IMPORTANT:  The Rotary servo control box does not come with batteries from the factory.  These batteries are used by the control to retain the rotary servo control configuration parameters and programs. Refer to the ROTARY CONTROL BOX - BATTERY INSTALLATION procedure.  

Rotary Compatibility

• Note: Rotary products equipped with a Sigma-7 motor requires a Haas rotary control box shipped after January 1, 2021 with software version 26.22 or newer and FPGA version 1.08.

This procedure tells you how to initialize a rotary servo control box to match the correct rotary model. Power on the control. 

Note: Legacy option is for older brushless models. For example, rotaries with sigma one motors. 

Use Display Scan to move through the options and CYCLE START to select the model and version (P code) and wait a few seconds for the controller to initialize and load the new set of parameters. The model and version of the rotary can be found on the serial plate on the rotary. 

Press MODE/RUN‑PROG to set the default values parameters for the rotary unit. The display stops flashing.

Power off the control. Connect the box to the rotary unit. Power on the control and press CYCLE START and ZERO RETURN.

To find the zero position automatically:

Press ZERO RETURN to start the automatic homing operation.

When the table/indexer stops, the display indicates: 01 Pnnn.nnn.

If the display shows a non-zero number, press CLEAR/ZERO SET for three seconds.

The Servo Control can be installed to communicate with your mill in two different ways:

• Remote input using CNC Interface Cable (two signal method), and/or
• RS-232 Interface. (Refer to the RS-232 Interface section tab for detail information on this connection.)

The relay inside the servo control has a maximum rating of 2 amps (1 amp for HA5C) at 30 volts DC. It is programmed as either a normally closed (closed during cycle) or a normally open after cycle relay. Refer to the “Parameters” section. It is intended to drive other logic or small relays, it will not drive other motors, magnetic starters, or loads exceeding 100 watts. If the feedback relay is used to drive another DC relay (or any inductive load), install a snubber diode across the relay’s coil in the opposite direction of coil current flow Failure to use this diode, or other arc suppression circuitry or inductive loads, damages the contacts of the relays.

1. Use an ohmmeter to measure resistance across pins 1 and 2, to test the relay.
   
   The reading should be infinite (open contacts), with the servo control off.
2. If a low resistance is measured (not infinite), the relay has failed and it must be replaced.

NOTE: All Haas Servo Controls come standard with 1 CNC interface cable. Additional CNC interface cables can be ordered (Haas P/N CNC).

CNC mills have miscellaneous functions called M-Codes. These control external switches (relays) that turn on or off other mill functions (e.g., spindle, coolant, etc.). The Haas remote cable CYCLE START pins are hooked into the normally open contacts of a spare M-Code Function relay. Our remote cable feedback pins are then connected to the M-Code-finished pins (M-FIN), an input to the mill control that tells the mill to continue to the next block of information. The interface cable is Haas P/N: CNC.

The Haas servo control has two signals, input and output. The mill tells the rotary control to index (an input), it indexes, and then sends a signal back to the mill that the index (an output) has been completed. This interface requires four wires; two for each signal, and from the rotary control remote input and from the mill.

The CNC Interface Cable provides these two signals between the mill and the Haas Servo Control. Since most CNC machines are equipped with spare M-codes, semi-fourth axis machining is achieved by connecting one end of the CNC Interface Cable to any of these spare relays (switches) and the other to the Haas Servo Control.

The Servo Control stores rotary position programs in memory and each pulse of the mill relay triggers the Servo Control to move to its next programmed position. Once the move is complete, the Servo Control signals that it has finished and is ready for the next pulse.

A remote input socket (CYCLE START and FINISH SIGNAL) is provided on the servo control back panel. Remote input consists of a CYCLE START and a FINISH SIGNAL command. To connect to the remote, a connector (contact your dealer) is used to trigger the servo control from any one of several sources. The cable connector is a male four-pin DIN connector. The Haas Automation part number is 74-1510 (Amphenol part number is 703-91-T-3300-1). The Haas Automation part number for the panel receptacle on the rear panel of the Servo Control is 74-1509 (Amphenol part number 703-91-T-3303-9).

For CYCLE START and FINISH SIGNAL operation:

1  When pins 3 and 4 are connected to each other for a minimum of 0.1 seconds, the servo control moves one cycle or step in the program.

When CYCLE START is used, pin 3 supplies a positive 12 volts at 20 milliamps and pin 4 is connected to the diode of an opto-isolator that grounds to chassis. Connecting pin 3 to pin 4 causes a current to flow through the diode of the opto-isolator, triggering the control.

NOTE: If the control is used around high-frequency equipment, such as electric welders or induction heaters, shielded wire must be used to prevent false triggering by radiated EMI (electromagnetic interference). The shield should be attached to earth ground.

2.  To move again, pins 3 and 4 must open for a minimum of 0.1 seconds and then repeat step 1.

CAUTION: Under no circumstances apply power to pins 3 and 4; a relay closure is the safest way to interface the control.

3. If your application is in an automatic machine (CNC mill), the feedback lines (FINISH SIGNAL pins 1 and 2) are used. Pins 1 and 2 are connected to the contacts of a relay inside the control and have no polarity or power on them. They are used to synchronize the automatic equipment with the servo controller.

4.  The feedback cables tell the mill that the rotary unit has finished. The relay can be used to FEED HOLD NC machine movements, or can be used to cancel an M function. If the machine is not equipped with this option, an alternative may be to dwell (pause) longer than it takes to move the rotary unit. The relay triggers for all CYCLE START closures, except G97.

The remote connection is used to index the Servo Control other than by the START switch. For example, using the optional Haas remote quill switch, every time the quill handle is retracted it touches a clamped micro switch, automatically indexing the unit. You can also use the switch to index the unit automatically during milling. For example, every time the table comes back to a specific position, a bolt on the table can press the switch, indexing the unit.

In order to index the Servo Control, pins 3 and 4 need to be connected (do not apply power to these wires). Connection at pin 1 and 2 are not needed for the Servo Control to operate. However, pins 1 and 2 could be used to signal another option, such as an automatic drilling head.

A color-coded cable is available to help with the installation (M-Function control); the cable colors and pin designation are:

HA5C Remote Input Example:

A common application for the HA5C is dedicated drilling operations. The CYCLE START wires are connected to a switch that closes when the drill head retracts, and the FINISH SIGNAL wires are connected to the Start wires of the drill head. When the operator pushes CYCLE START, the HA5C indexes to position and triggers the drill head to drill the hole.

The switch mounted to the top of the drill head indexes the HA5C when the drill retracts. This results in an endless loop of indexing and drilling. To stop the cycle, enter a G97 as the last step of the control. The G97 is a No Op code that tells the control not to send the feedback so the cycle can be stopped.

There are several requirements that must be met before a Haas Servo Control (HTRT and HA5C) can be interfaced with a FANUC controlled mill. These are as follows:

1. FANUC control with custom macro enabled and Parameter 6001, bits 1 and 4 set to 1.
2. A serial port on the FANUC control must be available for use by the Haas Servo Control while DPRNT program is running.
3. 25’ RS-232 shielded cable (DB25M/DB25M).

4 Shielded M-code relay cable

Once the requirements have been met, revise the parameters of the Haas Servo Control. These are the parameters that need to be changed.

Initial settings. Change these only after the interface is functioning.

The following Fanuc control parameters must be set to successfully communicate with the Haas Servo Control.

Be certain to set FANUC parameters related to the actual serial port connected to Haas Servo Control. The parameters have been set for remote operation. A program can now be entered, or an existing program run. There are several key items to consider to ensure your program runs successfully.

DPRNT must precede every command sent to the Servo Control. The commands are sent in ASCII code and terminated by a carriage return (CR). All commands must be preceded by an axis select code (U, V, W, X, Y, Z). For example, setting parameter 21 = 6, means Z represents the axis code.

NOTES:

1. Use of Z"above assumes Servo Control Parameter 21 = 6.
2. Leading and trailing 0 must be included (correct: S045.000, wrong: S45).
3. When writing your program in the FANUC format, it is important to not to have blank spaces or carriage returns (CR) in your DPRNT statement.

DPRNT Program Example:

The following is an example of one way to program using the FANUC style.

O0001
G00 G17 G40 G49 G80 G90 G98
T101 M06
G54 X0 Y0 S1000 M03
POPEN (Open FANUC serial port)
DPRNT [ ] (Clear/Reset Haas)
G04 P64
DPRNT [ZG090] (Servo Control Step should now read "00")
G04 P64 
DPRNT [ZS000.000] (Loads Step Size 000.000 into Step 00)
G04 P64DPRNT [ZF050.000] (Loads Feed Rate 50 units/sec into Step 00)
G04 P64
Mnn (Remote Cycle Start, moves to P000.0000, sends M-FIN)
G04 P250 (Dwells to avoid DPRNT while M-FIN is still high)
G43 Z1. H01 M08
G81 Z-.5 F3. R.1 (Drills at: X0 Y0 P000.000)
DPRNT [ ] (Make certain Haas Input Buffer is Clear) 
G04 P64
#100 = 90. (Example of correct Macro substitution)
DPRNT [ZS#100[33] ] (Loads Step Size 090.000 into Step 00) (Leading Zero converted to Space Param. must be off)
G04 P64
Mnn (Remote Cycle Start moves to P090.000, sends M-FIN)
G04 P250
X0 (Drills at: X0 Y0 P090.000)
G80 (Cancels drill cycle)
PCLOS (Close FANUC serial port) 
G00 Z0 H0
M05
M30

There are two connectors used for the RS-232 interface; one each of male and female DB-25 connectors. To connect multiple Servo Controls, connect the cable from the computer to the female connector. Another cable can connect the first Servo Control to the second by connecting the male connector of the first box to the female connector of the second. You can connect up to nine controls in this way. The RS-232 connector on the Servo Control is used to load programs.

The RS-232 connector on the back of most personal computers is a male DB-9, so only one type of cable is required for connection to the control, or between controls. This cable must be a DB-25 male on one end and a DB-9 female on the other. Pins 1, 2, 3, 4, 5, 6, 7, 8, and 9 must be wired one-to-one. It cannot be a Null Modem cable, which inverts pins 2 and 3. To check cable type, use a cable tester to check that communication lines are correct.

The control is DCE (Data Communication Equipment), which means that it transmits on the RXD line (pin 3) and receives on the TXD line (pin 2). The RS-232 connector on most PCs is wired for DTE (Data Terminal Equipment), so no special jumpers should be required.

PC RS-232 COM1 Setup

The RS-232 DOWN (out line) DB-25 connector is used when multiple controls are used. The first control’s RS-232 DOWN (out line) connector goes to the second controller’s RS-232 UP (in line) connector, etc.

If Parameter 33 is 0, the CTS line can still be used to synchronize output. When more than one Haas rotary control is daisy-chained, data sent from the PC goes to all of the controls at the same time. That is why an axis selection code (Parameter 21) is required. Data sent back to the PC from the controls is programmed together using digital logic OR gates (OR-ed) so that, if more than one box is transmitting, the data will be garbled. Therefore, the axis selection code must be unique for each controller. The serial interface may be used in either a remote command mode or as an upload/download path.