13.1. DC-Series - Spindle Chiller Operation

Introduction

The DC-1 comes with a spindle chiller unit located next to the control on the back of the machine. This spindle chiller helps regulate the temperature of the spindle. This section provides operation information specific to the spindle chiller.

View Parameters

The spindle chiller is automatically powered on when the spindle is operated, or when a tool change occurs. The power button on the front of the spindle chiller does not need to be changed.

The spindle chiller uses a parameter based system to determine how much cooling needs to be done. These parameters are set in the factory and should not be altered. If the Haas control is showing alarm 9003 - Low Spindle Coolant Chiller Oil Flow then refer to the troubleshooting section of this chapter before altering parameter values.

1

To view the parameter values on the spindle chiller, follow these steps:

  1. Press and hold the [UP] arrow [1] on the chiller control.
  2. Press and hold the [SET] button [2] while still holding the up arrow. There needs to be about a half second delay between pressing the [UP] arrow and the [SET] button in order to access the parameters.
  3. Hold these buttons until the display on the chiller shows a "0". Press the arrow keys untill the display shows "8" [3] as shown in the top image and then press the [SET] button to navigate into the parameters page.
  4. Once in the parameters page, you can press the arrow keys to navigate to diferent paramters. Each parameter has a value that can be accessed by pressing the [SET] button.

2

This image shows and example of accessing parameters and setting the values. 

After entering the parameters page and navigating to F9 using the arrow keys, press the [SET] button [1] to view the current parameter value. The value will appear on the display [2] and the value can be changed using the arrows. To set the new value press the [SET] button [3] again.

Note: Parameter values should not be changed from their factory set values. The parameter F9 should be set to 20 degrees celsius.

Note: Parameters are labeled F0-F9. Refer to the table below for an explanation of the parameters.

Parameter Functions

This table lists the parameters that can be accessed as well as their function and factory set value.

Important: These parameters should not be altered from the factory set point. This table is provided for troubleshooting information to return the spindle chiller to its factory condition.

Parameter Name Function Value Set in Factory
F0 Sets the temperature that the spindle chiller will try to keep the fluid at 25.0 Celsius
F1 Sets the allowed difference between the chiller fluid temperature and the ambient temperature 0.0 Celsius
F2 Sets the allowed temperature difference between the fluid going to spindle vs. fluid returning from spindle 3.0 Celsius
F3 Sets the method of temperature control 0
F4 Sets the temperature threshold above the set point for the low temperature alarm 20.0 Celsius
F5 Sets the temperature threshold above the set point for the high temperature alarm 15.0 Celsius
F6 Sets the temperature threshold for the high ambient temperature alarm 45.0 Celsius
F7 Password value 8
F8 Sets the maximum allowed chiller fluid temperature 30.0 Celsius
F9 Sets the minimum allowed chiller fluid temperature 20.0 Celsius

13.2. DC-Series - Spindle Chiller Maintenance

Introduction

This section provides details about the maintenance required for the DC-1 spindle chiller. This information can also be found in the DC-1 - Maintenance chapter of this manual.

Spindle Chiller 
Maintenance Item Interval
Inspect Fluid Tank Level.
 Daily
Fill Fluid Tank. As Required
Clean Air Inlet Filter.
 Weekly
Inspect/Clean Air Outlets.
 Weekly

DC-Series Spindle Chiller Maintenance

1

This image shows the key components of the Spindle Chiller:

Front of Chiller:

  • Temperature Control
  • Flow Indicators
  • Air Inlet Filter

Back of Chiller:

  • Fluid Tank Inlet
  • Alarm Terminal
  • Cooling Inlet/Outlet
  • Fluid Level Gauge
  • Air Outlets

2

Inspect the fluid tank level by looking at the fluid level gauge located on the back of the spindle chiller [2]. To add fluid to the tank, remove the cap to the inlet at the top of the unit, and fill the tank with a mixture of 30% ethylene glycol and 70% dionized water until the gauge reads the level is at the top of the NORMAL [3] or at the FULL level.

3

To clean the air inlet filter, remove the grate to gain access to the filter unit. From there, remove the filter screen so that any dust or debris can be picked out of the filter. If necessary, wash the filter using water to get rid of contaminants. 

4

Make sure that the air outlets are clear of dust and debris. It is also recommended to allow a clear area of 12 inches directly behind the air outlet vents. This will allow for proper air circulation in the system.

13.3. DC-Series - Spindle Chiller Troubleshooting

Introduction

This section provides troubleshooting information regarding the DC-1 spindle chiller. There are details about how to troubleshoot flow alarms.

DC Spindle Chiller - Symptom Table

If the spindle chiller is not working properly, the Haas control will show alarm 9003 - Low Spindle Coolant Chiller Oil Flow. This alarm is generated as a result of several possible symptoms. See the symptom table below for symptoms and recommended troubleshooting. 

This symptom table also includes potential alarm codes that could appear on the spindle chiller display. These are ambient and fluid temperature alarms.

Important: Changing parameter values should only be done in extreme cases. Make sure to perform all other troubleshooting and maintenance to try and clear the spindle chiller alarms.

Symptom Possible Cause Solution
Alarm 9003 is active on Haas Control. The flow alarm indicator on the front of the spindle chiller is on. (Red LED is on)  There is something blocking the circulation of chiller fluid. There is something blocking the chiller fluid from returning to the spindle chiller. Make sure that there are no leaks coming from the fittings on the back of the spindle chiller. Check underneath the spindle head cover sheet metal and verify that there is no leaks coming from the fittings on the spindle head casting for the spindle chiller.
There is a low amount of chiller fluid in the spindle chiller tank.  Make sure that there is no leaks coming from the chiller unit, or from the fluid lines that deliver chiller fluid to the spindle. After fixing any leaks that caused the chiller fluid level to drop, fill the tank with a mixture of 30% Dowfrost and 70% deionized water. Refer to the maintenance section on the DC-Series spindle chiller for more information on how to fill the tank.
The pump is not working properly.  Replace the spindle chiller pump. 
The flow sensor is faulty and not functioning. Check to make sure that there is circulation in the spindle chiller fluid lines. If there is flow in the lines, you can hold the fluid lines and feel the vibrations caused by the fluid flow. If you can detect flow, but the alarm indicator is on, replace the flow sensor.
Alarm 9003 is active on Haas Control, but the normal flow indicator on the front of the spindle chiller is on. (Green LED is on) The alarm signal cable could be damaged or not functioning. Inspect the spindle chiller alarm cable. Check for damage on both connectors and for damage along the length of the cable. If no damage can be seen on the cable remove the alarm cable from the spindle chiller unit. Use a voltmeter to check for continuity between pins H1 and H3 of the alarm connector. If there is continuity, then there are no alarms coming from the spindle chiller unit. See procedure below for where to check continuity.
The flow alarm indicator (Red LED) is slowly lighting up and the spindle chiller display is briefly flashes. Both then turn off and this cycle repeats. The IO PCB is leaking voltage to the spindle chiller even when the spindle chiller is not being powered on. This is expected behavior for the DC-Series spindle chiller. The spindle chiller will function properly when commanded to turn on. See the section below DC Spindle Chiller Behavior
Spindle chiller display shows E1 message The ambient temperature is above the maximum ambient temperature parameter. The maximum ambient temperature parameter is set to 45 degrees Celsius in the factory. This is parameter F6. See the operation page of this chapter to see factory set parameter values. If the ambient temperature is above 45 degrees Celsius (113 Fahrenheit), see the operation page about adjusting parameter values. If the ambient temperature is below 45 Celsius, check the parameter value and replace the ambient temperature sensor.
Spindle chiller display shows E2 message The fluid temperature is above the maximum fluid temperature parameter. The maximum chiller fluid temperature is set by parameter F5 and is set to 15 degrees Celsius in the factory. Clean the air intake filters to allow for proper ventilation. Make sure that the chiller fluid mixture has the right proportions. The chiller fluid should be 30% Dowfrost 70% deionized water. See the maintenance section for draining the chiller fluid. See the operation page for setting parameter values if needed.
Spindle chiller display shows E3 message The chiller fluid temperature is below the minimum fluid temperature parameter. The minimum chiller fluid temperature is set by parameter F4 and is set to 20 degrees Celsius in the factory. Make sure that the chiller fluid mixture has the right proportions. The chiller fluid should be 30% Dowfrost 70% deionized water.  See the maintenance section for draining the chiller fluid. See the operation page for setting parameter values if needed.
Spindle chiller display shows E4 message The ambient temperature sensor is failing. Replace the ambient temperature sensor.
Spindle chiller display shows E5 message The chiller fluid temperature sensor is failing. Replace the chiller fluid temperature sensor.

DC Spindle Chiller Flow Alarm Output

1

To check for continuity between 2 pins on the alarm connector, remove the spindle chiller connector to the alarm cable [4]. The connector on the spindle chiller [4] has 3 pins as shown in the image.

If there is no alarm being outputted by the spindle chiller, then there will be between pin H1 [1] and H3 [2].

Take a volt meter and set it to resistance mode.

Then touch one lead to pin H1 [1] and the other lead to pin H3 [3]. The volt meter display will show near zero resistance if there is continuity. 

If there is no continuity between H1 and H2, check if there is continuity between H1 [1] and H2 [2]. Continuity between H1 and H2 indicates an alarm is being outputted by the spindle chiller.

If this is the case, continue troubleshooting to determine the source of the alarm. 

Spindle Chiller Electrical Schematic

1

There are 3 cables that go from the spindle chiller to the control cabinet:

  • Ground cable [1] - From spindle chiller to control cabinet chassis
  • Flow alarm cable 33-1360 - From alarm port to cable 33-1299 which is connected to P39 on the I/O PCB.
  • Power cable 33-1361 - From power socket to P31 on the I/O PCB.

Important: The alarm cable from the spindle chiller needs to be connected to the SPINDL FLOW connector of 33-1299. This cable has 3 connectors, only the connector labeled SPINDL FLOW should be used.