HPC-300/1K- Troubleshooting Guide

Introduction

Download and fill out the coolant pump Inspection Report Checklist below before replacing any parts.

Coolant pump Inspection Report Checklist

The image shows the following components of the HPC system.

HPC Auto-Clean Coolant Pump
Check Valve
HPC Pressure Sensor

Recommended Coolants:

Good cutting performance and long pump life rely on using the proper type of coolant. Always use a soluble oil or a semi-synthetic coolant, mixed to the manufacturer’s recommended concentration. Full synthetic coolants typically do not have adequate lubricity and don’t always have adequate rust preventative properties.

Good system performance and reliability also relies on adequate coolant filtration. If you are cutting cast materials or abrasive materials you need to use the Haas Auxiliary Filter assembly.

Symptom Table

Symptom	Possible Cause(s)	Corrective Action(s)
Alarm 151 HPC LOW PRESSURE (HPC-300/1K)	A short circuit in the pump motor or pump motor cable caused the circuit breaker to trip on the motor drive PCB.	Check the circuit breaker on the motor drive PCB.
		Check for shorts in the HPC pump cable and on the motor leads.
	Incorrect power phasing - the pump motor is running backward.	Check the phasing indicators and change the incoming power cables, if necessary.
	Damage to the motor shaft key, shaft collar, or wear in other parts of the pump head assembly	Inspect the motor shaft / pump head assembly.
	The HPC pressure sensor is defective. Some coolant flow may occur if this is the case.	Troubleshoot the coolant pressure sensor. Refer to the HPC Pressure Sensor - Failure section below.
Low coolant flow, no alarm. (HPC-300/1K) Low coolant flow, the pump cavitates (cavitation sounds like heavy grit in the pump head, or a suction sound) or is otherwise noisy	The Auto-clean coolant pump filter (if equipped) is clogged.	Test and troubleshoot the Auto-clean pump filter.
	The pressure relief spring in the pump head is damaged.	Inspect the pressure relief spring.
	Damage to the motor shaft key, shaft collar, or wear in other parts of the pump head assembly.	Inspect the motor shaft / pump head assembly.
	Gear pump coupler misalignment.	Order kit 93-4195 Coolant Gear Pump Coupler Conversion. Follow the Pump Head Coupling - Flexible Coupling Replacement procedure.
Excessive noise from the HPC (HPC-300/1K) coolant pump.	Gear pump coupler misalignment.	Order kit 93-4195 Coolant Gear Pump Coupler Conversion. Follow the Pump Head Coupling - Flexible Coupling Replacement procedure.
Alarm 151 HPC LOW PRESSURE (HPC-1000)	There is an electrical fault with the HPC power supply.	Inspect the contactors.
	There is no incoming voltage.	Check the incoming power.
	The HPC pressure sensor does not work. Some coolant flow may occur if this is the case.	Test and troubleshoot the coolant pressure sensor.
Low coolant flow, no alarm. (HPC-1000) Low coolant flow, the pump cavitates (cavitation sounds like heavy grit in the pump head, or a suction sound) or is otherwise noisy.	The coolant level drops in the auxiliary filter tank while the machine is in operation.	Check for leaks and inspect the gasket.
	Air is trapped in the coolant pump.	Cycle the pump power.
	The vacuum generator, or the air bleed valve, on the pump does not operate correctly.	Clean the vacuum generator assembly, or the air bleed valve.
	The pickup hose fittings are loose.	Tighten the pickup hose fittings.
The 230V system does not turn ON and the red LED on the motor drive PCB is OFF.	The jumper on the motor drive PCB is incorrectly located or defective.	Make sure that the motor drive PCB has a jumper installed on P3 inbetween pin 1 and 2 (the bottom two pins).
	There is no 12V input power.	Make sure that the 12V input power is connected to P2 on the motor drive PCB.
There is a delay before the coolant starts to flow.	The coolant check valve is defective.	Inspect the check valve for contamination and proper operation.
There is a delay before the coolant starts to flow.	The Auto-clean cylinder is leaking.	Inspect the air cylinder for leaks into the coolant tank after it cycles.
Coolant is leaking from compensating union.	The seal within compensating union is damaged.	Replace seal by ordering 93-3179 (TSC SERVICE KIT).

Short Circuit

1. On the motor drive PCB:

Note: The PCB [2] on the HPC-1K has a fan. The HPC-300 PCB [1] does not.

Make sure that the circuit breaker is in the ON position.

If the circuit breaker has tripped, turn it back on. Test the HPC system. If the circuit breaker trips again, check for a short circuit in the HPC pump.

Note: You must use water-based coolants with the HPC-1K system. Thicker fluids like cutting oil will overload the pump and trip the breaker.

2. Check the pump for shorts:

Measure the (3) leads [1] to ground [2] on the HPC power cable. If all leads test open to ground, the pump and cabledo not have a short.

If the motor lead test indicates a short, disconnect the cable from the motor. Measure the (3) cable leads [3] to ground. If any lead tests short, the pump is at fault. If none of the leads test short, the cable is at fault.

3. If all leads test OK:

Check the HPC motor for binding that could cause an over amperage condition.

Incorrect Input-Power Phasing

The power supply PCB has a phase detect with neon indicators on the top center portion of the board. Make sure that the electrical power is phased correctly:

Green Light: The incoming power is phased correctly.
Orange Light: The incoming power is incorrectly phased.
Both Lights: A phase is missing (there is a loose cable in the system).

If the electrical power is phased incorrectly:

Set the main circuit breaker to the OFF position.

Lock the main circuit breaker. Use an approved lock with an approved safety tag.

Swap the #74 and #75 incoming power cables at the main transformer.

Coolant Pump Damage

Remove the pump from the tank. Rotate the pump motor fan [1] by hand clockwise. Make sure that the pump coupling [2] also turns.

If it does not turn, separate the pump from the motor. Check for a damaged key on the motor shaft.

HPC Pressure - Sensor Failure

Note: Depending on the year the machine was made, the HPC pressure sensor connects to the check valve inside the rear enclosure panel, behind the coolant connector bracket. On some models, the HPC pressure sensor is located behind the tool changer.

Machines with Analog HPC Pressure sensor:

Check the HPC check valve [1] to make sure is not stuck before replacing the sensor on the check valve assembly.

You will need to remove the rear sheetmetal to get to the analog pressure sensor [2]. Make sure the cable is securely connected to the sensor [2].

Refer to the Analog Input Troubleshooting Guide - CHC.

Machines equipped with Discrete HPC Pressure Sensor:

Press [PARAM/DGNOS]. Go to the I/O diagnostics page.

Short the sensor connector leads. The HPC Low Pressure bit state should change from 1 to 0.

If it does not change, then the cable or the I/O PCB is damaged. Measure for resistance at both ends of the cable. If the cable has resistance, go to the I/O PCB troubleshooting guide.

Replace the pressure switch if it is defective: If the bit changes, use an inline pressure gauge to verify the pressure is correct. If the pressure is over 40 psi, replace the switch.

Coolant Blockage HPC-300/1K

Machines made before March, 2015: Remove the filter retaining ring [1] and filter screen [2] from the bottom of the TSC pump assembly. Clean the filter screen [2] with warm, soapy water and a soft brush.
Machines made after March, 2015: Remove the filter tray from the bottom of the TSC assembly. Remove the tray lid [3] from the filter [4]. Use a brush to clean the filter.

Remove the chip basket and polyester mesh strainer (if the strainer is installed) from the chip tray. Remove all chips from the chip strainer basket.

To replace the mesh strainer [5], pull it tightly over the top of the chip basket [7]. Make sure that the elastic band [6] goes over the edge of the chip basket [7].

Make sure that the auto-clean plunger activates when the HPC pump shuts off. If it does not shut off, go to the solenoid troubleshooting guide. Test the HPC purge solenoid.

If the solenoid operates and it outputs air, check the air tube for kinks or breaks.

Do these steps for a damaged pressure relief spring.

Remove the HPC pump from the tank.
Remove the pressure relief plugs.
Inspect the spring and valve pin. Replace the spring if it is broken and the pin if it is pitted or worn.

Coolant Blockage HPC-1000

Check for leaks in the intake hose from the coolant tank.

Make sure that the tank lid gasket [1] is not damaged, and that it is clean. Make sure that the latches are tight and locked. Do not over-tighten the latches.

Replace the auxiliary filter, refer to the Auxilary Filter - Bag Filter - Replacement Procedure.

Use the wash down hose or the standard coolant pump to fill the auxiliary filter tank.

Cycle the power to the coolant pump to clear the empty chambers of air until the pump runs smoothly.

Drain the auxiliary filter tank. Remove the cover from the auxiliary filter cart.

Clean the auxiliary filter vacuum-generator assembly: Remove the components as shown in the illustration. Remove all of the chips that clog the supply hose in the coolant tank, the fittings, and the pipes.

Pumps without the vacuum generator have a prime line fitting [1] and an air bleed valve [2]. Clean prime line fitting [1] and the air bleed valve [2]. Make sure the prime line fitting [1] and the air bleed valve [2] are not clogged.

The oil level in the reservoir rises when the pump is hot and in operation. Check the oil level in the oil reservoir [1] when the pump is cold. Fill it to the cold fill line [2] with 5-30W synthetic oil.