer’s base plate a small amount to bring the alignment bracket into its proper position.
  • Page 22 8. Next, thread the four intermediate leveling bolts (four bolts with 30mm hex heads located near the center of each side of the base plate) down until they just touch the leveling blocks. Further tighten bolts approximately another 1/8 turn past this point to insure these screws are each sharing some portions of the load. 9.
  • Page 23 position press <A> to go to the control screen for the tool changer’s arm functions. The next screen states: Hydraulic tool changer bump arm Using arrow keys attempt to move the arm into its home position Pressing the cursor keys will move the tool changer’s arm and carriage. NOTE: The tool changer arm and carriage assembly will ‘jerk’...
  • Page 24 Key Tab Dowel Pin Taper Key Tab Alignment Alignment Jig 9. Press PAGE DOWN until the tool changer is back to the stow position. Using the alignment jig dowel pin, push the top half of the jig into the double arm fingers. Insure that it is inserted properly and that the flat side faces the spindle.
  • Page 25 NOTE: These Parameter numbers are entered without a decimal point and must be the same sign as that given on the POS-RAW DAT screen. For example, -0.7094 would be entered as -7094 and -278.8854 would be entered as -2788854. 9. Go to Parameter #64, Z Tool Change Offset, on the “Z PARAM B” screen. Enter the number (with the correct sign) recorded from the POS-RAW DAT screen for the Z-axis and press the WRITE/ENTER button.
  • Page 26 The carousel speed and the arm’s pull-in/push-out speed are directly controlled by the flow rate of the hydrau- lic pump. Thus, increasing the flow rate will increase the speed of these functions and conversely decreas- ing the flow rate will decrease their speed. The speed of the other six functions are controlled by flow control valves located on the tool changer’s valve manifold.
  • Page 27 1. With no tool in the machine, command a tool change. Press Emergency Stop before the double arm reaches the spindle. This will cause the mill to move the Y and Z axes to the ATC position. 2. Verify the spindle is free to rotate without hitting the double arm. If necessary, use the T/C Recovery commands to move the arm further from the spindle.
  • Page 28 15. Using a caliper, measure between the same two surfaces described in Step 13. The measurement should be the same, +/-.010” (.254 mm). Be sure that you are measuring the distance between the double arm and the tool holder, not the spring-loaded slide and the tool holder. If adjustment is required, refer to “Setting Parameter 64”...
  • Page 29 oolant ystem nstallation oolant eParator The coolant separator is mounted in its shipping position. Remove the two screws and remount the coolant separator in the lower mounting location. Do this for both of the coolant separators. Cable Coolant Separator Trough Operating Position Coolant Pump, coolant level sensor...
  • Page 30: Maintenance

    Coolant Level Sensor 55 Gallon tank shown 4. Connect the cable to the Coolant Level Gauge plug located on the bulkhead at the back of the X-axis table. Remove the cover from the RJ-12 style connector, plug in coolant level sensor cable, and replace cover. 5.
  • Page 31 NOTE: On a machine with a safety circuit, the chip auger will only run with the door closed regardless of the Conveyor Door Override bit. (tsc) s hrouGh the Pindle oolant ystem Warning! The TSC pump is three phase and must be phased correctly! Improper phasing will damage the TSC pump and void the warranty.
  • Page 32 Standard From TSC Pump Spindle Filter Pump (1) Head Gate Filter To TSC Filter Pump To TSC Pump (2) Gate Filter Standard Filtration Setup 2. Connect the hose attached to the spindle head to the hose connection on the Standard Coolant Pump. 3.
  • Page 33 240-230V 50/60HZ @ 20A or 480V 50/60HZ @ 10A To power the pump assembly from an alternate source, first replace the plug at the end of the cable with an appropriate plug for the voltage being used. Then, rewire the pump motor according to the directions on the side of the motor.
  • Page 34 NOTE: When inserting the pendant pivot into the pendant pivot block, make sure the pendant arm is perpendicular to the table, as shown in the figure below. Pivot Block Top Cover Pendant Pivot Block Table Cable Trough Place the table cable trough on the floor. Arrange the pendant wiring through the pendant pivot block and into the trough.
  • Page 35 Trough Extension w/Covers Table Cable Trough endant evelinG The pendant leveling feature allows the angle of the pendant to be adjusted during installation. 1. Rotate the pendant to the position in the following figure for proper leveling. Loosen These Two Screws, Leveling Screw Leveling Before Adjusting Leveling...
  • Page 36 will be used for all spindle types and RPM’s. Adjust spindle speed override depending on maximum spindle speed of machine: Set override 50% for 5,000 RPM machines; Set at 100% for 7,500 and 10,000 RPM ma- chines; Set at 150% for 15,000 RPM machines. For machies equipped with a 50 taper spindle, run spindle speed override at 50%.