This procedure tells you how to replace the PSUP PCB on a machine that has the Next Generation Control.

Safety Notes:

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 falling.
• Never alter any safety circuits on the machine.
• Never change any parameter while in [DEBUG] mode (Classic Haas Control) and he servos [ON]. Put the machine in [EMERGENCY STOP] mode to change any parameters.
• Never operate the machine in [DEBUG] mode (Classic Haas Control).

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 serice work performed by our 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 procedure contact you Haas Factory Outlet (HFO) and schedule a service visit.

Prerequisites

Caution: If the machine has a 4075-N and software version lower than 100.16.000.1040 you must install a patch to change Parameter 2009 Before you install the replacement PSUP PCB. Failure to do so will cause the machine to shut down immediately upon power up. If you are replacing a 4075-P or later, no patch is required. Refer to Patch File Load / Uninstall - NGC.

If you install the new PSUP PCB on a machine with software lower than 100.16.000.1040 and did not applied the patch, you must do a clean software installation. Refer to Software Update - (Option 5) Clean Installation - NGC.

This Document Applies to:

• KIT PN: 93-32-4075T, SVC KIT NGC PSUP-T 3PH CCA

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 vectore drive to go off completely.

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

If a circuit breaker is at the TSC/HYD pump position on the PSUP PCB, remove it. Keep this breaker to install on the replacement PCB.

Put an identification label  each cable that is attacjed to the PCB. This makes the installation easier. Disconnect these cables.

Remove the standofs.

Remove the PCB.

If the machine uses 480V, remove the jumper [1] at JP1 on the PSUP- T 3PH CCA PCB [A].

If the machine has a 60 hp vector drive, install the 2A CERAMIC FUSE [B] at F1.

If the machine uses a circuit breaker for the TSC/HYD pump, do these steps:

• remove the covers [2] for the connectors.
• remove the jumper [3] at JP2.
• install the breaker [4] at the TSC/HYD pump position.

Install the replacement PSUP PCB.

Install the standoffs.

Connect all of the cables.

Set all of the circuit breakers on the PSUP PCB to the [ON] position.

[POWER ON] the machine.

Make sure that LE1 [1], LE2 [2], and LE3 [3] are [ON], and the phase detect-pass lamp [4] is [ON] (green light).

• Single phase machines
  • The phase-detect-pass lamp [4] must be on
  • The phase-detect-fail lamp [5] must be on
• Three phase machines
  • The phase-detect-pass lamp [4] must be on
  • The phase-detect-fail lamp [5] must be off

Caution: 3 Phase Machines Only:

If lamps [4] and [5] are [ON]. the system has a loose wire, or a defective power source. 

Make sure that all three phases have power.

If only the phase-detect fail lamp is on, the leads are in the incorrect sequence.

Disconnect the machine from the main power supply and interchange two of the three leads to the machine.

• Embeds the Power Fault Detect Module. Now standard on all machines equipped with the Next Generation Control.
• Indicates the Status of the three phase power.
• Low Voltage power indicator LEDs.
• Circuit breaker open indicator circuit.
• Added a ground fault detect circuit for the 115 VAC line.

There is an embedded power fault detect monitor built-in to the NGC power card PCB. The circuit monitors the 115VAC output of the main transformer (TB 94, 95). This circuit produces a 0 - 5 VDC reference voltage to the main NGC PCB. This reference voltage varies in proportional to the incoming AC voltage. The variance in this voltage will cause the AC Line Voltage gauge to change. When the output of the transformer equals 120 VAC the control will show 100% AC LINE VOLTAGE. This gauge is located under DIAGNOSTIC / GAUGES. 

 Note: The data signal input from the PFDM can be viewed under the MOCON Tab listed as Pfdm Incoming Power Voltage.

Corrective Action:

1. Measure the incoming AC voltage to the machine.
2. Make sure the transformer taps are in the correct voltage range.
3. Make sure the 115 VAC output cable from the transformer terminal block 94, 95 is properly connected to the power card at P1.
   

    Note: When the 115 VAC output of the transformer equals 120VAC the control will show 100% AC LINE VOLTAGE.

4. Measure the brown and the blue wire on the PSUP PCB behind the P20 connector (see illustration) .
   

    Caution: Make sure you use needle tip leads on your meter. Be careful not to short your leads together this can cause damage to the NGC power PCB.

   You should measure approximately:
   • For a Rev -N Power Card 3.56 VDC.
   • For a Rev -P Power Card 3.74 VDC.
   If low or no voltage is measured, the voltage monitor circuit on the power card is damaged and will need to be replaced.

   If the voltage is correct:

   • For a Rev -N Power Card make sure parameter 2009 ADC VALUE FOR AC INPUT is set to 3550.
   • For a Rev -P Power Card make sure parameter 2009 ADC VALUE FOR AC INPUT is set to 2850.

    Note: To view the parameter values refer to Next Generation Control - How to Read an Error Report for more information.

    

   If the value of parameter of 2009 is not correct you will need to load a patch file. Go to the portal click on Service>Machine Activation Codes>NGC-Configuration, and download the patch under the Field Installed Options section.

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
9. Circuit breakers not installed correctly.

Use a magnifying glass to inspect the circuit components on the front and back of the PSUP PCB. Below are the circuit component zones to inspect depending on the alarm or symptom:

1. Power Fault Detect Module circuit components, look for leaky capacitors, damaged components.
2. Ground fault monitor circuit, inspect surface mount components, resistors and bent pins on the connectors.
3. Circuit breaker trip circuit, pull breakers and inspect for burnt components underneath the breakers.
4. Inspect for bent or missing pins on the connectors.
5. Inspect all solder joints and surface mount components on the back of the PSUP PCB.

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