8 - Rotary - Troubleshooting

8.1 Rotary - Troubleshooting - NGC
8.2 Rotary - Troubleshooting - CHC
8.3 Rotary - Trunnions with Scales - Compatibility Solution
8.4 Rotary Servo Control Box - Troubleshooting

Symptom Table

Do not perform any type of maintenance on the rotarty if it is under warranty, contact your Haas Factory Outlet for further assistance.

Symptom	Possible Cause	Corrective Action
Alarm 5.108, 6.108 or 7.108 A, B or C AXIS SERVO OVERLOAD	The feeds and speeds are too high for the work.	Decrease the feeds and speeds.
	The cutting tool is not sharp or is damaged.	Install a new tool or a new tool insert.
	There is a mechanical blockage in the axis of travel.	Make sure the axis has a clear path of travel.
	There is an internal mechanical obstruction in the rotary unit.	Test the rotary unit.
	The brake solenoid for the rotary unit has an electrical fault.	Troubleshoot the brake solenoid.
	The servo amplifier has a problem	Troubleshoot the servo amplifier.
Alarm 5.103, 6.103, 7.103 A, B or C AXIS SERVO ERROR TOO LARGE	The air brake did not disengaged.	Remove the air from the rotary and see if the unit will now rotate without an alarm.
	The connection to the encoder or power is faulty.	Check the encoder and power cable connections to the motor.
The machined part has inaccurate features	There is lost motion or backlash in the rotary.	Do the rotary backlash test.
The machined part has inaccurate features	The feeds and speeds are too high for the work.	Decrease the feeds and speeds.
The tilt (A) axis of the trunnion does not find home.	The home sensor or cable is faulty.	Jog the tilt axis from the positive travel limit to the negative travel limit. Make sure the A HOME SWITCH bit changes (on the Diagnostics INPUT 2 screen). If the bit does not change, replace the home switch. This can be done in the field This cannot be done on TR110 units. Note: The A HOME SWITCH change cannot be seen on machines with software version 18.16A or higher. Caution: If the A axis (tilt) moves more than 20 degrees past the home position, Push [EMERGENCY STOP]
The tilt (A) axis does not home to a horizontal position.	The tool change offset parameter has not been set.	Set the rotary platter flatness: Refer to the Rotary - TR/TRT/T5C - Platter Flatness - Adjustment procedure.
Starting in software version 100.19.000.1120 when using P11, P12, P13 parameters for T5C/Trunnions. There is an excessive rotation when the unit is commanded to zero return.	Parameter .161 AXIS HOME SWITCH ACVITE HIGH is incorrectly set to TRUE*.	Go to the Haas Service Portal and download the latest configuration files. Update the rotary configuration files refer to the Update Rotary Configuration Files - NGC procedure.
Alarm 5.423, 6.423 or 7.423 A,B or C AXIS SECONDARY ENCODER POSITION MISMATCH Alarm 5.9944, 6.9944 or 7.9944 A,B or C AXIS SECONDARY ENCODER Z FAULT Alarm 5.9945, 6.9945 or 7.9945 A,B or C AXIS SECONDARY ENCODER Z CHANNEL MISSING Alarm 5.9946, 6.9946 or 7.9946 A, B or C AXIS SECONDARY ENCODER CABLE FAULT	The rotary scale or scale cable is faulty.	Check the rotary scale cable.
Alarm 175 GROUND FAULT DETECTED Alarm 552 TRIPPED CIRCUIT BREAKER	There is a short to ground in the axis motor cable.	Test the axis motor cable for short.
	There is a short to ground in the axis motor.	Test the axis motor for short.
HRC rear seal is popping out	Oil level is too high.	Drain oil until the correct level is reached, use sight glas to identify oil is filled to top of glass.
HRC rear seal is popping out	Internal pressure is unable to escape	NOTE: ONLY DO THIS ONCE THE OIL LEVEL HAS BEEN VERIFIED AND THE SEAL CONTINUES TO POP OUT. Replace two of the break fastners with modified fastners see "Rear seal popping out" section below for further instruction.
Alarm 5.9948, 6.9948 or 7.9948 A, B or C AXIS SECONDARY ENCODER SERIAL FAULT	The encoder read head software is outdated.	Please contact Customer Service for assistance.
Air leak/hissing sound coming from motor enclosure. Motor enclosure ballooning out. Excessive bubbles leaking between the side plate and the motor enclosure. Oil leaking from behind the platter.	The pressure switch may have failed and is leaking.	Install a 0-15 PSI pressure gauge on the enclosure cover. Do not actuate the rotary brake. If the gauge reads any pressure, check the fittings, airlines, and pressure switch for a leak. If the pressure switch is the source of the leak, replace the pressure switch and reseal the cover when reinstalling.
HRT 160 & HRT 210 Brake Booster assemblies are leaking air from the brake	There is an excessive amount of pressure build up in the reservoir.	A change to the brake booster manifold was made to address this issue. Return the rotary unit to the factory for the brake booster upgrade. Refer to the HRT-160/210 Manifold Identification section to see if the A version of the manifold is already on the brake booster assembly.
HRT 160 & HRT 210 Brake Booster assemblies are blowing out the reservoir feed lines
Custom rotary config file generated with, Custom Rotary Configuration Setup, does not load properly.	All of the XML objects in the config files need to have the tag "<name>[contents]</name>". It is possible for this tag to not be properly generated.	Open the XML file in a text editing program and check that each XML object has the nessary tag. If The tag is missing remove the XML object.
Alarm 5.4004 A-AXIS AXIS MOTION OCCURRED WHILE THE ROTARY BRAKE WAS ENGAGED	Faulty solenoid.	Test the solenoid.
	Pressure switch failure.	Check the pressure switch.
Oil leaks under platter, rotary, or trunnion	Machine shop air pressure builds up slowly.	Add a valve and gauge inline to the rotary and open valve once pressure builds up to 85 psi or higher.
Oil leaks under platter, rotary, or trunnion	Positive pressure builds up inside the enclosure.	Follow the instructions in the section titled "Leaking Pressure Switch" lower on this page.

Program

Possible Cause: The feeds and speeds are too high for the work.

Corrective Action:

Decrease the feeds and speeds of the active program to decrease the machine load.

Tooling

Possible Cause: The cutting tool is not sharp or is damaged.

Corrective Action:

Examine the cutting tool for damage. Install a new tool or a new tool insert if the cutting tool is damaged or is not sharp.

Axis Obstruction

Possible Cause: There is a mechanical blockage in the axis of travel.

Corrective Action:

Make sure the axis has a clear path of travel. Tools, part fixtures, or work pieces that are too large can crash into the machine enclosure.

Mechanical Obstruction

Possible Cause: There is an internal mechanical obstruction in the rotary unit.

Corrective Action:

Disconnect the air supply to rotary unit. Press [ZERO RETURN], press the rotary axis letter, Press [SINGL], and jog the axis. If an alarm is generated, remove the necessary enclosure covers to get access to the faulty axis. Rotate the axis motor drive pulley by hand. If the axis cannot be rotated by hand, there is internal mechanical bind. The rotary unit needs to be serviced. For instructions on where to find a rotary repair facility and how to send your rotary unit, go to Rotary Repair on our website.

Brake Solenoid

Possible Cause: The brake solenoid for the rotary unit has an electrical fault.

Corrective Action:

Make sure the air supply is connected to the rotary unit. In MDI mode, push the rotary axis letter. Push [HAND JOG], you should hear air go out from the rotary unit. For solenoid test instructions, refer to Solenoid - Troubleshooting Guide.

Electrical Short

Possible Cause: There is a short to ground in the axis motor cable.

Corrective Action:

Inspect the rotary cables for wear or damage, refer to electrical diagram below.

Servo Amplifier

Possible Cause: The servo amplifier has a problem.

Corrective Action:

For servo amplifier troubleshooting instructions, refer to Servo Amplifier - Troubleshooting Guide.

Backlash

Possible Cause: There is lost motion or backlash in the rotary.

Corrective Action:

Test for backlash. For backlash test instructions, refer to HA5C Indexer - Backlash Test or Rotary Tables - Backlash Test.

Proximity Sensor

Possible Cause: The home proximity sensor is faulty.

Corrective Action:

For proximity sensor troubleshooting instructions, refer to Proximity Sensor - Troubleshooting Guide.

TRT70 Servo Errors

Possible Cause:

There is an O-ring inside the TRT70's 5th axis head that can cause the following symptoms:

Servo Humming
Servo Error Alarms
Accuracy Issues

Corrective Action:

The O-ring has been removed on current production rotaries but previous models will need to have it removed in the field. A plug bolt may need to be added, 40-1631 & 49-4101.

Go to the TRT70 O-ring Removal procedure for details.

Rotary Scale

Possible Cause: The rotary scale or rotary scale cable is faulty.

Corrective Action:

Make sure the cables are connected correctly.

Inspect the rotary scale cables for wear or damage.

Inspect the internal rotary scale cable interface cable, slightly pull on the wires to make sure they have a good crimp. If the cables are connected correctly and not damaged, and the alarm persists, the rotary unit needs to be serviced.

For instructions on where to find a rotary repair facility and how to send your rotary unit, go to Haas Rotary Repair Center page.

HRT 450 Brake Bleeding

A fully extended rod indicates a full resevoir [1]

After bleeding the rod will stick out slightly less.

Disconnect one of the oil lines and dip the tube in oil. Push and pull the rod to fill the resevoir. Reconnect the line and perform bleeding procedure.

Disconnect the the oil line [2] and insert tube into a container of hyraulic fluid when filling resevoir.

1

Bleeding Procedure

Set regulator A to the max
Set regulator B to zero
Loosen top air bleed plug [1] until air is out.
NOTE: Use bleed plug [2] if top plug is not accessable.
Set regulator B to 80 PSI
Set regulator A to 7 PSI

Check the main gauge, it should be 0 PSI when unclamped and 1000 PSI when clamped.

2

Use the image on the left for additional reference.

HRC Units - Rear Seal Popping Out

Do not perform any type of maintenance on the rotarty if it is under warranty, contact your Haas Factory Outlet for further assistance.

This section will show explain what to do if the rear seal keeps popping out.

NOTE: This should only be done if the oil level has been verified and the seal is still popping out.

1

Before starting a fixture needs to be fabricated, the fixture will have two through holes [1] to be threaded to the back of the brake cap and two threaded holes [2] on the outer section that will act like a jack and be placed on a plate [3] so it will not damage the rotary casting

An example of this is shown.

2

Remove the air supply to the table.

Place the rotary on its platter face and remove the rear M5 brake bolts.

Use the fixture made to thread to the back of the brake cap and remove it [1].

The threaded holes should be the ones denoted [2] and should be across from each other.

By using the other bolts on the threaded holes [3] as jacks turn the bolts on each side evenly so the plate comes off.

Make sure to use place plates of some sort [4] to prevent damage to the rotary.

3

Using the same fixture pull out the brake piston.

NOTE: Longer bolts will be neeed to reach the brake piston [1]. Make sure the jack bolts are in the position indicated by the arrows to have leverage. Make sure plates are under the bolts to avoid damage to the rotary.

4

Remove the two M5 brake fastners that are 180 degrees apart [1] and replace with the modified fastners.

The modified fastners have through hole to relieve pressure from under the rear brake seal. These have no part number at the moment and will need to be made.

Leaking Pressure Switch

1

Install a 0-15 PSI pressure gauge on the enclosure cover. Do not actuate the rotary brake. If the gauge reads any pressure, check the fittings, airlines, and pressure switch for a leak. If the pressure switch is the source of the leak, replace the pressure switch and reseal the cover when reinstalling.

Electrical Diagrams

SIGMA-5 Cable Diagram

HRT-160/210 Manifold Identification

The dimple [1] indicates the brake booster manifold is an A version.

Symptom Table

Do not perform any type of maintenance on the rotarty if it is under warranty, contact your Haas Factory Outlet for further assistance.

Symptom	Possible Cause	Corrective Action
Alarm 106 A SERVO ERROR TOO LARGE Alarm 111 A SERVO OVERLOAD Alarm 164 A AXIS DRIVE FAULT Alarm 187 B SERVO ERROR TOO LARGE Alarm 188 B SERVO OVERLOAD Alarm 193 B AXIS DRIVE FAULT	The feeds and speeds are too high for the work.	Decrease the feeds and speeds.
	The cutting tool is not sharp or is damaged.	Install a new tool or a new tool insert.
	There is a mechanical blockage in the axis of travel.	Make sure the axis has a clear path of travel.
	There is an internal mechanical obstruction in the rotary unit.	Test the rotary unit.
	The brake solenoid for the rotary unit has an electrical fault.	Troubleshoot the brake solenoid.
	The servo amplifier has a problem	Troubleshoot the servo amplifier.
The machined part has inaccurate features	There is lost motion or backlash in the rotary.	Do the rotary backlash test.
The machined part has inaccurate features	The feeds and speeds are too high for the work.	Decrease the feeds and speeds.
The tilt (A) axis of the trunnion does not find home.	The home sensor or cable is faulty.	Jog the tilt axis from the positive travel limit to the negative travel limit. Make sure the A HOME SWITCH bit changes (on the Diagnostics INPUT 2 screen). If the bit does not change, replace the home switch. This can be done in the field This cannot be done on TR110 units. Note: The A HOME SWITCH change cannot be seen on machines with software version 18.16A or higher. Caution: If the A axis (tilt) moves more than 20 degrees past the home position, Push [EMERGENCY STOP]
The tilt (A) axis does not home to a horizontal position.	The tool change offset parameter has not been set.	Set the rotary platter flatness: Refer to the Rotary - TR/TRT/T5C - Platter Flatness - Adjustment procedure.
The tilt (A) axis does not home to a horizontal position consistently.	The parameters 1115, 1116, 1122 are not set correctly.	On a machine with a rotary scale, when you install version M18.18A or higher to improve zero-return consistency: Be sure to set parameters 1115, 1116, 1122 correctly, as follows: UMC-750: Parameter 1116 (B Axis) = 5 Parameter 1122 (C Axis) = 5 TR-Series Rotaries with Scales: Parameter 1115 (A Axis) = 4 Note: On machines that do not have rotary scales, set parameter 1115 to 0. TR-series rotary products that do not have a P2 or P4 on the name tag do not have rotary scales. After you change parameter 1116, 1122, 1115: When the rotary searches for zero, it may travel farther than it did before. This is normal. You must adjust the tool-change offset parameters (Parameter 212 for A Axis, Parameter 213 for B Axis, Parameter 523 for C Axis). Reference: Rotary - TR/TRT/T5C - Installation procedure
Alarm 426 A AXIS SECONDARY ENCODER POSITION MISMATCH Alarm 558 B AXIS SECONDARY ENCODER POSITION MISMATCH Alarm 559 C AXIS SECONDARY ENCODER POSITION MISMATCH	The rotary scale or scale cable is faulty.	Check the rotary scale cable.
Alarm 175 GROUND FAULT DETECTED Alarm 185 A CABLE FAULT Alarm 195 B CABLE FAULT Alarm 552 TRIPPED CIRCUIT BREAKER	There is a short to ground in the axis motor cable.	Test the axis motor cable for short.
	There is a short to ground in the axis motor.	Test the axis motor for short.
HRC rear seal is popping out	Oil level is too high.	Drain oil until the correct level is reached, use sight glas to identify oil is filled to top of glass.
HRC rear seal is popping out	Internal pressure is unable to escape	NOTE: ONLY DO THIS ONCE THE OIL LEVEL HAS BEEN VERIFIED AND THE SEAL CONTINUES TO POP OUT. Replace two of the break fastners with modified fastners see "Rear seal popping out" section below for further instruction.
Alarm 138 A-axis Overheat	The rotary product has an air pressure sensor.	The updated P12 and P15 rotary products were intended to run on NGC machines. Note: There was some P3 rotary products that were built with the air pressure sensor. To run these units on a Classic Haas Control see Air Pressure Sensor section.

Axis Obstruction

Possible Cause: There is a mechanical blockage in the axis of travel.

Corrective Action:

Make sure the axis has a clear path of travel. Tools, part fixtures, or work pieces that are too large can crash into the machine enclosure.

Air Pressure Sensor

The P12 and P15 rotary units were intended to run on NGC machines, if the unit is connected to a Classic Haas Control the control will generate overheat alarms.

Note: There was some P3 rotary products that were built with the air pressure sensor.

If you want to run the unit it on a Classic Haas Control machine the following needs to be done:

Get the correct CHC parameters, contact your local (Haas Factory Outlet).

Disconnect the air pressure sensors. This will prevent the overheat alarms to be generated.
Power off the machine.
Remove the motor enclosure cover [1].
Disconnect the air pressure sensors [3] shown in the illustration.
Test the operation.
Install the enclosure cover. Make sure the o-ring [2] is not pinched
IMPORTANT: The sensors will need to be connected when the rotary is used on a NGC machine.

TR160-P15 The rotary axis zero return position needs to be checked at power on.
Due to the ratio of this unit the rotary axis will find the zero position in two positions.
The work around is to zero return the rotary axis and permanently identify the zero position with engraved arrows or two lines.
If the marks do not line up during the zero return process (usually off by 3.8 degrees) jog the platter at least 45 degrees in the same direction the unit homed in and then perform another zero return. The platter will now be in the proper zero position.

Program

Possible Cause: The feeds and speeds are too high for the work.

Corrective Action:

Decrease the feeds and speeds of the active program to decrease the machine load.

Tooling

Possible Cause: The cutting tool is not sharp or is damaged.

Corrective Action:

Examine the cutting tool for damage. Install a new tool or a new tool insert if the cutting tool is damaged or is not sharp.

Mechanical Obstruction

Possible Cause: There is an internal mechanical obstruction in the rotary unit.

Corrective Action:

Brake Solenoid

Possible Cause: The brake solenoid for the rotary unit has an electrical fault.

Corrective Action:

Servo Amplifier

Possible Cause: The servo amplifier has a problem.

Corrective Action:

For servo amplifier troubleshooting instructions, refer to Servo Amplifier - Troubleshooting Guide.

Backlash

Possible Cause: There is lost motion or backlash in the rotary.

Corrective Action:

Test for backlash. For backlash test instructions, refer to HA5C Indexer - Backlash Test or Rotary Tables - Backlash Test.

Proximity Sensor

Possible Cause: The home proximity sensor is faulty.

Corrective Action:

For proximity sensor troubleshooting instructions, refer to Proximity Sensor - Troubleshooting Guide.

Rotary Scale

Possible Cause: The rotary scale or rotary scale cable is faulty.

Corrective Action:

Make sure the cables are connected correctly.

Inspect the rotary scale cables for wear or damage.

For instructions on where to find a rotary repair facility and how to send your rotary unit, go to Haas Rotary Repair Center page.

Electrical Short

Possible Cause: There is a short to ground in the axis motor cable.

Corrective Action:

Inspect the rotary cables for wear or damage, refer to electrical diagram below.

HRC Units - Rear Seal Popping Out

Do not perform any type of maintenance on the rotarty if it is under warranty, contact your Haas Factory Outlet for further assistance.

This section will show explain what to do if the rear seal keeps popping out.

NOTE: This should only be done if the oil level has been verified and the seal is still popping out.

1

An example of this is shown.

2

Remove the air supply to the table.

Place the rotary on its platter face and remove the rear M5 brake bolts.

Use the fixture made to thread to the back of the brake cap and remove it [1].

The threaded holes should be the ones denoted [2] and should be across from each other.

By using the other bolts on the threaded holes [3] as jacks turn the bolts on each side evenly so the plate comes off.

Make sure to use place plates of some sort [4] to prevent damage to the rotary.

3

Using the same fixture pull out the brake piston.

4

Remove the two M5 brake fastners that are 180 degrees apart [1] and replace with the modified fastners.

The modified fastners have through hole to relieve pressure from under the rear brake seal. These have no part number at the moment and will need to be made.

HRT 450 Brake Bleeding

A fully extended rod indicates a full resevoir [1]

After bleeding the rod will stick out slightly less.

Disconnect one of the oil lines and dip the tube in oil. Push and pull the rod to fill the resevoir. Reconnect the line and perform bleeding procedure.

Disconnect the the oil line [2] and insert tube into a container of hyraulic fluid when filling resevoir.

1

Bleeding Procedure

Set regulator A to the max
Set regulator B to zero
Loosen top air bleed plug [1] until air is out.
NOTE: Use bleed plug [2] if top plug is not accessable.
Set regulator B to 80 PSI
Set regulator A to 7 PSI

Check the main gauge, it should be 0 PSI when unclamped and 1000 PSI when clamped.

2

Use the image on the left for additional reference.

Electrical Diagrams

SIGMA-5 Cable Diagram

HRT-160/210 Manifold Identification

The dimple [1] indicates the brake booster manifold is an A version.

Rotary - Trunnions with Scales - Compatibility Solution

AD0366

Introduction

Identify the type of scale in your trunnion:

Trunnions built from 2011 (when scales were introduced) to September 2016 use a scale that requires 12VDC power
Trunnions built from October 2016 to mid-January 2017 require 5VDC power.
Trunnions built after mid-January 2017 work with either 5VDC or 12VDC power. These can be identified by the gray connector on the scale cable.

Applicable to the following kits:

93-2683: CABLE KIT 5/12VDC ROTARY SCALE FEEDBACK TO 12VDC CONTROL

Compatibility Solution

1

Identify the voltage supplied by the I/O PCB:

Look at the label on the cable that connects the scale connector to the I/O PCB.

All Classic Haas Control (CHC) machines with the 32-10049 cable are configured for trunnions with 5VDC scales. Install the 32-10053 (not included in the kit 92-2863) to configure the machine for 12VDC scales.

NGC machines with the 32-10053 cable are configures fro trunnions with 12VDC scales.

2

Solution:

The best solution is to configure the machine and the trunnion with 12VDC power. This maintains compatibility with the past, current, and future equipment.

All CHC machines are configured for 12VDC.

If the NGC machine is configured fro 5VDC, install the 32-10053 cable ( not included in kit 93-2683) to configure it for 12VDC.

Any trunnion can be made compatible with a 12VDC machine by installing the 32-10055 rotary cable. the 32-10055 cable can be identified by the grey connector [1] on the scale cable.

3

Do this step if the trunnion has a 12VDC scale installed.

The 32-10055 cable has a flying connector [1] inside of the rotary enclosure. Plug the 33-10088 jumper [2] to the flying connector as shown.

4

Do this step if the trunnion has a 5VDC scale installed.

The 32-10055 able has a flying connector [1] inside of the rotary enclosure. Plug in the 32-10057 voltage reducer [2] to the flying connector as shown. The trunnion can now be plugged into any 12VDC configured machine.

Introduction

When used with any CNC machining center, the control performs as a semi-4th axis, activated by a single M-code.

You can program the control to rotate the rotary spindle in either direction, in step sizes from 0.001° to 999.999°.

There can be up to 99 different steps in memory, and each step can be repeated (or looped) up to 999 times.

Non-volatile memory retains programs, even when the power is turned off, and you can store up to 10 separate programs.

Servo Control - Front Panel

Display – 4-lines show current data.
0 - 9 - Data entry keys and jog speed selection.
MODE/RUN PROG – Switches from Run mode to Program mode (with blinking display).
DISPLAY SCAN – Scans display to show either the screen with Position, Step Angle, Feed Rate, Loop Counts, G Code, and status line, or position and status line in RUN mode. It scans left/right in Program mode.
STEP SCAN – Scans step numbers from 1 through 99 in Run mode. It scans up/down in Program mode.
- (Minus) - Selects negative step values or Prog/Upload/Download functions. Feed Rate Override (50, 75 or 100%).
CLEAR/ZERO SET – Clears the entered data, resets program to 0, or defines the present servo position as Home.

8. ZERO RETURN – Causes the servo to return to the Home position, search for mechanical Home, delete a step, or move forward to the mechanical offset.

9. Load meter – Indicates (%) of spindle load. A high load indicates excessive load or workpiece support misalignment. Hi-Load or Hi Curr alarms occur if not corrected. Damage to the motor or table may result if excessive loads continue. Refer to the "Troubleshooting" section, starting on page , for more information.

JOG– Causes the servo to move in either the forward + or backward - direction at a rate defined by the last numeric key pressed.

10. EMERGENCY STOP – Turns off the servo when on and aborts the step in progress.

11. CYCLE START – Begins a step, stops a continued operation, inserts a step, or turns the servo on.

Servo Control - Rear Panel

Unused access
Remote input with Cycle Start and Finish Signal connections/Pin DIN connector for CNC interface cable.
RS-232 Up Connector
RS-232 Down Connector
Power Switch
15 Amp Fuse
120VAC 1-phase 50/60 Hz power cord
Caution label
Motor / Brake Socket
Encoder Socket

Servo Control - Display

The display shows the program and mode for the rotary unit. The display consists of 4 lines with up to 80 characters per line. Data displayed includes:

Position (Spindle)
Step Size (Angle)
Feed Rate
Loop Count
G-Code
Current Step Number (Step numbers 1 to 99 are available)
Any Start-Up Errors or Alarms

The display highlights a single step of the program on display line 2. Press DISPLAY SCAN right arrow to scan sideways and see all the information for a single step, loops from left to right at the end of the row. Press STEP SCAN up arrow to display the previous step; press STEP SCAN down arrow to display the next step. You can scan to anywhere in the program with these keys. If a new number is entered in that position, the number is stored when scanned to another position or returned to Run mode.

Every step (or block) contains several pieces of information that are necessary for the program and are displayed simultaneously. The data is preceded by a letter(s) to indicate what type of information is displayed.

Each time you press the DISPLAY SCAN right arrow, the display cycles to the next register; that is, Position - Step Size - Feed Rate - Loop Count - G-Code - Position - etc. In Run mode, the DISPLAY SCAN right arrow button selects among any of these five displays. In Program mode, all of these but the Position may be displayed.

The first line displays current spindle position (POS), followed by the G-Code display (G) then the loop count display (L).
The second and third lines display the step number (N) followed by the step size, then the feed rate (F).The left three characters on the second or third line contain the step number from 1 to 99. They cannot be changed with the numeric keys and are selected by using the STEP SCAN arrow buttons.
See item 2.
The fourth line is the control status line. It provides three control operations: RUN, STOP, ALARM. These operations are followed by the percentage of load, and the last status of the air brake.

Power On - Error Codes

A set of self tests are run when the control is turned on and the results may indicate a control fault. These are displayed on the Alarm: 4th line.

NOTE: Intermittent low voltage errors or power failures may be the result of inadequate power to the controller. Use short, heavy-duty extension cords. Make sure that the supplied power is a minimum of 15 amps at the plug.

ERROR Code	Probable Cuase	Corrective Action
Blank front panel	Program CRC failure	Bad RAM, or cycle power if bad ROM to RAM program transfer.
E0 EProm	EPROM CRC error	Internal EPROM chip on the main pcb has failed. Contact your local Haas Factory Outlet.
Frt Pnel Short	Front panel switch closed or shorted	The control sense buttons or switches made during power on. Check the buttons on the keypad and make sure they are not pushed in.
Remote Short	Remote Start switch closed and enabled, or remote CNC input shorted.	Remove the remote start cable and cycle power, if alarm goes away the cable or remote device has a short.
RAM Fault	Memory fault	Contact your local Haas Factory Outlet.
Stored Prg Flt	Stored program fault (low battery)	The internal battery is low. Contact your local Haas Factory Outlet.
Power Failure	Power failure interrupt (low line voltage)	Check your incoming voltage.
Enc Chip Bad	Encoder chip bad	Contact your local Haas Factory Outlet.
Interrupt Flt	Timer/interrupt fault	Contact your local Haas Factory Outlet.
1khz Missing	Clock generation logic failure (1 kHz signal missing)	Contact your local Haas Factory Outlet.
Scal Cmp Lrge	Exceeding maximum allowed rotary scales compensation. (HRT210SC only)	Verify the parameters for the unit.
0 Margin Small	(Zero margin too small) Distance between the home switch and the final motor position, after seeking home, is either less than 1/8 or greater than 7/8 of a motor revolution.	This alarm occurs while homing the rotary table. Parameter 45, for the A Axis, or Parameter 91, for the B Axis, must be set properly. Use the default value (0) for the axis parameter (45 or 91), and add 1/2 of a motor revolution. 1/2 motor revolution is calculated by taking the value in Parameter 28 for the A Axis, or Parameter 74 for the B Axis, and dividing by 2. Enter this value for parameter 45 or 91, and re-home the rotary table.
Enc Type Flt	Detected motor type is different from the one specified by Parameter 60.	Contact your local Haas Factory Outlet.
Mot Detect Flt	No motor detected at power-up or during control initialization.	Check that the motor cables are connected to the control box.

Servo Off - Error Codes

Any time the servo (motor) is turned off, a reason code is displayed on the Alarm: 4th line, along with the following codes.

An A or B may precede the code for TRT units. This is the reference to the axis that caused the fault.

ERROR Code	Probable Cuase	Corrective Action
Por On	Power just applied.	This is a normal message at power on.
Servo Err Lrge	The air brake did not disengaged.	Remove the air from the rotary and see if the unit will now rotate without an alarm.
Servo Err Lrge	The connection to the encoder or power is faulty.	Check the encoder and power cable connections to the motor.
E-Stop	Emergency stop on	The Emergency stop button is active. Pull the Emergency stop button and press Cycle Start.
Servo Overload	The cutting tool is not sharp or is damaged.	Install a new tool or a new tool insert.
	There is a mechanical blockage in the axis of travel.	Make sure the axis has a clear path of travel.
	There is an internal mechanical obstruction in the rotary unit.	Test the rotary unit.
	The brake solenoid for the rotary unit has an electrical fault.	Troubleshoot the brake solenoid.
RS-232 Problem	Remote RS-232 commanded off	Check the RS-232 cable to PC,
Encoder Fault	Z channel fault (bad encoder or cable)	Test the axis motor cable for short.
Scale Z Fault	Rotary scale Z channel fault (bad rotary scale encoder or cable) HRT210SC only	Check the rotary scale cable.
Z Encod Missing	Z channel missing (bad encoder or cable)	Test the axis motor cable for short.
Scale Z Missing	Rotary scale Z channel missing (bad rotary scale encoder or cable) (HRT210SC only)	Check the rotary scale cable.
Regen Overheat	High line voltage	Check the incoming voltage to the servo control box.
Cable Fault	Break detected in encoder cable wiring	Test the axis motor cable for short.
Scale Cable	Break detected in rotary scale cable wiring (HRT210SC only)	Check the rotary scale cable.
Pwr Up Phase Er	Power up phase error	Test the axis motor cable for short.
Drive Fault	An over current or drive fault.	Test the axis motor cable for short.
Enc Trans Flt	Encoder transition fault had been detected.	Test the axis motor cable for short.
Indr Not Up	Platter not fully up (HRT320FB only). Can be caused by low air pressure.	Check the air connection to the HRT unit.

Remote Input Troubleshooting

Servo Control Relay:

[1] CNC Mill Internal,

[2] M Function Relay,

[3] CNC Interface Cable,

[4] Servo Control Internal

Troubleshooting a Working Interface on a CNC

If there are problems, try to isolate the problem by checking the Servo Control and the mill separately. There are only two signals and each one can be checked separately from the other. If the rotary unit stops indexing because of an interface problem, follow these simple checks:

Check the Servo Control remote input alone
Check the CNC cable interface alone
Check the Servo Control and the mill together

Check Servo Control Remote Input Alone

To check the Servo Control remote input:

Disconnect the remote cable from the back of the controller.
Set the control to index a single step of 90°�.
Connect a continuity tester or a voltmeter (a digital meter may not be fast enough to sample the brief pulse) set for low ohms across pins 1 and 2; they are marked on the rear of the control as FINISH SIGNAL.
It must show an open circuit, otherwise check relay Parameter 1 (should be 1) and Parameter 2 (should be 0). The relay must show an open circuit with the control turned off, otherwise the relay is defective.
Use a jumper wire to short pins 3 and 4 together, they are marked on the rear of the control as CYCLE START.
The unit must index, and at the end of the index, the voltmeter should deflect briefly toward low ohms or continuity. If this works as described, the problem is NOT in the rotary control, but may be the interface cable or mill.

Check The CNC Cable Interface Alone

To check the CNC cable interface:

Check the signals from the CNC using your voltmeter.

NOTE: The pin orientation is reversed.

Execute an M function from the mill to rotate.

The mill beacon light should come on (green) and stay on.

Use the meter and check continuity across the CYCLE START pins 3 and 4. Try not to short the test leads and pins against the shield of the male plug.

note: Some mills may have a +12 to +24 volt signal on pin 4 to activate a rotary unit. Check if there is voltage between pin 4 and the ground, if the continuity test fails, this is also a valid CYCLE START signal. If there is voltage present on Pin 4, a Haas interface box must be used (Part # IB). Contact your dealer if there are questions on how to use the interface box.

To check the CYCLE FINISH signal, use a voltmeter test probe to short together pins 1 and 2 on the mill cable.

The mill beacon light should turn off.

Result:

If the above tests pass, there is a valid signals coming from the mill.

Check Servo Control And Mill Together

To check the Servo Control and mill:

1. Reset the mill by pressing RESET or turn it off by pressing POWER OFF.

2. Connect the remote cable, then turn both the Servo Control and mill on.

Once connected, the rotary unit should remain idle. If the rotary unit moves, the CYCLE START signal from the mill is shorted.

3. If it remains idle, execute or MDI an M function from the mill to index.

Do not index from the program unless using single-block. If the rotary unit does not move, the mill is not outputting a signal or there is a break in the cable.

If the Servo Control indexes properly, ensure that the mill beacon light goes out at the end of the index. If the light does not go out, the CYCLE FINISH signal is not returning to the mill. This could be an open wire in the remote cable, or a problem in cables that connect to the CNC.

4. If the unit works only in single block, but not in the Run mode, there may be a timing problem involving two M functions, or a simultaneous milling problem. Review the section on simultaneous milling. If there are two M functions, separate them with a dwell of ¼ second.

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