SKBIF PCB - Replacement

AD0340

Introduction

This procedure tells you how to replace the SKBIF PCB.

This document applies to these parts:

  • 93-32-4510: SKBIF FOR NGC W/ RJH-C/VID CCA SVC KIT
  • 93-34-4510: SKBIF FOR NGC W/ RJH-C/VID CCA REFURB

Replacement

1

When you handle a PCB, you must wear the electrostatic discharge (ESD) strap.

Push [POWER OFF]. Set the main circuit breaker to the OFF position. Lock the main circuit breaker. Use an approved lock with an approved safety tag.

Danger: After turning off the machine, wait at least 5 minutes before working in the control cabinet, to allow power to dissipate. Wait for the voltage indicator LED on the vector drive to go off completely.

2

Remove the rear cover and disconnect all cables connected to the SKBIF PCB. Record the location of each cable.

Remove the (4) 6-32 x 3/8" Phillips pan-head screws (PPHS) and the SKBIF PCB from the control pendant.

Make sure the positions of the DIP switches on SW1, SW2, SW3, SW5, and SW6 on he replacement SKBIF PCB [A] are the same on the removed SKBIF PCB.

Make sure there is (1) jumper at JP27 and (1) jumper on JP19 on the replacement SKBIF PCB [A].

Install the replacement SKBIF PCB [A] and the (4) 6-32 x 3/8" PPHS [8].

Connect all of the cables to the replacement SKBIF PCB [A].

Monitor - 15-inch LCD - Replacement

AD0107

Introduction

This procedure tells you how to replace a 15-inch LCD monitor.

Caution: When you do maintenance or repair on CNC machines and their components, you must always follow basic safety precautions. This decreases the risk of injury and mechanical damage.

Do these steps before you do work in the machine or in the control cabinet:

  • Set the main circuit breaker to the [OFF] position.
  • Use an approved lock with an approved safety tag. Always follow lock-out procedures in accordance to local government rules.
  • After turning off the machine, wait at least 5 minutes before working in the control cabinet, to allow power to dissipate. Wait for the voltage indicator LED on the vector drive to go off completely.
  • Always turn off the main air supply when you work on any part of the pneumatic system.
  • Make sure to rest the spindle head on a block of wood when work is done on a vertical axis. this will prevent any unintended movement that could result in the axis failing.
  • Never alter any safety circuits on the machine.
  • Put the machine in Emergency Stop mode to change any parameters.

You should not do machine repair or service procedures unless you are qualified and knowledgeable about the processes. Serious damage to the machine components can result in costly repairs. the service technicians at your Haas Factory Outlet (HFO) have the training and experience, and are certified to do these tasks safely and correctly. the repair and service work performed by your HFO is protected with a limited warranty.

Danger: Some service procedures can be dangerous or life-threatening. DO NOT attempt a procedure that you do not fully understand. If you have any doubts about doing a procedure contact your Haas Factory Outlet (HFO) and schedule a service visit.

Do this procedure for machines:

  • Made after June 1, 2006.
  • That have a 15" LCD monitor.

If your monitor has a differential receiver card [1],  do the Monitor - 15-inch LCD - WIth Differential Card - Replacement section of this procedure.

If your monitor does not have a differential receiver card, do the Monitor - 15-inch LCD - Without Differential Receiver Card - Replacement section of this procedure.

Document applies to these parts:

  • 93-0875A: LCD ASSY 15IN SERVICE KIT

Tools Required:

  • ESD Strap

Monitor - 15-inch LCD - With Differential Receiver Card - Replacement

Note: This section tells you how to:

  • Remove and install a differential receiver card (PCB)
  • Install a 15-inch LCD monitor

1

Push [POWER OFF].

Set the main circuit breaker to the OFF position.

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

Caution: When you handle a PCB, you must wear an Electrostatic Discharge (ESD) strap.

2

Remove the rear cover of the pendant.

Disconnect the power-off contactor [1] from the monitor. Push the lever [2] fully to the right while you pull the contactor out.

Disconnect the LCD video data cable [3].

Remove the (4) nuts that hold the monitor.

Caution: Before you remove the last top nut, support the weight of the monitor.

Clean the inside of the protective glass on the pendant.

3

Put each of the monitors on a flat, anti-static surface.

Note: If necessary, use the packing foam and the anti-static packaging that came with the new LCD monitor.

Remove the rear metal casing on each of the monitors. On the monitor you removed, disconnect the LCD inverter cable [1], the LCD data cable [2] and the power cable [3] for the differential receiver card.

Remove the differential receiver card and each standoff that supports it. Install the standoffs and the differential receiver card on to the new LCD MONITOR [A].

Make these connections on the differential receiver card:

  • Connect the LCD inverter cable [1] into J1
  • Connect the LCD data cable [2] into J2
  • Connect the differential receiver card's power cable [3] into P1

Do not use the other (2) connectors [4].

Install the rear metal casing.

Remove the protective cover from the monitor.

Install the monitor. Install the top nuts first.

4

Connect the LCD video data cable [1] to the J6 on the differential receiver card.

Install the power off contactor [2] into the monitor.

Push the contactor in until you hear a click.

Set the main circuit breaker to the ON position.

Push [POWER ON].

Install the rear cover of the pendant.

Note: If the differential receiver card fails, you must upgrade the SKBIF PCB to a version that has the differential receiver interface.

Monitor - 15-inch LCD - Without Differential Receiver Card - Replacement

 Note: This section tells you how to remove and install a 15-inch LCD monitor that does not have differential receiver card.

1

Push [POWER OFF].

Set the main circuit breaker. Use an approved safety tag.

Caution: When you handle a PCB, you must wear an Electrostatic Discharge (ESD) strap.

2

Remove the rear cover of the pendant.

Disconnect the power-off contactor [3] from the monitor. Push the level [4] fully to the right while you pull the contactor out.

Disconnect the LCD inverter cable [1] and the LCD data cable [2] from the SKBIF.

Remove the (4) nuts that hold the monitor. 

Caution: Before you remove the last top nut, support weight of the monitor.

Clean the inside of the protective glass on the pendant.

3

Put the new LCD MONITOR [A] on a flat, anti-static surface.

 Note: If necessary, use the packing foam and the anti-static packaging that came with the new LCD monitor.

Find the LCD inverter cable [1] and the LCD data cable [2]. Pull these cables out of the cover.

Do not use the other (3) connectors [3].

Remove the protective cover from the new monitor.

Install the monitor. Install the top nuts first.

4

Connect the LCD data cable [3] to the J16 socket on the SKBIF PCB. Connect the LCD inverter cable [2] to the J13 socket on the SKBIF PCB.

Install the power-off contactor [1] into the monitor.

Push the contactor in until you hear a click.

Set the main circuit breaker to the ON position.

Push [POWER ON].

Install the rear cover of the pendant.

Keypad - Membrane-Type - Replacement

Introduction

1

This procedure tells you how to replace the membrane-type keypad on the control pendant.

Tools Required:

  • Electrostatic Discharge (ESD) strap
  • Tongue and groove pliers

Parts Required:

  • 93-0636: Keypad Membrane Type

Removal

1

Press [POWER OFF] and Lockout/Tag Out the machine.

Caution: Wear an electrostatic discharge (ESD) strap connected to unpainted bare metal on the chassis.

2

Remove all of the screws that attach the rear panel to the control pendant enclosure.

Remove the rear panel.

Note: The pendant rear panel design may be different from the one shown.

3

Disconnect the (4) electrical wire lugs from the back the jog handle.

Remove the (3) nuts that attach the jog handle assembly to the control pendant enclosure.

Remove the jog handle assembly.

Note: Be sure to identify each wire connection correctly. Use adhesive tape and a marker to record the locations of the connections.

4

Disconnect the (2) electrical wire lugs from the back of the spindle load meter.

Remove the (4) nuts that attach the spindle load meter to the control pendant enclosure.

Remove the spindle load meter.

5

You must remove the button assemblies from the pendant enclosure before you remove the front panel and the membrane keypad.

These assemblies have three parts, the electrical switch [1], the plastic locking nut [2], and the button [3].

6

Remove all the switches and buttons as follows:

  • Push the locking tab clockwise [1] until it snaps into the unlock position.
  • Once the tab is unlocked, pull the electrical connector [2] off the button [3].

Note: Make a mark on each connector to record its location.

Note: It is not necessary to disconnect the wiring attached to the electrical switches.

7

Use tongue and groove pliers to loosen the locking nut [1].

Manually remove the locking nut from the button.

Push on the back of the button [2] and remove it through the front of the pendant enclosure.

8

Remove the front panel.

Note: The front panel design may be different from the one shown.

9

Carefully disconnect the keypad's 24-pin ribbon cable from the keyboard interface PCB.

Note: Be careful when you remove the ribbon cable connector from the connector of the keypad interface PCB. Be sure not to bend the pins.

10

The membrane keypad is glued to the enclosure.

Use a putty knife or a small flat screwdriver and work all around the edges to pry the keypad away from the enclosure.

11

Carefully pull out the 24-pin ribbon cable through the front opening of the control pendant panel as you remove the keypad.

Installation

1

Caution: Use the electrostatic discharge (ESD) strap connected to unpainted bare metal on the chassis.

2

To install the keypad, insert the 24-pin ribbon cable through the front opening of the control pendant panel.

3

Connect the 24-pin ribbon cable into the keypad interface PCB.

Note: Be careful when you insert the ribbon cable connector into the connector of the keypad interface PCB. Be sure not to bend the pins.

4

Press [POWER ON].

Make sure the keypad works.

Press [POWER OFF].

5

Remove the cover of the adhesive strip on the back of the keypad.

Use the upper right corner to align the keypad on the control pendant enclosure.

Press the keypad in place.

6

Attach the jog handle assembly to the control pendant enclosure with (3) nuts.

Connect the (4) electrical wire lugs to the back of the jog handle.

7

Attach the spindle load meter to the control pendant enclosure with (4) nuts.

Connect the (2) electrical wire lugs to the back of the spindle load meter.

8

Install the switches and buttons for the [POWER ON], [POWER OFF], [FEED HOLD], [CYCLE START], and [EMERGENCY STOP] as follows:

  • Install the button on the control enclosure.
  • Use tongue and groove pliers to tighten the locknut.

9

Insert the switch [1] into the button [2] and push the tab [3] to lock it in place.

Repeat this procedure for all switches.

10

Install the rear and front panels.

11

Press [POWER ON].

Make sure the keypad works. If it does not work, contact your Haas Factory Outlet.

Introduction

[1] 15" LCD.

[2] 15" Touchscreen LCD.
NOTE: Not all machines are equipped with the LCD touchscreen.  The LCD touch screen has a USB cable that plugs into the SKIBF PCB.  

[3] SKBIF PCB

[4] Handle Jog

[5] E-Stop Button

[6] Power Off

[7] Power On

Symptom Table

Symptom Possible Cause Corrective Action
Machines with SKBIF Version 6.xx.  Alarm 546 SERIAL KEYBOARD COMMUNICATION FAULT. The SKBIF firmware is outdated. Make sure you have SKBIF firmware version 6.6 or higher.  Refer to SKBIF PCB / RJH Firmware Update - NGC procedure.
The LCD turns to a black screen. Alarm 967 SKBIF COMMUNICATION FAULT. There is a problem with the communication cable from Main PCB to SKBIF PCB. See SKBIF Troubleshooting section below.
The supply voltage from PSUP PCB to SKBIF PCB is not correct.
The backlight and LCD data cables are not connected correctly.
The wires to the [POWER ON], [POWER OFF], [EMERGENCY STOP], [FEED HOLD] and [CYCLE START] contactors terminals are loose.
The beacon light does not turn on. The beacon light cable is not connected. Make sure the beacon light is connected to SKBIF at P10.
The control has a blurry screen.

A switch on the SKBIF is not correctly set.

 Change the MAPSEL switch to the opposite position. See the section below.
The screen flickers during spindle deceleration (running spindle then pressing "Reset" key) or during heavy cuts. The cable from the Maincon PCB connected J9 to the SKIBF at J28 is defective.
  1. Check the RJ-45 cable connection from Maincon PCB (J9) to SKIBF PCB (J28). To test the cable refer to Network Cable Tester Tool procedure.
  2. Inspect the RJ-45 connector housing on the Maincon PCB & SKIBF PCB for bent pins.
The RJ-45 connector housing is damaged on the SKIBF or Maincon PCB. Make sure the RJ-45 connector housing is solder to the PCB and not loose.
You get a blank screen with continuous beeping at power on. The jog handle or wiring is defective.
  1. Power off the machine.
  2. Check the wiring to the jog handle, make sure all the cables are connected in the correct location.
  3. Set the meter to ohms, measure resistance between front panel ground to the +5Vdc of jog handle - it should not read zero ohms. If shorted, disconnect the +5Vdc wire from the Jog Handle and check if the problem is the jog handle or the SKIBF.
Machines with software version prior to 100.17.000.2034 . The control freezes, blank monitor, black screen, keypad not working, won't boot sometimes, random shutdowns, or software alarms. Caused by a software error. Refer to the: Next Generation Control - Maincon / Software Update Troubleshooting Guide
Alarm 2001 EMERGENCY STOP SWITCH ERROR
 There is a loose connection from the E-stop button to the SKBIF PCB.
  1. Go to Diagnostic Page --> Keyboard I/O
  2. Type REDUNDANT_ESTOP then press [F1].
  3. With [EMERGENCY STOP] released the INPUT #26 REDUNDANT _ESTOP value should = 1.
  4. Press [EMERGENCY STOP].  The INPUT #26 REDUNDANT _ESTOP value should = 0. If it remained = 1 check the cable plug to SKBIF J26 see diagrams located at the end of this Troubleshooting Guide.
LCD Touchscreen.  Turned setting 381 to On, but the touchscreendoes not respond to touch commands. The touchscreen feature is not enabled. To enable the Touchscreen set setting 381 Enable Touchscreen to On.
The configuration files are outdated. As of software version 100.19.000.1400 or higher a parameter 2257 Touchscreen Suport has been added, this parameter must be set to TRUE.  If not you will need to contact the service department to have it enabled.
LCD Touchscreen
The TouchScreen does not respond to touch commands.		 The touchscreen feature is not enabled. To enable the Touchscreen set setting 381 Enable Touchscreen to On.
The touchscreen is not calibrated. Use the touchscreen configuration page to calibrate, test, and restore default settings.
The touchscreen configuration is located in the maintenance section.
Press [DIAGNOSTIC] to go to the Maintenance and navigate to the Touchscreen tab. 
Follow the instructions on the screen.  After calibration you need to cycle power.
The touchscreen USB cable is not connected correctly to the SKBIF PCB. Make sure that the USB cable connection is connected to J21 at SKBIF PCB.
LCD TouchScreen.
Some tabs look dark as they have been pushed.		 This is normal,  this is used to distiguish the family of tabs the current screen is showing.
The sound of the beeper only works when I power on the machine. The beeper volume setting is turned off. Go to setting 356 and set to a value higher than 0.
The beeper volume is low or inaudible. The SKIBF PCB or beeper is defective. Machines with SKBIF (34-4510) PCB the beeper is built into the SKIBF.  This beeper can not be tested,  check for voltage going to the SKIBF, if everything checks out ok then the SKIBF PCB is defective. Note:  Do not replace the speaker,  the speaker does not produce the beeper sound.

Machines with SKIBF  (34-4243G) PCB the beeper is mounted outside and connected to the SKIBF.  This beeper can tested with a 9V battery.

SKBIF Troubleshooting

  1. Remove the LCD back cover.
  2. Check J13 backlight and J16 LCD data connectors. Make sure the connectors are seated, and wires are not broken.
  3. Check the wires going to the [POWER ON], [POWER OFF], [EMERGENCY STOP], [FEED HOLD] and [CYCLE START] 
    contactors. Make sure the connections are tight.
  4. Look at the status LED lights.  Refer to the LED table below.
  5. Set the volt meter to DC. Check for +12Vdc supply voltage at J20 you should measure approximately +12Vdc. If this voltage is lower than +11Vdc or not present make sure J20 connector is properly seated, and trace the voltage back to the LVPS. Refer to the above electrical diagram.
  6. The SKBIF PCB generates +3.3Vdc, +5Vdc. Check these voltages at the following test points (TP).
    • Put the black probe at TP(GND) and the red probe at TP (+3.3Vdc) you should measure approximately +3.3Vdc.
    • Put the black probe at TP (GND) and the red probe at TP (+5Vdc) you should measure approximately +5Vdc.
    • Put the black probe at TP (GND) and the red probe at TP (+12Vdc) you should measure approximately +12Vdc.

    If these voltages are low or no voltage is measured, disconnect all the connectors from the SKBIF PCB except the J20 connector, and measure again. If after doing this there is still no voltage then the SKBIF PCB is defective.

    If after disconnecting the components, the voltages are correct, then there is a short circuit in one of the components connected to the SKIBF for example, remote jog handle, handle Jog, etc. Determine which component is at fault.

LED table

The following table applies to -4243G SKIBF PCB.

LED# Status Corrective Action
LE1 (PASS/EQ, Lock) Amber This is normal condition. The SKBIF and Main PCB are communicating.
LE3 Sync Green
LE1 (PASS/EQ, Lock) Red The communication between the Main PCB and SKBIF PCB is lost or no signal. Check the RJ45 cable connected to SKIBF at J28 to Main PCB J9, make sure the cable is not damaged or it has a loose connection.
LE3 Sync OFF

Blurry Screen - Dip Switches

Corrective Action: Locate the MAPSEL / S1 dip switch on the SKBIF PCB. Switch the dipswitch to the opposite position.

PCB Component Inspection

Intermittent symptoms or alarms can be caused by component failure. Below is a list of possible failures:

  1. Missing solder on all or some components pins
  2. Poor solder
  3. Solder bridges
  4. Wrong component installation (orientation)
  5. Missing components

     Note: Some PCB's have unused circuits and are missing components intentionally, look for broken off components.

  6. Broken components
  7. Broken pins on IC's
  8. Bent pins on the connectors

Use a magnifying glass to inspect the circuit components on the front and back of the SKIBF PCB. Below are the circuit component zones to inspect:

  1. Inputs connectors (Keyboard, E-stop, Power On/OFF etc.)
  2. RJ-45 connector (SKIBF PCB communication with Maincon PCB, LCD Data)
  3. LCD circuit components (LCD Backlight, LCD Data).
  4. Inspect all solder joints for missing solder.

 Important: If you find a damaged component, replace the SKIBF PCB, inspect the new SKIBF PCB circuit components before installing.

Electrical Diagrams

SKIBF / LCD Interconnect Diagram

Pendant E-stop Circuit Diagram

PSUP (P16) to SKIBF (J20) / SKIBF (J5) Detail Diagram

PSUP (P17) to I/O PCB (P56) Detail Diagram

Symptom Table

Symptom Possible Cause Corrective Action
A keypad button sticks or does not actuate when pressed.
 The flex cable from the keypad to SKBIF PCB is damaged.
 Inspect the cables and the connections.
The dome for a specific key fails to make a contact.
Alarm 546 Serial Keyboard Buffer Overflow One or more keys are stuck. Go to the Key History and see if there are keystrokes being generated without the buttons being pressed.   For NGC press the [ALARMS] button and go to the Key History tab.  Find out which key is getting stuck and determine if the keypad is defective.
Machines with SKBIF Version 6.xx.  Alarm 546 SERIAL KEYBOARD BUFFER OVERFLOW. The SKBIF firmware is outdated. Make sure you have SKBIF firmware version 6.6 or higher.  Refer to SKBIF PCB / RJH Firmware Update - NGC procedure.

Cable Connections

Corrective Action:

If any of the 24 wires fail to make connection, or if they have an intermittent connection, the keypad will malfunction.

  • Make sure the pins in the connector [1] on the SKBIF is in good condition.
  • Make sure the flex cable [2] is in good condition. A broken trace or open contact will cause a row or column to be inoperative.
  • Replace the keypad if the cable is damaged.

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