Vector Drive - 20HP and 40HP - Replacement

AD0056

Revision A - 05/2025

Introduction

This procedure tells you how to replace a 20 hp or a 40 hp vector drive.

Haas machines have one of these vector drive types:

  1. Type 1: Smart vector drive, with built-in filter (current style)
  2. Type 2: Smart vector drive, with front cover
  3. Type 3: Smart vector drive, without front cover
  4. Type 4: Classic vector drive        

All of the replacement vector drives look like Type 1. The procedure varies depending on which type is currently installed.

Note: PN: 93-3754 CABLES FOR UPGRADE TO SMART VD HFD2/HFD4 needs to be ordered when replacing a Type 4 Vector Drive.

If replacing a type 4 vector drive, you may need to cut holes in the control cabinet door for the vents on the Type 1/2 vector drive. Refer to AD0245 - Vector Drive - Vent Hole Modification for how to cut the holes in the cabinet door.

Caution: Make sure you correct the root cause of the vector drive failure before you power on the new vector drive. Failure to correct the root cause of the vector drive failure can cause the new vector drive to fail. Refer to the Haas Vector Drive Troubleshooting Guide.

  • KIT PN: 93-32-5559E, VECTOR DRIVE, 20HP SMART WITH BUILT-IN FILTER 
  • KIT PN: 93-32-5558E, VECTOR DRIVE, 40HP SMART WITH BUILT-IN FILTER

Note: Refer to AD0294 for instructions on how to replace a 60HP Vector Drive.

Electrical Safety

 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.

  • Set the main circuit breaker to the [OFF] position.

 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.

Replacement

1

Push [POWER OFF].

Set the main circuit breaker to the [OFF] position. Lock the main circuit breaker.

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

Put a label on each cable connected to the vector drive. Disconnect all of the cables from the vector drive.

Loosen the (2) bottom screws [1].

Remove or loosen the top (2) screws [1].

Remove the vector drive [2].

3

Do this step to replace a Type 1 or Type 2 vector drive assembly only.

Install the replacement VECTOR DRIVE [A].

Tighten the (4) screws.

Connect all of the cables.

Note: The door intake filter [1] is not necessary when installing a Type 1 vector drive. To prevent confusion remove and discard the door intake filter and frame if equipped. Having both filters will cause inadequate air flow to the vector drive.

4

Do this step to replace a Type 3 or Type 4 vector drive assembly only.

Remove and discard the VECTOR DRIVE [A] cover [1].

Move the heatsink cover [2] to the front.

Install the replacement vector drive.

Tighten the (4) screws for the vector drive.

For only type Type 3: vector drives connect all of the cables.

5

Do this step only for Type 4: vector drives.

 Note: PN: 93-3754 needs to be ordered when replacing a Type 4 Vector Drive.

Remove cable 33-4049A. This cable is connected between J1 on the vector drive and P11 on the I/O PCB.

Note: For machines made before January 2000, the cable is connected to P18.

Remove cable 33-0969A. This cable is connected between the vector drive and the transformer.

Connect CABLE 970 [C] between J1 [2] on the vector drive and P11 [1].

Note: For machines made before January 2000, connect the cable to P18.

Connect CABLE 77/78/79 [B] between the power-distributor block [4] for the transformer and the vector drive terminals 4, 5, and 6 [3].

6

Set the main circuit breaker to the ON position.

Push POWER ON.

Classic Haas Control

Change parameter 57:29, INV BUSS PWR FAULT to 1.

For machines with lathe software versions 7.02, 8.04, 8.05, and 8.06: Change parameter 712, VDI/MINI P.S. TYPE to 2.

For machines with mill software versions 14.05, 15.04, 15.05, and 15.06: Change parameter 712, VDI/MINI P.S. TYPE to 2.

Vector Drive - 60 HP - Replacement

AD0294

Revision A - 05/2025

Introduction

This procedure tells you how to replace a 60 hp vector drive.

Haas machines have one of these 60 hp vector drives:

  1. Type 1: Classic vector drive
  2. Type 2: Smart vector drive (current style)

All of the replacement vector drives look like Type 2.

Document Applies to these Parts

KIT PN: 93-32-5560, VECTOR DRIVE, 60HP SMART.

Electrical Safety

 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.

  • Set the main circuit breaker to the [OFF] position.

 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.

Replacement

1

Push [POWER OFF].

Set the main circuit breaker to the [OFF] position. Lock the main circuit breaker.

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

Put a label on each cable connected to the vector drive. Disconnect all of the cables from the vector drive.

Loosen the (2) bottom screws [1].

Remove or loosen the top (2) screws [1].

Remove the vector drive [2].

3

Install the replacement VECTOR DRIVE [A].

Tighten the (4) screws.

Connect all of the cables.

4

After you replace a Type 1 vector drive with a Type 2 vector drive, you must do the Control - Cabinet Door - Vent Hole Modification procedure.

Vector Drive - Intake Filter - Installation

AD0097

Applies to machines built from: January, 2007

Introduction

This procedure tells you how to install the intake filter [1] for the vector drive.

Document Applies to these Parts

KIT PN: 93-2185    FILTER, VECTOR DRIVE INTAKE KIT

Electrical Safety

 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.

  • Set the main circuit breaker to the [OFF] position.

 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.

Installation

1

Clean the electrical cabinet door around the vector drive air intakes with alcohol.

Put the GASKET [B] on the FILTER POCKET [A].

Remove the paper [1] that covers the adhesive on the GASKET [B].

Attach the top hook of the FILTER POCKET [A] to the bottom edge of the upper door vent opening [2].

Press down on the edges [4] of the FILTER POCKET [A] to attach it to the electrical cabinet door.

Note: Make sure that the coarse side of the VENT FILTER [C] (the side with the pull tab [3]) faces out.

Insert the VENT FILTER [C] into the frame until it clips into place.

2

Filter Maintenance

  1. Check the filter at regular intervals for dirt.
  2. Remove the filter from the frame.
  3. Clean the filter with warm soapy water and a soft brush.
  4. Rinse the filter with warm water and dry it.
  5. Insert the filter into the frame until it clips into place.
    Note: Make sure that the coarse side of the filter (the side with the pull tab) faces out.

Vector Drive - Maintenance

Introduction

Dust builds up around the vector drive and causes the vector drive to over-heat. This procedure tells you how to clean the vector drive.

Haas machines have one of these vector drive types:

  1. Type 1: Smart vector drive, with built-in filter (current style)
  2. Type 2: Smart vector drive, with front cover
  3. Type 3: Smart vector drive, without front cover
  4. Type 4: Classic vector drive

Electrical Safety

 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.

  • Set the main circuit breaker to the [OFF] position.

 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.

Maintenance

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.

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 60 seconds

2

Do this step for Type 1 vector drive only.

Open the electrical cabinet door and pull out the vector drive filter [1].

Clean the filter as shown on the decal and re-install it to the vector drive. Close the cabinet door.

Important: Make sure the filter is completely dry before reinstalling it to the vector drive.

3

Do this step for Type 2 and 3 vector drive only.

Remove the cover [2] and the heat sink cover [3]. The heat sink cover [3] is installed on the top or the front of the vector drive.

Use a vacuum with a brush adapter to remove dust from the vector drive vents [4]. Install the heat sink cover [5] to the front of the vector drive. Do not install it on the top of the vector drive. Install the cover [2]. Examine the weather strips on the door for the electrical cabinet. Replace them if necessary.

Optional: Add a filter to your electrical cabinet door to decrease the amount of dust that enters the electrical cabinet. Go to parts.haascnc.com. Under Find Replacement Parts, search for your Filter in the category Electrical Cabinet

4

Make sure the Vector Drive operates correctly: Run the spindle for several minutes. The fan on the vector drive will only operate when it becomes hot.

Introduction

Download and fillout the Vector Drive Inspection Report Checklist below before replacing any parts.

Vector Drive Inspection Report Checklist

The Haas Vector drive is the source of power for the spindle motor and the servo amplifiers. There are three sizes of Haas Vector drives: 20HP [1], 40HP [2] and 60HP [3].

Spindle Drive Components Overview Video

This service video shows a quick illustration of how the Haas Control functions during a spindle command.

Note: This service video is for reference only and does not replace the written troubleshooting information.

Electrical Safety

 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.

  • Set the main circuit breaker to the [OFF] position.

 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.

Vector Drive Troubleshooting Video

Symptom Table

Symptom Possible Causes Corrective Action

Alarm 123 SPINDLE DRIVE FAULT and

Alarm 993 SHORT CIRCUIT

 The vector drive detected a short circuit. Inspect the Vector Drive and the Wye-Delta contactors for a short circuit. For Delta-Wye Contactor Troubleshooting refer to: Wye-Delta Contactor - Troubleshooting Guide - NGC. See the Vector Drive short-circuit inspection section below.
Alarm 4.993 S (SPINDLE) SHORT CIRCUIT The vector drive has detected a short circuit.
  1. Inspect the Vector Drive using the Short-Circuit Inspection section below. 
  2. Once the Vector Drive is inspected refer to the Spindle Motor Troubleshooting Guide to inspect the spindle motor and cable.

Alarm 123 SPINDLE DRIVE FAULT

Alarm 160 LOW INCOMING AC LINE VOLTAGE

 There is a problem with the DC Bus. Compare the measured DC voltage to the Diagnostic page. See the DC BUSS section below.

Alarm 123 SPINDLE DRIVE FAULT

Alarm 160 LOW INCOMING AC LINE VOLTAGE

at power on.		 The vector drive J3 connector inserted upside down. The old style Vector Drive J3 connector does not have ribs and can be accidentally inserted upside down. This could damage the pins. Correctly inserted, the latch faces away from the Vector drive.
Alarm 647 REGEN LOAD SHORTED
 There is a problem with the REGEN. Measure the resistance across the REGEN leads. See the Regen Load section below.

Alarm 648 DC BUS SHORTED

 

 There is a problem with the REGEN circuit on the vector drive. Check the regen circuit on the vector drive. See the Regen Load section below.
Alarms 9911 AXIS AMPLIFIER CABLE DISCONNECTED The motor drive cable from Maincon to Amplifier is not connected or has a bad connection. Check the corresponding axis motor drive cable from the Maincon to the Amplifier and make sure is seated correctly.
Alarm 200 HIGH VOLTAGE POWER SUPPLY OVER–TEMPERATURE
 There is a problem with the vector drive cooling fan. Inspect the cooling fan. See the Cooling Fan section below.

Alarm 444 REGEN REMAINED ON TOO LONG

 There is a problem with the incoming AC power. Measure the incoming voltage to the machine. See the Incoming AC Voltage section below.
The Machine Fails to Maintain Spindle Orientation. The vector drive output is unbalanced. Measure voltage outputs across the vector drive terminals. See the Unbalance Output Inspection section below.
The wye contactor has a loose connection on the buss bar or jumper cables. Inspect the wye-delta assembly for loose connections.
Alarm 119 INPUT AC LINE OVERVOLTAGE The incoming voltage to the machine is too high. The check incoming voltage and transformer taps.
The vector drive over voltage cable is not plugged in or defective. Disconnect the 970 cable from connector J1 on the vector drive. Inspect the J1 connector pins and the pins on the 970 cable for damage. Make sure that the cable is connected to the correct I/O PCB location.
  • I/O PCB: P49
Alarm 9931 UNDEFINED HIGH VOLTAGE POWER SUPPLY FAULT The cable from the vector drive to the I/O PCB is not plugged in correctly. Make sure the cable from the Vector drive is correctly connected to the I/O PCB at P49.
Alarm 4.182 S (SPINDLE) AXIS ENCODER CABLE FAULT The Vector Drive cables are missing the ferrite filter or wrong filters nstalled.  Refer to the Spindle Encoder - Troubleshooting Guide - NGC
Vector Drive ground cable is routed in the large ferrite filter

Short Circuit Inspection

Corrective Action:

Inspect the spindle motor cables. Make sure the spindle motor cables are not contaminated or pinched.

Inspect the vector drive. Disconnect all the vector drive terminals and do the following tests:

Set your meter to Ohms test mode.

  • Put the black lead on chassis with the red lead measure terminals 4 (A), 5 (B) and 6 (C).

If the meter does not show OPEN (O.L) the vector drive is damaged.

Set your meter to Ohms test mode.

  • Put the black lead on terminal 2 (+) with the red lead measure the motor output terminals 9 (A), 10 (B) and 11 (C).

The meter should show high resistance readings typically in the Kilo or Mega ohms or O.L.  If the meter reads very low resistance the Vector drive is damaged.

Note: If the meter shows O.L this indicates an open circuit and there is no short between the terminals.

Set your meter to Ohms test mode.

  • Put the black lead on terminal 3 (-) with the red lead measure the motor output terminals 9 (A), 10 (B) and 11 (C).

The meter should show high resistance readings typically in the Kilo or Mega ohms or O.L.  If the meter reads very low resistance the Vector Drive is damaged.

Note: If the meter shows O.L this indicates an open circuit and there is no short between the terminals.

Set your meter to Ohms test mode.

  • Put the black lead on terminal 3 (-) with the red lead measure terminal 1 (R).

If your meter reads less than100k ohms, the vector drive is damaged.

Regen Load

Corrective Action:

Press [POWER OFF]. If the vector drive voltage indicator light is on, do not touch the electrical components. The high voltage in the control cabinet can kill you. Wait for the voltage indicator LED on the vector drive to go off completely.

Disconnect the REGEN load leads from the vector drive at terminals 1 and 2. Measure the resistance across the leads. The reading must be as follows:

  • 2-resistor box: between 9.5 and 12.5 ohms.
  • 3-resistor box: between 6.3 and 8.3 ohms ohms. (As shown in the illustration.)
  • 4-resistor box: between 4.6 and 6.6 ohms.

If the REGEN loads are within specification, there can be a problem with the vector drive. Measure the resistance across terminals 1 and 3 on the vector drive.

 Note: A good drive will read a high resistance across 1 and 3 (somewhere in the Kilo ohm range). A short circuit indicates a faulty vector drive.

DC BUSS

Corrective Action:

Press [POWER ON]. Measure the DC voltage between terminals 2 and 3 on the vector drive. Compare the measured voltage with the DC VOLTAGE on the diagnostics page on the control. The readings must match +-2%.

If the readings do not match, the problem can be:

  • A bad connection on the 640C cable. Make sure there is a tight connection on the J3 connector on the Vector Drive and the P17 connector on the Maincon/Mocon.
  • A faulty Vector Drive if you have incorrect voltage at P17.
  • A faulty Maincon/Mocon if you have the correct voltage on the 640C cable at the P17 connector of the Maincon/Mocon. There is 0.01 VDC for every 1 VDC Bus. For example, 320 VDC must show 3.2VDC.

Disconnect the DC Bus cables from terminals 2 and 3 on the vector drive. Power on the machine. Monitor the DC VOLTAGE on the diagnostics page of the control.

  • If the DC Bus goes back to the nominal value, there is a short in one of the servo amplifiers. A low resistance or a short is a sign of a faulty servo amplifier.
  • If the readings match and the alarm continues, the problem is a faulty vector drive.

Cooling Fan

Inspect the spindle fan cable connection.  Make sure both spade connectors are properly going into the female connector.

Corrective Action:

An over-temperature alarm is generated when the vector drive's heat-sink reaches 90°C. The cooling fan must turn ON when the heat-sink temperature reaches 50°C. The cooling fan must turn OFF as the heat-sink cools down.

Measure the temperature of the vector drive's heat-sink through the exhaust vents when this alarm occurs. If the temperature is above 60°C and the fan is not ON, the vector drive has a faulty cooling fan. Replace the cooling fan.

Incoming AC Voltage

Corrective Action:

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).

 The input voltage cables labeled 74, 75, and 76 must be moved to the terminal block triple which corresponds to the average voltage measured.

Unbalance Output Inspection

Corrective Action: Disconnect the motor cables at the vector drive. Push [POWER ON]. Push [RESET] to clear any alarms. Use a multimeter to measure the DC voltage across the following terminals on the vector drive (see the illustration):

  • 3 and 9
  • 3 and 10
  • 3 and 11

The voltage measured must be approximately half of the DC Buss in all three readings.

IMPORTANT: If any of the voltage readings is 0V or 330V, then this is a sign of an unbalanced output from the vector drive.  DO NOT REPLACE THE VECTOR DRIVE IF THE ABOVE CONDITIONS ARE NOT MET.

Check Cables & Terminal Connections

Reconnect all cables that were removed and check that all terminal connections are tight and secure. After connecting all cables, power on the machine and try to reproduce the alarm(s). 

Electrical Diagram