VS-Series - Installation

Introduction

1

Use these numbers to identify which foot to adjust.

Prerequisites:

Adjust each leveling screw until the base is 4" (10 cm) above the floor (3" (76 mm) leveling pad height plus 1" (25 mm) of screw below the bottom of the pad).

Note: The condition of the foundation may require different heights at some leveling screws to make the machine level.

Important: it is required that the machine be anchored. Refer to the following link: ANCHORING INSTRUCTIONS.

Using the anchor pattern from Machine Layout to mark the machine location.
Print the anchor footprint from AD0456 to mark anchor location.
- Important: Footprint must be printed at 1:1 ratio

Tools Required:

Electronic differential level, precision bubble level, calibrated to show 0.0005 inch per 10"
Test indicator (0.0005")
Two ¾" hex wrenches (one open end or box and one ratchet)
600 # TORQUE WRENCH , ¾ DRIVE w/ 1.5" Socket
50T X 8” PREC SPINDLE ALIGNMEN TOOL
3 x 4 x 40 GRANITE PARALLEL
3 x 12 x 18 GRANITE TRI SQUARE
2 x 6 x 6 GRANITE PARALLEL
50T Alignment Split Tool

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.

Leveling Overview

Wiring connections to power the machine must be made before the Levelling Procedure can be followed. It is required that the machine be anchored in place for best and most consistent results while in use. The anchoring bolts (in accordance with the anchoring instructions) should be installed prior to the machine being set in place.

The installation process will be further aided if, when each base assembly is set in place, a very rough leveling procedure be done. The theoretical distance from the floor to the bottom of the two bases is 4 inches. The use of a machinist scale or small gauge blocks will expedite the process. While all leveling screws and leveling pads are in place measure from the floor to the bottom of each base until the distance is very close to the 4 inch height. This will accomplish two things: First, that the machine is set to the proper height to receive the coolant tank/Conveyor and, second, that the machine will be very much closer to level than without having done this procedure.

The installation procedure will necessarily follow the general outline below (a more detailed explanation follows). Depending on the available space and equipment it may be simpler to place the column base assembly before the table base assembly. Regardless of which assembly is placed first, the concepts of the general outline need to be adhered to:

Remove the column base assembly from the truck
Stone and clean the table base mating flange
Remove the table base assembly from the truck and set 6" away from the column
Stone and clean the column base mating flange
Move the table base to mate with the column base
Be certain that all connecting bolts are in place but not tightened
Run the Pendant electrical wires over the top of the table enclosure and connect them in Operator pendent
Rough level the column base assembly
Remove the side panel from under the tool changer assembly
Install the counterbalance cylinder and charge the system
Relocate the tool changer ** (See Note Below)
Remove shipping blocks from the table base assembly
Connect all air/electrical/oil lines between the two assemblies
Remove shipping blocks from the column base assembly
Power up the control
Fine level the column base assembly assembly
Fine level table base assembly/squaring the table base assembly to the column.
Fully tighten the connecting bolts and tighten anchors
Fully check machine geometry
Replace the side panel from under the tool changer assembly
Install the coolant supply system
Check all motors for rotation/phasing

Note: (**) Depending on the available space and equipment it may be simpler to relocate the tool changer assembly before moving the Column Base into the facility

Tool Changer Installation

1

Important: Depending on the available space and equipment it may be simpler to relocate the tool changer assembly before moving the Column Base into the facility

Remove the side panels from under the tool changer.

Clean the mating surface for the tool changer [1].

Place a piece of cardboard between the spindle head and the tool changer to prevent scratching the spindle head covers.

2

Note: Some components of the Carousel where removed for illustration purpose only.

Using the proper lifting equipment and lifting straps (2x) as shown to support the tool changer (aprox. 2670 lbs / 1211 kg).

Unbolt [2] the tool changer from the shipping location and lift it into position on the column and tighten the (6) bolts to 80 ft-lb (108 Nm).

Machine Placement

1

Important: Ensure the anchoring preparations are in accordance with the anchoring instructions prior to setting the machine in place. Image [1] Anchor hole [2] Leveling Pad

Place the column base assembly in position on the following leveling screws.

1 - 2
4 - 26
6 - 24

Rough level by measuring from the floor to the bottom of the base 3". (4 - 4 1/2 inches for Conveyor Option).

This will ensure that the final leveling procedure will go more quickly and that the coolant tank will properly fit beneath the coolant discharge. Loosely screw the jam nuts onto the leveling screws.

2

Place the table base assembly in position on the following leveling screws.. When placing the table base in position with respect to the column base, it is important that the two mating flanges be as parallel as possible (vertically and horizontally).

Rough level by measuring from the floor to the bottom of the base 3" (4 - 4 1/2 inches for Conveyor Option). This will ensure that the final leveling procedure will go more quickly.

After rough leveling, verify that each of the screws are actually engaged in the threads, and that when the column base is in place and the mating surfaces are in contact that each.

3

Be certain that the connecting screws are still free to rotate (do not leave the connecting bolts tight at this time because the machine still must be final leveled and squared)

INSTALL COUNTER BALANCE CYLINDER

1

Note: The counterbalance cylinders have been removed (for overhead clearance during shipping), and they must be reinstalled and recharged with dry nitrogen prior to enabling the column axis

Re-install alignment collar and thrust bearing

Note orientation of alignment collar - deep shoulder faces rod end.

2

Insert the cylinder down between the spindle head casting and Column casting.

Slide the top of cylinder into the Rod Bracket until the bottom clears the Mount Block

Install cylinder assembly into mounting block on column

3

From the rear of the Column casting, extend cylinder rod and re- connect to the Rod End that is mounted on spindle head.

4

WARNING : Use appropriate PPE equipment (face shield, gloves, etc.) when filling the hydraulic tanks.

Make sure all tank valves are closed before beginning.

Attach nitrogen tank fill nozzle

Begin filling counterbalance tank by SLOWLY cracking open the valve

Fill tank until gauge reads 750psi.

Wiring the Machine

1 Wiring the Column Base

On the electrical cabinet side, Locate the bundle of wires (Purple Line) containing
- Right Door sensor cable
- Air line (Right Door Interlock)
- Right Side work light
- RJ45 SHIELDED CABLE
- USB 2.0 CABLE
- CBL740/770/+12V&GND-SKBIF EXT VS
- Work light
Route cable through the cable channel along the base of the Column and Table assembly.
Continue up the rear panel of the Table assembly and over the top of the enclosure in the cable channel.
Connect the work light cable into the splitter connector
Insert the air into the right Door Interlock and connect the Right Door Sensor
From the Front Panel connect the RJ45 SHIELDED CABLE, USB 2.0 CABLE and CBL740/770/+12V&GND-SKBIF EXT VS
route the Air Line into Front Panel and connect to the quick connect for the air nozzle.

2

Wiring the Column Base (Continue)

On the Tool Changer Side locate the bundle of wires containing
- Coolant Electrical connection bracket (Blue Line)
- Left Door Sensor cable (Orange Line)
- Air Line (Left Door Interlock) (Orange Line)
- Left side work light (Orange Line)
Route cable and coolant lines through the cable channel along the base of the Column and Table assembly.
Split the Door and work light cable from the coolant lines, continue routing the door and work light cables up the rear panel of the Table assembly and over the top of the enclosure in the cable channel.
Connect the work light cable into the splitter connector
Insert the air into the Left Door Interlock and connect the Left Door Sensor
Continue routing the Coolant Line through the cable channel and mount the coolant electrical connection bracket to the back of the enclosure panel

3 Wiring the Table Base

On the Table Base locate the bundle of cable (Red Line) containing
- X - axis motor / encoder cable
- X - axis Linear Scale cable
- X - axis lube lines (2x)
Route the cables through the cable channel located on the side of the Column base and into the bottom control wire box.
In the wire box find the X-axis linear scale interpolation box and connect the X axis linear scale cable
Route the X-axis motor / encoder cable up into the Electrical Cabinet
Connect the X axis motor cable the Amplifier and route the X axis encoder cable up to the Main Processor (P1)
Locate the Chip Auger motor cable (Green line) in the cable channel and route to the electrical cabinet.
Connect auger motors to open locaion on QUAD CHIPC PBC (P4 - P7)

Electrical Connections

Danger: 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

Danger: 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.

Refer to Haas Main Circuit Breaker - Torque Specifications for what value to torque the circuit breaker power leads.

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).

SMinimill - Reboot: The AC voltage must be between 198 and 242 volts for machines without a high voltage transformer. Refer to the Minimill/SMinimill - Identification document.

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

Important: 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 220V-240V 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 50/60Hz power should use the 340-380V connector while users with 380V-440V 50/60Hz power should use the 381-440V connector.

Important: 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.

Danger: 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.

Unblocking the Machine

1 Unblocking the Column Base

CAUTION: Before unblocking machine ensure that counterbalance cylinder charging hose is attached to nitrogen tank and nitrogen tank is fully charged to 750 psi.

Remove the shipping bracket and hardware completely from the side of column base on the Tool Changer side.
Handle jog (without zero return) the spindle head to the up position and support the bellows.
Remove the spindle shipping bracket

2 Unblocking the Table Base

Remove the shipping bracket and hardware completely from the front of Table base

Machine Leveling

Leveling the Machine

At this point the machine is completely unblocked and all axes are enabled. The process of leveling can now begin. The following criteria should have already been met at this point:

The machine correctly placed with respect to the anchoring points.
The rough leveling has taken place, ensuring that the bottom of the two bases are very close to 4 inches off the floor
The mating flanges of the two bases have been pulled into contact.
The screws that connect the two bases have been backed off and can rotate freely

1 Rough leveling the Column Base

Zero return all axes 3.
Move the Y-axis to the center of travel.
With four leveling screws on the corners on the column base.
- 1 - 2
- 6 - 24
With the column at approximately center of travel, using gauge blocks lay one granite parallel across the linear guides as close to the table as possible and another granite parallel across the linear guides as near the rear of the machine as possible.
Place a level on each parallel and adjust the level of the column from side to side.
Check the freedom of the mating flange screws to be certain there is no binding.
On the guide nearest the control, place one level on the linear guide in front of the column and one level on the linear guide to the rear of the column. Adjust the level of the machine in the direction of Y-axis travel. Move the levels to the opposite linear guide and complete the process.
When the column base is level to earth in both directions, the six center leveling screws should be lowered to touch the leveling pads.
Remove the granite parallels from the column base.

2

Level of the Column Base

Handle jog the column to the rear.
Place a single level (T-2181 and T-2192) on the spindle, parallel to the X-axis of the machine. It is very unlikely that this surface will read zero; do not expect it to. Make note of the reading that is present.
While monitoring the level, move the column all the way forward and check if there is a change in the level reading. If there is no change in reading, then the column base has no twist. If there is a twist in the base, this must be corrected by using leveling feet 1,2,4 and 26.

3 Rough leveling the Table Base

Move the X-axis to the center of travel.
Place two levels at right angles to each other as close as possible to the center of the table. One will show the level across the width of the table and the other will show the level along the length of the table.
Focus on leveling the table only in this X-axis position to establish a primary datum for the machine. Adjust only the four leveling screws: 7, 14, 16 and 23.
When the table level is close to zero in both directions, the four very end leveling screws (10, 11, 19 and 20) may be brought down to touch the leveling pads.
Continue to level the table base until both levels on the table read zero.

4 Sweeping the Table

Mounting the indicator on the spindle, first verify that the table is flat to the Y-axis plane.
Place a parallel granite (32") on the table surface. Sweep the granite in the Y-axis to determine, and correct column / table flatness in the Y-axis direction. This is a very sensitive measurement method and corrections to this flatness should be made in conservative steps.
Raise or lower the front of the table to get the flatness within specification using leveling screws 14 and 16.
Move the levels to the table and place them as close to the center as possible.
One level should be parallel to the X-axis and one level should be perpendicular to the X-axis.
Once the Column to Table flatness has been established, jog the X-axis and adjust the remaining leveling screws to maintain the current level reading.

5 level the Table

Focus on leveling the table only in this X-axis plane to establish a primary datum from the granite.
Make note of the reading that is present.
While monitoring the level, jog the table all the way to left and check if there is a change in the level reading.
While monitoring the level, jog the table all the way to right and check if there is a change in the level reading.
If there is no change of reading, then the column base has no twist. If there is a twist in the table, this must be corrected.
the remaining leveling screws should be lowered to touch the leveling pads.

Geometry Check

1

Every point of inspection must be verified to be within the tolerances specified for the machine.

1A. FLATNESS OF COLUMN TRAVEL MOVEMENTS
1B. FLATNESS OF TABLE TRAVEL MOVEMENTS
2. INSPECT SQUARENESS OF X-AXIS TO Y-AXIS
3. TABLE STRAIGHTNESS
4A. SQUARENESS OF Z-AXIS MOTION TO X-AXIS
4B. SQUARENESS O F Z-AXIS MOTION TO Y AXIS
5. SPINDLE SWEEP
6A. SPINDLE RUNOUT AT TAPER
6B. SPINDLE RUNOUT ON TEST TOOL BAR
7. PARALLELISM OF TABLE TO X - Y MOTION

2

Two fundamental geometry checks need to be made. The first is the perpendicularity of the X-axis to the Y-axis, and the second is to verify the sweep of the Z-axis.

The sweep of the X-axis to the Y-axis is accomplished using a granite square. Set zero by sweeping the Y-axis on one side of the square, and then to verify that the motion of the X-axis is perpendicular by sweeping the adjacent side of the square. If the X-axis and Y-axis are not found to be within tolerance, between the mating flange surfaces that is creating this error.

Observe readings and adjust base to saddle perpendicularity as follows:

Route ratchet straps from both sides of base to ends of saddle, looping through casting holes.
Remove slack from both straps without over tightening.
Gently tighten the appropriate strap observing reading changes on indicator.
Continue making slight adjustments with straps and repeat granite sweeps until perpendicularity reading is within traveler specifications - record readings.

3

Verify the sweep of the Y/Z-axis:

Sweeping the Z-axis is accomplished using a cylinder square.
The line of motion of the Z-axis will be checked by comparing it to the line of intersection of the two most convenient relative planes, that of the X-Z plane and the Y-Z plane.
By assuring that each of these planes are perpendicular to the X-Y plane within specification, the machine geometry will be preserved.

Observe readings and adjust the needed Column Base leveling screws:

X-Z plane:
- Adjust the left / right leveling screw evenly up or down to bring the reading within specification.
Y-Z plane:
- Adjust the rear leveling screw evenly up or down to bring the reading within specification.

Final Connection of the Column Base to the Table Base

Before tightening all the connecting screws, recheck the table level to be certain that the squaring process of the column base did not affect table level.
Torque the connecting screws with lock washers in place to 400 ft-lb.

Anchoring the Machine in Place

NOTE: Ensure the anchoring preparations are in accordance with the anchoring instructions prior to setting the machine in place

1

Complete the machine installation, install the anchor bolts and tightening to 25 ft-lb.
Repeat of the basic leveling procedure and a recheck of the geometry to be done. All criteria must be met.

Completing the Installation

1

Seal the shipping bracket bolt holes to prevent oil leaks.
Replace all sheet metal removed paying particular attention to sealing any component mating surface potentially exposed to coolant flow.
Verify alignment and operation of the tool changer.

Using a split tool in RECOVERY mode, verify the alignment to the pocket and check the alignment to the spindle.
With the (4) TC bolts loose support the weight of the tool changer, use the jacking screws for the SMTC adjuster to align the front-to-back of the arm to the spindle. The tool changer will not move unless you support the weight.
If the spindle alignment is out side-to-side, insert a shim between the tool changer and the mount. Do not leave the shim exposed

4. Verify all machine functions.