36.1 - 115V High Intensity Lighting - Installation

115V High Intensity Lighting - Installation

AD0052

Introduction

This procedure tells you how to install the optional 93-1000288 115VAC High Intensity Lighting (HIL) systems on VMCs and lathes.

 NOTE: For VF-6 to VF-12 order 93-1000523  HIL MOUNT BRACKET KIT to mount the High Intensity Lights.

Machine Compatibility:

  • Next Generation Control
  • 115V LED Work Lights

Tool Required:

  • 1/4" Hex
  • 1/4", 3/8" Wrench

 

High Intensity Lighting - Installation

1

Attach the BRACKET, LIGHT MOUNT ARM [C] to the BRACKET, LIGHT MOUNT PIVOT [F]. Use the 1/4-20 LOCKNUT NYLN INSRT [I].

Attach the HIL power cable [3] to the BRACKET, LIGHT MOUNT ARM [C]. Use the (2) CABLE CLAMP 1/4 [K] and (2) NUT, 10-32 NYLON LOCK [L].

Make (2) of these assemblies.

2

Remove the top cover panel [1] from the enclosure as necessary to get access to the control cabinet.

Put the CABLE, NGC HIL LIGHT [E] into the control cabinet and attach it to the enclosure. Use CLAMP 7/16" [J], CABLE TIE BLK 5.6 LG [N], and CABLE TIE CLAMP 16 LBS [O].

Install the WORKLIGHT, LED LAMP ASSEMBLY [B] above the main doors. Use (2) SCREW, FBHCS 1/4"-20 X 1/2" [H].

Connect the lamp cable to the CABLE, NGC HIL LIGHT [E].

3

For models: VF-1/2

NOTE: If the autodoor option was installed with the HIL option a riser plate [1] will need to be installed to avoid interference. 

The image shows the left HIL riser plate being installed, the plate [1] will need to be installed using FBHCS 1/4-20 X 1/2 LOCTITE [2] to the top enclosure. Then you will mount the HIL to the riser using FBHCS 1/4-20 X 1/2 LOCTITE [3]

 

4

For models VF-1/2:

The image shows the right HIL riser plate being installed, the plate [1] will need to be installed using FBHCS 1/4-20 X 1/2 LOCTITE [2] to the top enclosure. Then you will mount the HIL to the riser using FBHCS 1/4-20 X 1/2 LOCTITE [3].

 

5

For models: VM-6, VF-6 through 12.

 Note: Use the HIL MOUNT BRKT KIT VF-LARGE (P/N 30-12027A) kit.

Fully clean the front panel above the doors.

Attach the BRACKET, HIL MOUNT [G] to the BRACKET, LIGHT MOUNT ARM [C]. Use (1) SCREW,FBHCS 1/4"-20 X 1/2" [H] and (1) 1/4-20 nut.

Remove the backing paper from the adhesive tape [1] at the bottom of the BRACKET, HIL MOUNT [G].

Install the light assemblies above the main doors. Use (2) SCREW, FBHCS 1/4"-20 X 1/2" [H]. Push the tape tightly against the front panel.

Connect the cables from the light assemblies to the CABLE, 24V EXT [E].

Put the CABLE, 24V EXT into the control cabinet. Attach the cable to the cable channel [3]. Use CABLE TIE BLK 5.6 LG [N].

6

Connect the CABLE, HIGH INTENSITY LIGHTING BRANCH [E] to P22 [1] on the I/O PCB.

Do these steps to install the PUSH BUTTON, BLACK [D]:

  • Remove the switch plug [2] from the pendant.
  • Install the PUSH BUTTON, BLACK [D].
  • Connect the CABLE, HIGH INTENSITY LIGHTING COMMAND [M] to the PUSH BUTTON, BLACK [D].
  • Connect the other end of the command cable to J8 [3] on the SKBIF PCB.

7

To install the PUSH BUTTON, BLACK [D]:

  • Remove the pendant cover [1].
  • Remove the switch plug [2] from the pendant.
  • Install the PUSH BUTTON, BLACK [D].
  • Connect the CABLE, HIGH INTENSITY LIGHTING COMMAND [M] to the PUSH BUTTON, BLACK [D].
  • Connect the other end of the command cable to J8 [3] on the SKBIF PCB.

8

Push [POWER ON].

Change Setting 238, HIGH INTENSITY LIGHT TIMER, to 1.

Open the doors. If the HIL system operates correctly, the lights come on.

Wait one minute. If the HIL system operates correctly, the lights go off.

Change Setting 238, HIGH INTENSITY LIGHT TIMER to your preference.

36.2 - 24V High Intensity Lighting - Installation

24V High Intensity Lighting - Installation

AD0614

Introduction

This procedure tells you how to install the optional 93-1000278 24VDC High Intensity Lighting (HIL) systems on VMCs and lathes.

 NOTE: For VF-6 to VF-14 order 93-1000523 HIL MOUNT BRKT KIT LRG VF to mount the High Intensity Lights.

Machine Compatibility:

  • Next Generation Control 
  • 24V LED Work lights

Tool Required:

  • 1/4" Hex
  • 1/4", 3/8" Wrench

NOTE: 93-1000393 AUTODOOR & HIL RISER SML/MED MILL,LATHE needs to be ordered if you are installing HIL on a VF-1/2 or Lathe with autodoor already installed.

NOTE: HIL MOUNTING BRACKET, is only for VF-6 thru 14. It is included in HIL MOUNT BRKT KIT LRG VF (P/N 93-1000523).

High Intensity Lighting - Installation

1

Attach the BRACKET, LIGHT MOUNT ARM [C] to the BRACKET, LIGHT MOUNT PIVOT [F]. Use the 1/4-20 LOCKNUT NYLN INSRT [I].

Attach the HIL power cable [3] to the BRACKET, LIGHT MOUNT ARM [C]. Use the (2) CABLE CLAMP 1/4 [K] and (2) NUT, 10-32 NYLON LOCK [L].

Make (2) of these assemblies.

2

For Lathes

NOTE: If the autodoor option was installed with the HIL option, a riser plate will need to be installed to avoid interference. 

Remove the top cover panel [1] from the enclosure as necessary to get access to the control cabinet.

Put the CABLE, 24V EXT [E] into the control cabinet and attach it to the enclosure. Use CLAMP 7/16" [J], CABLE TIE BLK 5.6 LG [N], and CABLE TIE CLAMP 16 LBS [O].

Install the WORKLIGHT, LED LAMP ASSEMBLY [B] above the main doors. Use (2) SCREW, FBHCS 1/4"-20 X 1/2" [H].

Connect the lamp cable to the CABLE, 24V EXT [E].

NOTE: Neatly tidy up and route the power cables. For Reboot style Lathe Machines, see the step below.

Lathe Reboot Power Cable Routings

Route the power cables [1] through the cable covers as shown.

 

 

 

3

For models: VF-1/2

NOTE: If the autodoor option was installed with the HIL option a riser plate [1] will need to be installed to avoid interference. 

The image shows the left HIL riser plate being installed, the plate [1] will need to be installed using FBHCS 1/4-20 X 1/2 LOCTITE [2] to the top enclosure. Then you will mount the HIL to the riser using FBHCS 1/4-20 X 1/2 LOCTITE [3]

 

4

For models VF-1/2:

The image shows the right HIL riser plate being installed, the plate [1] will need to be installed using FBHCS 1/4-20 X 1/2 LOCTITE [2] to the top enclosure. Then you will mount the HIL to the riser using FBHCS 1/4-20 X 1/2 LOCTITE [3].

 

5

For models: VM-6, VF-6 through 14.

 Note: Use the HIL MOUNT BRKT KIT LRG VF (P/N 93-1000523) kit.

Fully clean the front panel above the doors.

Attach the BRACKET, HIL MOUNT [G] to the BRACKET, LIGHT MOUNT ARM [C]. Use (1) SCREW,FBHCS 1/4"-20 X 1/2" [H] and (1) 1/4-20 nut.

Remove the backing paper from the adhesive tape [1] at the bottom of the BRACKET, HIL MOUNT [G].

Install the light assemblies above the main doors. Use (2) SCREW, FBHCS 1/4"-20 X 1/2" [H]. Push the tape tightly against the front panel.

Connect the cables from the light assemblies to the CABLE, 24V EXT [E].

Put the CABLE, 24V EXT into the control cabinet. Attach the cable to the cable channel [3]. Use CABLE TIE BLK 5.6 LG [N].

6

Mount 100W POWER SUPPLY [P] above the standard 24V work light power supply using PPHS SCREWS [R].

Connect the POWER SUPPLY CABLE [Q] to the 100W POWER SUPPLY [P] terminals L,N and ground.

Route the other end of the POWER SUPPLY CABLE [Q] over and 100W POWER SUPPLY down the left cable track and connect it to P22 on the I/O PCB.

Connect the HIL EXTENSION CABLE [E] to V+ and V- terminals on the 100W POWER SUPPLY. Red to V+ and black to V-. 

Important:  Cable HIL EXTENSION CABLE [E] needs to be routed along the left panel.  Do not route the extension cable through the center track with the High Voltage cables..

Important: Secure all cables and make sure the wires don't get caught on the door.

 

7

To install the PUSH BUTTON, BLACK [D]:

  • Remove the pendant cover [1].
  • Remove the switch plug [2] from the pendant.
  • Install the PUSH BUTTON, BLACK [D].
  • Connect the CABLE, HIGH INTENSITY LIGHTING COMMAND [M] to the PUSH BUTTON, BLACK [D].
  • Connect the other end of the command cable to J8 [3] on the SKBIF PCB.

8

Push [POWER ON].

Change Setting 238, HIGH INTENSITY LIGHT TIMER, to 1.

Open the doors. If the HIL system operates correctly, the lights come on.

Wait one minute. If the HIL system operates correctly, the lights go off.

Change Setting 238, HIGH INTENSITY LIGHT TIMER to your preference.

36.3 High Intensity Light - Troubleshooting Guide

High Intensity Light - Troubleshooting Guide - NGC

TG0169

Introduction

High Intensity Lighting (HIL) are either:
  • 120VAC LED lamps . 
  • 24VDC LED lamps .

 

Symptom Table

Symptom Possible Cause Corrective Action
The light does not power on. Problem with the GFCI circuit/receptacle.

If the machine has a GFCI, check if the GFCI is tripped.
If the receptacle needs to be replaced, order the following part number:

  • For machines with 120VAC LED lamps: 74-1807
  • For machines with 24VDC LED lamps: 74-0078
Problem with the LED assembly. Check the light for damage. Check for 120 VAC or 24 VDC at the fixture connector. It must be replaced if the voltage is correct and the LED does not work. If the LED is flickering on and off, re-seat the connections. If flickering continues, replace the LED assembly.
Problem with the worklight or HIL momentary button. Go to the Diagnostics / Keyboard I/O page and toggle the button. Check the switch operation with an Ohm meter to see if the bit does not toggle in Diagnostics.
The cable from the HIL momentary button to the SKBIF is incorrectly wired. See the HIL Button Cable Incorrectly Wired section for additional details.
Incorrect input voltage selection on Worklight or HIL low voltage power supply.

Locate the 24V Work Light/HIL LVPS next to the left panel, and set the voltage input switch to 115V. 

Follow the  24V Work Light - LVPS - Replacement procedure for detailed instructions.
The light flickers. Problem with the LED assembly. Check the light for damage. Check for 120 VAC or 24 VDC at the fixture connector. If the voltage is correct and the LED does not work, it must be replaced. If the LED is flickering on and off, re-seat the connections. If flickering continues, replace the LED assembly.
Problem with the HIL/Worklight cable routing or a missing ferrite filter. This applies only to the 24VDC HIL/Worklight assemblies. Make sure the Hil/Worklight cable is routed on the left side of the cabinet. Also, make sure a ferrite filter is installed on the regen cable.
On Medium VMCs (VF-3 to VF-5), the 24V Work Table Light flickers when the machine comes on or when commanded to turn on. The machine has a 100W power supply for the work lights installed. DO NOT REPLACE THE TABLE WORK LIGHT.  Upgrade to the 200W power supply,  order 93-3521, and follow the 24V Work Light - LVPS - Replacement procedure.  

NOTE: Not all VF-3 to VF-5 with the work table option will experience light flickering. Depending on the tolerances/voltages, plugging the 3 lights into the 100W power supply in some scenarios wouldn't cause the lights to flicker as the power supply doesn't enter the overload protection mode.
Alarm 552  TRIPPED CIRCUIT BREAKER The incorrect GFCI was installed If a machine has a 120V Worklights or HIL, ensure the outlet is a GFCI. 
Note:  Machines with the 24V Worklights and HIL do not need a GFCI outlet. 

Tripped Breaker/GFI Plug

Corrective Action:

  • Check if CB2 (NGC) on the PDIST PCB has been tripped. If necessary, reset the circuit breaker.
  • Disconnect anything connected to the GFCI receptacle. Push the [RESET] button on the GFCI receptacle. Measure the voltage at the plug. When the [RESET] button is fully engaged, the voltage must measure 120 VAC.
  • If the [RESET] button does not fully engage, disconnect the light cable:
    • Work light: I/O P18-21 (NGC)
    • HIL: I/O PCB P22 (NGC)
  • Push the [RESET] button on the GFCI receptacle again.
    • The GFI plug works correctly if the [RESET] button fully engages and you have 120 VAC. Check the cable and fixtures to find the cause of the short in the light circuit.
    • If the [RESET] button does not fully engage, the GFCI receptacle is defective. Replace the GFCI receptacle.
  • After you replace the GFCI, if there is still no voltage, go to

HIL Button Cable Incorrectly Wired

Symptom: After installing HIL, pressing the momentary button on the pendant does not turn on the lights. Quickly jumping the bottom two pins on J8 on the SKBIF is 

Probable Cause: The wires going to the momentary button J8 on the SKBIF need to connect to the middle and bottom pins. The momentary signal will not trigger the HIL to turn on if it goes to the top and middle pins. 

Corrective Action: Order replacement part 33-4511. 

Electrical Diagram

115VAC HIL/Worklight LED diagram.

                            

24VDC HIL/Worklight LED diagram.