This procedure will show you how to install the hinged door on the I/O PCB.
This Document Applies to the Following Kits:
93-1000297 DOOR, HINGED FOR I/O PCB
93-1000573 DOOR, HINGED CAN INSTALL KIT FOR I/O PCB
This procedure will show you how to replace the I/O PCB on an NGC machine.
Download and fill out the NGC I/O PCB Inspection Report Checklist below before replacing any parts. It can be found at the I/O and TC PCB troubleshooting guide.
This procedure applies to these kits:
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.
Operate the spindle, tool changer, coolant, through-spindle coolant (TSC/HPC), P-cool spigot, Emergency Stop, beacon, operator door, barfeeder, and all optional equipment.
Make sure that all machine parts and installed options work correctly. If the Side Mount Tool Changer operates slowly, cycle power.
In an EC series machine, make sure the external resistor you connected to P57 does not heat up while the machine is idle.
This procedure will show you how to replace the Tool changer PCB on a NGC machine. This tool changer PCB is used on 34-349x I/O PCB that have a DC-Motor Tool changer or a bar feeder option.
This procedure applies to these kits:
Download and fillout the NGC I/O PCB Inspection Report Checklist below before replacing any parts.
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.
Danger: Before beginning any work inside the control cabinet the High Voltage indicator light on the 320V Power Supply / Vector Drive must have been off for at least 5 minutes.
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.
|Symptom / Alarm||Possible Cause||Corrective Action|
|Alarm 9924 CONTROL AND IO BOARD COMMUNICATION LOST
Alarm 9925 CONTROL AND IO BOARD COMMUNICATION DID NOT INITIALIAZE.
Alarm 9915 IO BOARD CONFIGURATION CRC MISMATCH
|The I/O PCB built-in Low Volt Power Supply (LVPS) voltages are not present or the LVPS is not working.||Troubleshoot the I/O PCB LVPS. Refer to the I/O PCB Low Volt Power Supply section below.|
|Alarm 9100 NON RESETTABLE SOFTWARE ERROR at Power On, or Alarm 9915 IO BOARD CONFIGURATION MISMATCH.||Main CRC and Factory CRC do not match due to the I/O PCB being swapped out.||
The Main CRC and the Factory CRC are now the same.
|Alarm 9933 SOFTWARE VERSION MISMATCH and 9100
NON RESETTABLE SOFTWARE ERROR
|The firmware update failed, or I/O firmware is corrupted.||Reload the I/O PCB main firmware refer to Next Generation Control - I/O PCB Main Firmware - Update.|
|Alarm 9899 IOPCB CAN FAULT and/ or 9105 IO BOARD COMMAND EXECUTION FAILURE. See the CAN Bus Systems Troubleshooting Guide for more information.||The CAN node I/O Configuration is incorrect.||Update the I/O configuration via the I/O Config tab.|
|The incorrect CAN node is enabled.||Verify that Factory Settings 9000.001 -> 9031.001 are set correctly. Only active nodes should be enabled.|
|The Autodoor CAN PCB does not have power.||Verify that the Low Volt Power supply is supplying power to the CAN Autodoor PCB.|
|The CAN node Communication cable is disconnected.||Power down machine for at least a minute. Verify all CAN communication cables are connected correctly.|
|The CAN Module ID Selector is incorrect.||Power down machine for at least a minute. Set ID selector correctly. Power up machine.|
|The CAN Modules have incorrect termination.||Power down machine for at least a minute. Verify that only last node in the chain is terminated. Power up machine.|
|The CAN Node needs to be reset.||Disable CAN Node via 9000.001 -> 9031.001. If the machine recovers (I/O page isn’t “X”) after disabling a particular node, try to enable the node again.|
|Spindle load pegs to 200%||
There is a problem with the 120 VAC outputs circuit components (solenoids, Wye-Delta, Oil Pump etc.)
|Inspect the wiring, pins, and connectors for this circuit. Inspect the I/O board for faults. Replace the I/O if necessary|
|Machine generates multiple Alarm 20014.1 SIO TOOL CHANGER PCB IS NOT PRESENT and 20014.0 SIO TOOL CHANGER PCB PRESENT after the I/O TC PCB is installed.
||The I/O or TC PCB firmware is outdated.||Update I/O Main and TC firmware version to the latest. Refer to Next Generation Control - I/O PCB Main Firmware - Update.|
|Machines equipped with I/O PCB P/N: 34-3490A/B with an auxiliary estop that generates an estop alarm after the closing of machine doors.||The doors closing have shaken the estop and caused a momentarily disconnect and caused an estop of the machine.||A debounce capacitor will need to be added to the I/O PCB. Refer to the E-Stop - Debounce procedure.|
|Main I/O Firmware fails to load.||TC PCB is causing the failure.||Remove the TC PCB from the Main I/O PCB. Then try the Firmware upgrade again.|
Depending on the machine software version, I/O PCB main firmware version you will get a different alarm, see table below:
Alarm# / Title
Software 100.17.000.2021 and lower
I/O PCB Main Firmware 02.04 and lower
Alarm# / Title
Software 100.17.000.2030 and higher
I/O PCB (34-348xC) Main Firmware 02.05 and higher
|9830-IOPCB MEMORY DATA LOCKED||Attempts were made to download an I/O configuration file while configuration memory was locked.|
|850-INTERNAL I/O ERROR||9800-INTERNAL I/O ERROR- SHIFT CHAIN||An internal I/O circuit board error has been sensed in it's shift chain. - Press the [RESET] button. Power off, and inspect the circuit components on the I/O PCB, see section below.|
|9801-INTERNAL I/O ERROR-TC COMMUNICATION||
An internal I/O circuit board error has been sensed where the main and tool changer microcontrollers could not communicate. - Press the [RESET] button.
Inspect the tool changer relays, make sure the relay sockets are solder into the PCB board.
Do not replace the I/O PCB.
For IO PCB (34-348xA):
· Upgrade the I/O PCB Tool Changer firmware to the latest 01.xx version.
For IO PCB (34-348xC):
· Update the I/O PCB Main firmware to the latest 02.xx version.
· Update the I/O PCB Tool Changer firmware to the latest 01.xx version.
For IO PCB (34-349x):
· Update the I/O PCB Main firmware to the latest 03.xx version.
Refer to Next Generation Control - I/O PCB Main Firmware - Update procedure.
|9900-IOPCB COMMUNICATION LOST||9802-SIO MCU COMMUNICATION LOSS||Communication has been lost to the I/O PCB. Check that the I/O PCB has power by looking for the 12/24V green leds. Look for a tripped circuit breaker. If the board has power, then|
|1. Check the RJ-45 cable connection from Maincon PCB (J14) to I/O PCB (J4). To test the cable refer to Network Cable Tester Tool procedure.|
|2. Check the 3-Phase power input from PSUP (P4) to I/O PCB (P55).|
|3. Inspect the RJ-45 connector on the Maincon PCB & I/O PCB for bent pins.|
|Upgrade the software to 100.17.000.2045 or higher. If you get this alarm with version 100.17.000.2045 or higher download an error report and e-mail to Haas service.|
|9831-I/O # ERROR||The main processor has command an output that is not configured in the I/O configuration file.|
|9832-SIO COMMUNICATION ERROR||The I/O PCB has received partial or invalid communication from the main processor.|
|9833-PCB OVER TEMPERATURE||The I/O PCB is reporting a temperature that exceeds limits (65 degrees C)|
|9834-12V FAULT||The 12V supply on the I/O PCB is outside of its limits of 10 to 14V.|
|175-GROUND FAULT DETECTED||9803-120VAC GROUND FAULT||A 120 VAC ground fault condition was detected by the I/O PCB. The ground fault signal gets generated by the PSUP PCB. The ground fault signal gets sent to I/O PCB at P56 for monitoring. Check all 120V outputs for possible shorts to earth ground. See ground fault troubleshooting section below.|
|9804-240VAC GROUND FAULT||A 240 VAC ground fault condition was detected by the I/O PCB. The ground fault signal gets generated by the PSUP PCB. The ground fault signal gets sent to I/O PCB at P56 for monitoring. Check all 240 V outputs for possible shorts to earth ground. This includes short circuits in any amplifier or vector drive ouput as well as any 240V pumps or chip conveyor. See ground fault troubleshooting section below.|
|9903-120 VAC SHORT CIRCUIT||9805-120VAC PHASE C SHORT CIRCUIT||A short circuit was detected in the 120V outputs from the iopcb. Check all 120V outputs for possible shorts to earth ground. See ground fault troubleshooting section below.|
|9835-120VAC PHASE C OVER CURRENT||A partial short circuit was detected in the 120V outputs from the iopcb. Check all 120V outputs for possible shorts to earth ground. See ground fault troubleshooting section below.|
|9836-120VAC PHASE C NO CURRENT||An output was turned on but no change in current was detected. Check for broken wires/cables.|
|9837-CALIBRATION ERROR||I/O PCB Calibration error. Either calibration did not occur during power up. Or the new calibration values don't match the previous values.|
|9838-TSC FAN FAILURE||The fan for the TSC heat sink stopped; could cause TSC over heating later on.|
|9820-TSC HEAT SINK OVER TEMP||The TSC Heat sink temperature is over the limit of 85°C. Check for a damaged fan.|
|9904-PCOOL MALFUNCTION||9806-PCOOL SHORT CIRCUIT||The programmable coolant circuit has detected a short circuit (>2.5A) and has shut down. Press the [RESET] button to clear alarms. If necessary, cycle power on the machine. Check for a shorted cable.|
|9807-PCOOL GROUND FAULT||The programmable coolant circuit has detected a ground fault condition and has shut down. Press the [RESET] button to clear alarms. If necessary, cycle power on the machine. Check for a shorted cable to earth ground.|
|9808-PCOOL OVERHEAT||The programmable coolant circuit has overheated and shut down. Give time for it to cool, then press the [RESET] button to clear alarms. Check for obstructions to pcool movement.|
|9839-PCOOL STALLED||A high current (2.5A> I >1A) was detected in the programmable coolant circuit. Check for obstructions to pcool movement. Check for binding in the pcool unit.|
|9840-PCOOL OVERLOAD||The programmable coolant circuit has detected an overload condition. Check for binding in the pcool unit.|
|9841-PCOOL MOTOR DISCONNECTED||The programmable coolant circuit was commanded on but no current was detected. Check to see if the pcool will turn when commanded. Check for broken wires. If the machine is equipped with 34-3090B I/O PCB make sure the Main I/O firmware has version 3.18 or higher. Refer to Next Generation Control - I/O PCB Main Firmware - Update procedure.|
|9905-IOPCB TOOL CHANGER FAULT||9809-TOOL CHANGER BUS SHORT CIRCUIT||The I/O PCB experienced an internal short circuit. Replace the 4 tool changer relays. If problem persists, then replace the iocpb.|
|9810-INTERNAL I/O ERROR-TC TRANSISTOR FAILURE||The I/O PCB tool changer (or bar feeder) transistor appears to be damaged. Replace the I/O PCB.|
|9811-TOOL CHANGER CABLE SHORT CIRCUIT||One of the tool changer outputs has detected a short circuit. Check all tool changer motor outputs for possible short circuits.|
|9812-TOOL CHANGER GROUND FAULT||A ground fault condition was detected by the I/O PCB tool changer. Check all tool changer motor outputs for possible short circuits to earth ground.|
|9813-TOOL CHANGER REGEN SHORTED||The I/O PCB experienced a short circuit on the tool changer regen circuit. Check for a short circuit on it's external regen resistor at P57.|
|9814-CAROUSEL BRAKE RESISTOR OVER TEMPERATURE||TBD|
|9815-ARM BRAKE RESISTOR OVER TEMPERATURE||TBD|
|9817-MULTIPLE MOTOR COMMANDS||TBD|
|9818-TOOL CHANGER OVERLOAD||TBD|
|9822 - IOPCB VERTICAL BRAKE FAILURE||NGC machines equipped with I/O PCB P/N: 34-3490A/B and a servo brake motor may generate alarm 9822 IOPCB Brake. Upgrade the Main I/O PCB firmware to 3.06 or higher. Refer to I/O PCB Firmware - Update - NGC procedure.|
Upgrade the Main I/O PCB Firmware to 4.21 or higher.
|880 - UNDER VOLTAGE ON 160V DC BUS||9843-TC UNDER VOLTAGE||
The system detected an undervoltage condition from the TC circuit or the TC PCB. Check the 115 VAC input to the TC PCB, check for shorts on the tool changer motors.
|9847-MOTOR DISCONNECTED||The control software and the I/O firmware are not compatible, or the I/O firmware is outdated.|
|9906-CHIP CONVEYOR MALFUNCTION||9819-CHIP CONVEYOR SHORT CIRCUIT||TBD|
|9848-CHIP CONVEYOR MOTOR DISCONNECTED||TBD|
Components to Check when a Ground Fault Alarm Occurs
Note: *These devices can be disconnected from the I/O PCB without an alarm being generated.
|Machine Components||I/O PCB Location||Operating Voltage|
|4th and 5th Axis Brake Solenoids*||P16 - P17||120 VAC|
|Worklights*||P18 - P21||120 VAC|
|High Intensity Lights*||P22||120 VAC|
|Door Interlocks*||P40, P41, P42||120 VAC|
|Lube Panel Solenoids||P35, P36||120 VAC|
|Y/D Contactor Coil||P37, P38||120 VAC|
|DC Tool Change Motors*||P58||160 VDC, generated from the 120 VAC|
|Spindle Motor Fan / Oil Pump||P32||120 VAC|
|Sub Spindle Fan / Hydraulic Pump Fan||P33||120 VAC|
|TSC/HPC Pump*||P31||240 VAC|
|Coolant Pump*||P29||240 VAC|
|Chip Auger / Conveyor*||P24, Quad PCB||240 VAC|
|Axis Motors||240 VAC|
|Spindle Motor||240 VAC|
|Hydraulic Pump Motor||240 VAC|
I/O PCB Interconnect Diagram
I/O PCB (P39) to Mill - Spindle Head Inputs Detail Diagram
I/O PCB (P34, P35) to Mill - Air/Lube Panel Detail Diagram
PSUP (P17) to I/O PCB (P56) Detail Diagram
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