10.1 40T Pin Drive Motor - Replacement

40T - Pin Drive Motor - Replacement - VMC

AD0649

Applies to machines built after August 2016

Introduction

New motors ship with non-contact encoders (NCE's). If you have an early NGC machine you may have a magnetic encoder and will need to order the new cable for the NCE encoder before you make any repairs.

This procedure applies to the following kits:

  • 93-30-11973: SPNDL MTR 40T 12K INLINE PIN DRIVE
  • 93-30-11980B: SPNDL MTR 40T INLINE 15K PIN DRIVE
  • 93-30-11995A: SPINDLE MTR 40T INLINE 15K PIN DRIVE NCE
  • 93-30-12117: SPINDLE MTR 40T INLINE 12K PIN DRIVE NCE
  • 93-30-14460: SPNDL MTR 40T INLINE 18K PIN NCE VF SVC
  • 93-30-12078: SPNDL MTR 40T INLINE 12K PIN DRV
  • 93-30-12078A: SPNDLE MTR 40T INLINK 12K NCE GEN2 EC SVC

 NOTE: Machine software must be updated to 100.20.000.1110 or later before replacing spindle motor. For help with installation, refer to Software Update - (Option 2) - NGC.

 Note:  This procedure should only be performed by a Haas certified service technician. 

 

Replacement

1

Remove the sheet metal surrounding spindle motor [1].

Remove TSC or air purge assembly [2].

Unplug encoder cable and ground [3].

Remove terminal block cover and disconnect wires from terminal black.

Note: Remove motor mounting screws and rotate motor 90° for easy access to terminal block.

Connect lifting hooks to bracket.

Remove motor.

Note: Make sure transfer tube is still fully seated into spindle drawbar after removing motor.

2

Lift new motor from shipping crate.

Lightly stone mounting surfaces [1],[2] with alcohol and wipe clean.

Apply Red-I Grease to motor coupling groove [3] and motor coupling pins [4].

 

 

 

 

3

Verify the 3 rubber bushings for the pins are still installed to the spindle coupler and are not crushed [1].

Ensure transfer tube is seated on drawbar [2].

Align pins in motor coupler to holes in spindle coupler and lower slowly with caution.

Lightly rotate spindle nose to help align if necessary.

Once motor is fully lowered and seated, install motor plate screws hand tight.

Re-connect wiring for encoder and terminal block.

Re-install TSC or air purge.

4

To align motor to spindle:

Run spindle at 1000 RPM clockwise/forward for 30 seconds.

Run spindle at 1000 RPM counterclockwise/reverse for 30 seconds.

Run spindle at 1000 RPM clockwise/forward for 1 minute.

Snug mounting screws while motor is running.

Note: When motors stops it will jolt to the side and misalign if not snugged down.

Note: The Octavis Vibration Analyzer can be used when aligning motor to find where vibration displacement spike is the smallest.

Torque screws per Haas Torque Specifications.

Run the mill spindle vibration test per Mill - Spindle Vibration - Tolerances.

Re-install the sheet metal assembly.

Update Spindle Motor Brand on HBC

1

Visit Spindle Motor Brand Update in HBC

Note: Only Haas Certified Service technicians can log into this site.

Enter the machine's serial number and click Find [1].

 

 

 

2

Select the appropriate Spindle Motor Brand [2] and click Update [3].

 

 

Configure on Machine

The following service kits require a Hardware Definition File (HDF).  If you have recently installed one of these kits, see 10.4 40T Spindle Motor - Brand Configuration to update your spindle motor brand configuration on HBC and your machine.

Kit Number Kit Name Valid Date
93-30-12078 SPNDL MTR 40T INLINE 12K PIN DRV 12/1/2024
93-30-12078A SPNDL MTR 40T INLINE 12K NCE GEN2 EC SVC 12/1/2024

10.2 40T Spindle Motor - Troubleshooting

30T/40T - Spindle Motor - Troubleshooting Guide - NGC

Introduction

  1. Drive shaft
  2. Power leads
  3. Built-in Spindle Motor Overheat switch connector
  4. Spindle Motor Overheat Analog Sensor

Download and fillout the Spindle Motor Inspection Report Checklist below before replacing any parts.

Spindle Motor Inspection Report Checklist

Symptom Table

Symptom Possible Cause Corrective Action

Alarm 123 SPINDLE DRIVE FAULT

Alarm 236 SPINDLE MOTOR OVERLOAD

 Internal short circuit. Test the spindle motor.
Failed temperature sensor. Test the overheat sensor.
Over-aggressive application. Adjust the program.
Vector drive shorted. Test the vector drive.
Vector drive fans failed.
Cable connection incorrect or loose. Inspect cables and connections.
The spindle motor cable is shorted.
Wye/Delta contacts burnt or shorted. Test the Wye/Delta.
Spindle encoder belt worn or damaged. Examine the encoder belt.
Alarm 4.254 SPINDLE MOTOR OVERHEAT Over-aggressive application. Adjust program.
Spindle fan failed. Check spindle fan and cable.
The input cable for the spindle head does not have a ferrite filter. See Spindle Motor Overheat section below.
Alarm 4.9975 S (SPINDLE) MOTOR TEMPERATURE CRITICAL OVERHEAT This alarm is generated through the built-in spindle motor overheat switch. See Spindle Motor Overheat section below.
Alarm 4136 MOTOR CONFIGURATION FILE NOT SELECTED Motor configuration file was not selected after new kit download. Refer to Spindle Motor - Brand Configuration tab.

Alarm 4136 MOTOR CONFIGURATION FILE NOT SELECTED 

and Load Hardware Definition File menu is blank.

 

 Missing configuration files.  Take an error report and contact your HFO. 

Motor noise.

Poor finish on parts (Inline only).

 Determine if the problem is mechanical or electrical.
  1. Run the spindle to where the noise is heard.
  2. Turn off the machine.
  3. If the noise is still heard then the problem is mechanical.
  4. If the noise goes away then test all the electrical components in the spindle drive system.
Vibration due to damaged bearings. Do a vibration analysis.
Coolant contamination. Inspect the TSC union for leaks.
Spindle motor coolant damage. Coolant intrusion due to TSC union leaking. Upgrade machine software to version 100.22.000.1000 or higher.
Loud screeching during acceleration/deceleration or RPM change. Motor parameters set incorrectly. Refer to Spindle Motor - Brand Configuration tab.

Spindle Motor Overheat

Alarm 4.254

  • This alarm is generated when the analog sensor [1] detects a limit in temperature for a certain amount of time.
  • It can be also caused if there is too much electrical noise in the cable that provides wrong feedback to the control.  Make sure the cable has a ferrite filter installed at connection P39 on the I/O PCB. If the cable does not have a ferrite filter installed, install one. (P/N: 64-1252).
  • The analog sensor data can be seen in DIAGNOSTIC>I/O tab, Analog input #9 SPINDLE MOTOR TEMPERATURE.

Alarm 4.9975

  • This alarm is generated through the built-in spindle motor overheat switch [3].  
  • If spindle motor temperature checks correct.   Make sure that the cable is not damaged and that it is connected.  Check the connection at the Maincon PCB Channel 6.
  • The spindle motor overheat switch status can be viewed on Diagnostic>Mocon tab, “CH 6 [S] Axis Brake Air Pressure” [4].

Spindle Motor Test

Corrective Action:

Disconnect all the wires from the terminal block that come from the electrical cabinet and remove the jumpers.

Use a multimeter to check these terminals on the motor:

  • Measure between motor leads or terminals (1-4) (2-5) (3-6). If the difference between each pair is more than 0.1 Ohms, replace the spindle motor.
  • Measure between motor leads or terminals (2-4 and 3-4) (1-5 and 3-5) (1-6 and 2-6). If the multimeter reading is not open (O.L.), replace the spindle motor.
  • Measure between each individual motor lead or terminal and the motors armature. If the multimeter reading is not open (O.L.), replace the spindle motor.

Vector Drive Test

Corrective Action:

Press [POWER OFF].

If the vector drive voltage indicator light is on, do not touch the electrical components. The high voltage in the control cabinet can kill you. Wait for the voltage indicator LED on the vector drive to go off completely.

Inspect the vector drive.

Disconnect terminals 2 and 3 and check for a short to the spindle motor circuit by measuring the resistance of terminal 2 to 9, 10, and 11. Measure terminal 3 to 9, 10, and 11.

Go to Vector Drive - Troubleshooting Guide to troubleshoot the vector drive.

Wye/Delta Inspection

Corrective Action:

Check for loose connections or burn marks.

Go to Wye-Delta Contactor - Troubleshooting Guide to troubleshoot the Wye/Delta contactors.

Spindle Motor Cables Test

Corrective Action:

  1. Disconnect all the spindle motor cables from the amp/vector drive (terminals A, B, C. + GND).
  2. If machine is equipped with a Wye-Delta contactor, disconnect the cable going to the motor. (L1,L2,L3 + GND).
  3. Disconnect the spindle motor cables from the motor, including the ground cable.

     Important: At the motor end put electrical tape to each lead to make sure the leads do not touch each other.

  4. At the electrical cabinet end, using a meter test for resistance across each lead. Take the same readings from the cable that goes to the motor from the Wye-Delta contactor.
    • If the meter reads O.L. then the cable is good.
    • If the meter reads a short circuit or low resistance the cable needs to be replaced.

Make sure all cable connections are not damaged. Use a multimeter to test each cable connection.

Regen

Corrective Action:

Disconnect the REGEN load leads from the vector drive at terminals 1 and 2. Measure the resistance across the leads. The reading must be as follows:

  • 2-resistor box: between 9.5 and 12.5 ohms.
  • 3-resistor box: between 6.3 and 8.3 ohms ohms. (As shown in the illustration.)
  • 4-resistor box: between 4.6 and 6.6 ohms.

Go to Vector Drive - Troubleshooting Guide to troubleshoot the vector drive.

Go to REGEN - Troubleshooting Guide to troubleshoot the REGEN resistors.

Spindle Fan

Corrective Action:

Check for airflow on top of the spindle enclosure. Make sure there is air flow out of the spindle enclosure when the spindle is commanded to run. DT/DM were setup to blow air down onto the motor but it should now be blowing out the top. Change the fan direction to blow out the top.

Run this command in MDI: S50 M03;

Check the voltage across the black and red wires on the I/O PCB at this location:

  • P32 if the machine has a Next Generation Control

The voltage should be 120 VAC. If no voltage is present, the I/O PCB is bad.

Encoder Belt

Corrective Action:

Make sure the encoder belt is adjusted correctly and is not damaged. Replace a damaged or worn belt.

Make sure the encoder pulley is not damaged. Make sure the set screw is tight.

Program/Application

Corrective Action:

Reduce the axis feed rate, or adjust the spindle rpm in the program.

Check for dull or damaged tooling.

Coolant (TSC Only)

Corrective Action:

Remove the head cover and inspect the TSC union for leaks. A leaking coolant union may cause coolant to get into the motor and wash the grease out of the bearings.

Bearings

Corrective Action:

Damaged bearings in the spindle motor can cause finish issues on the part. Contact your local HFO for a vibration analysis to see if the bearings are damaged.

Electrical Diagrams: Spindle Encoder Feedback / Drive Command

10.3 Spindle Motor - Brand Identification - VMC

Spindle Motor Brand - Identification

Applies to machines built after August 2016

Introduction

 This reference document demonstrates how to identify the spindle motor brand by inspecting the label on your spindle motor.

 

Remove JBOX - VF/VM

 NOTE: If it is necessary to remove (or partially disassemble) spindle motor assembly to access JBOX, refer to 40T Pin Drive Motor- Replacement for more information. 

1

Unbolt cover on JBOX [1]

Remove nuts securing terminal block and lift off of threads. [2]

Remove screw on the bronze bracket holding the thermal probe wire. 

Remove screws securing JBOX to spindle motor. [3]

Lift JBOX and locate spindle motor label. [4]

Identification

1

Identify motor brand name at the top or bottom of spindle motor label:

  1. HPB 
  2. HiGen
  3. Yaskawa

When identification is complete, reinstall JBOX and spindle motor. See Brand Configuration to update the brand on HBC and your machine.

 

Remove JBOX - VF/VM

 NOTE: If it is necessary to remove (or partially disassemble) spindle motor assembly to access JBOX, refer to 40T Pin Drive Motor- Replacement for more information. 

1

Unbolt cover on JBOX [1]

Remove nuts securing terminal block and lift off of threads. [2]

Remove screw on the bronze bracket holding the thermal probe wire. 

Remove screws securing JBOX to spindle motor. [3]

Lift JBOX and locate spindle motor label. [4]

Identification

1

Identify motor brand name at the top or bottom of spindle motor label:

  1. HPB 
  2. HiGen
  3. Yaskawa

When identification is complete, reinstall JBOX and spindle motor. See Brand Configuration to update the brand on HBC and your machine.

 

10.4 40T - Spindle Motor - Brand Configuration

40T Spindle Motor - Brand Configuration

Applies to machines built after August 2016

Introduction

This guide demonstrates how to update your spindle motor brand configuration on HBC and your machine. 

 

The Hardware Definition File (HDF) allows you to configure your machine to be compatible with multiple spindle brands. In the event of a spindle motor replacement, a service tech may easily swap out the motor and update the spindle motor brand configuration.  If you have recently installed one of these kits, you will need to update your spindle motor brand configuration on HBC and your machine

 Note: Check 40T Spindle Motor - HDF Requirements to see if this procedure applies to your machine. 

 Note: If Spindle Motor Brand is unknown, see Spindle Motor - Brand Identification

 Note:  This is procedure should only be performed by a Haas certified service technician. 

 

Configure on Machine

1

Enter Service mode. 

Press [DIAGNOSTIC] to access the Parameters, Diagnostics, and Maintenance screen. 

Navigate to PARAMETERS > FACTORY tab. 

Set Parameter 4.329 Spindle Motor Configuration Type to Manual

 

Note: Alarm 4.4136 Spindle Motor File Not Selected may be triggered. This alarm should be resolved by step 3. 

2

Press [Insert] to open the Load Hardware Definition File window.

 

 

3

Select the appropriate motor brand from the list [1].

Press [Enter] to confirm your choice.

Cycle power on machine to apply updates.

Note: If the menu is blank and you cannot select an option, take an error report and contact your HFO. 

Note: If the spindle motor brand is unknown, see Spindle Motor Identification 

Warning: Selecting the incorrect brand can cause issues with part finishes during machining

Update Spindle Motor Brand on HBC

1

Visit Spindle Motor Brand Update in HBC

Note: Only Haas Certified Service technicians can log into this site.

Enter the machine's serial number and click Find [1].

 

 

 

2

Select the appropriate Spindle Motor Brand [2] and click Update [3].

 

 

10.5 40T Spindle Motor - HDF Requirements

40T Spindle Motor - HDF Requirements

Applies to machines built after August 2016

Introduction

The Hardware Definition File (HDF) allows you to configure your machine to be compatible with multiple spindle brands. In the event of a spindle motor replacement, a service tech may easily swap out the motor and update the spindle motor brand configuration. This guide lists the VF/VM 40T spindle motor service kits that currently require a Hardware Definition File (HDF). If you have recently installed one of these kits, see 10.4 40T Spindle Motor - Brand Configuration to update your spindle motor brand configuration on HBC and your machine.

 

 

Kit Number Kit Name Valid Date
93-30-12078 SPNDL MTR 40T INLINE 12K PIN DRV 12/1/2024
93-30-12078A SPNDL MTR 40T INLINE 12K NCE GEN2 EC SVC 12/1/2024