HA5C Workholding

The HA5C accepts standard 5C collets and step collets.

HA5C Chuck Install:

[1] SHCS

[2] LC5C-B

[3] HA5C

[4]Face Plate

[5] Chuck

[6] 70 ft-lb

To install collets, chucks, and faceplates in an HA5C:

  1. When inserting the collets, align the keyway on the collet with the pin inside the spindle.
  2. Push the collet in and turn the collet drawbar clockwise the collet is correctly tightened.
  3. Chucks and face plates use the 2-3/16-10 threaded nose on the spindle. You should use chucks with a diameter smaller than 5" and that weigh less than 20 pounds.
  4. Pay special attention when installing chucks, always make sure that the thread and the outside diameter of the spindle are free of dirt and chips.
  5. Apply a thin coating of oil to the spindle, and screw the chuck on gently until it seats against the rear of the spindle.
  6. Tighten the chuck to approximately 70 ft-lb with a strap wrench.
  7. Always use a firm, steady pressure to remove or install chucks or face plates, otherwise damage to the indexing head may result.

WARNING: Never use a hammer or pry bar to tighten the chuck; this will damage the precision bearings inside your unit.

AC25/100/125 Air Collet Closers - Draw Force

The AC25 is a non through-hole type closer that holds parts using air pressure, which provides up to 3000 pounds of draw force, depending on air pressure supplied. The unit provides 0.03" of longitudinal movement so diameter variations of up to 0.007" can be clamped securely without readjustment.

The AC100 is a through-hole type closer that holds parts using spring force, providing up to 10,000 pounds of draw force. The unit provides 0.025" of longitudinal movement so diameter variations of up to 0.006" can be clamped securely without readjustment. Set air pressure between 85 and 120 psi.

The AC125 air collet closer has a 5/16" through-hole that allows small diameter stock to extend out of the unit. The AC125 also has a large diameter counterbore in the drawtube that allows stock to pass through a standard 5C collet up to approximately 1.6" out the rear of the collet. This also allows the use of most standard collet stops. The AC125 uses air pressure to provide up to 12,000 lb. of draw force (adjustable through a customer-supplied air pressure regulator). The drawtube travel of 0.060" allows the unit to securely clamp parts with up to 0.015" variation in diameter without readjustment.

Manual Collet Closer Removal

Collet Closer:

[1] AC25,

[2] AC125,

[3] AC100

[4] Manual Collet Closer

Before installing the air collet closer on the unit, you must first remove the manual collet closer assembly [4]. To remove this assembly:

  1. Remove the top and bottom mounting bolts for the handle [A].
  2. Slide the handle off the collet closer assembly.
  3. Remove the collet closer and slide the collet closer assembly out the back of the spindle.
  4. Remove the flathead screw [C] and locking pawl [B], and unscrew the spindle nut [D].
    It may be necessary to use two 1/8" pins and a screwdriver to break the spindle nut loose.

AC25 Collet Closer Installation

CAUTION: The Model AC25 Collet Closer relies on air pressure to maintain clamping force and will release if the air supply is accidentally removed. If this presents a fail-safe problem, an air switch should be installed in-line to stop machining operations if the air supply should fail.

To install the AC25:

  1. Install new spindle nut [6], locking pawl [3] and FHCS [4].
  2. Insert drawtube of assembled AC25 [5] into back of HA5C spindle, and screw the main body onto the back of the spindle.
  3. Tighten with a strap wrench to approximately 30 ft-lb.
  4. Mount valve assembly [2] to top of HA5C as shown using ½-13 SHCS [1].
  5. Assemble the fittings of the copper tube [7] between the valve and the fitting on the back of the collet closer and tighten.

AC25 Collet Installation

To install a collet:

  1. Line up the collet keyway with the spindle key and insert the collet.
  2. There are two ways to turn the draw tube to adjust the collet:

A collet with an 11/64" or larger opening can be adjusted using a 9/64" hex wrench.

Collets smaller than 11/64" are adjusted by turning the drawtube with a pin through the slot. Look between the back face of the worm gear and collet closer to see the holes in the draw tube. It may be necessary to jog the spindle until they are visible. Use a 9/64 diameter pin to rotate the draw tube and tighten the collet. There are 15 adjustment holes, so it will take 15 steps to turn the draw tube one full revolution. Put a part in the collet and tighten until it grips the part off then back the draw tube one-quarter to one-half turn. Do not do this for multi-head HA5C units.

AC100 Collet Closer Installation (HA5C Only)

CAUTION: The AC100 Collet Closer is designed to clamp parts when the air pressure is off. Do not index while air pressure is applied to the unit; this causes excessive loading on the slip ring and damage the motor.

To install the AC100:

  1. Assemble the brass air fittings with the valve and slip ring as shown in the figure below.
  2. When assembling the fittings, ensure they are all tight and square with the valve.
  3. Mount the valve to the bracket with the 10-32 x 3/8" BHCS.
  4. Bolt the bracket to the back of the indexing head with the 1/4-20 x 1/2" SHCS and 1/4" split lock washers.
  5. Before you tighten the bracket, make sure the slip ring and bracket are square and the unit can rotate freely.
  6. Connect the valve and slip ring with the copper tubing and tighten down these fittings.

AC100 Collet Installation

NOTE: The air pressure for the AC100 should be set between 85 and 120 psi.

To install the AC100 collet:

  1. Align the collet keyway with the spindle key and insert the collet.
  2. Hold the collet in place and tighten down the drawbar by hand.
  3. With the air pressure valve on, place your part in the collet and tighten the drawbar until it stops.
  4. Back off ¼-½ turn, then turn off the air.

    The collet will clamp your part with maximum holding power.

  5. For thin-walled or fragile parts, turn off the air pressure, place your part in the collet, and tighten the drawbar until it stops.

    This is your starting point for adjustment at the loose end.

  6. Turn on the air pressure valve and tighten the drawbar ¼-½ turn.
  7. Turn off the air and the collet will begin to clamp your part.
  8. Repeat until you achieve the desired amount of clamping force.

AC125 Collet Closer Installation

CAUTION: Hitting the collet assembly against the spindle can cause damage to the threads on the end of the draw bar.

To install the AC125 collet closer:

  1. Carefully insert the drawtube of the assembled AC125 [1] into the back of HA5C spindle and screw the main body onto the back of the spindle.
  2. Tighten with a strap wrench to approximately 30 ft/lbs.
  3. Mount the valve assembly [2] to the top of the HA5C as shown using 1/2-13 SHCS [3].
  4. Assemble the fitting [4] part number 58-16755 and copper tube [5] part number 58-4059 between the valve and fitting on the back of the collet closure and tighten.
  5. Never use a hammer to remove or install these items. The shock will damage the precision bearings and gears inside the unit.

AC125 Collet Installation

All collets used with the AC125 must be clean and in good condition. To install a collet in the AC125:

  1. Align the collet keyway with the spindle key and insert the collet.
  2. Insert a 5/16" hex wrench into the hex in the back of the drawtube, and turn the drawtube to engage the collet.
  3. Tighten the drawtube until it grips the part, and then back off approximately 1/4 turn.

    This is a good starting point for fine-tuning the grip range.

Air Collet Closer Removal

Air collet closers fitted at the factory are not intended to be removed. However, if you need to remove the air collet closer:

  1. Use a woven strap wrench to remove the collet assembly.
  2. Do not use a hammer or impact wrench to remove the closer bodies; damage may occur to the gear and bearing sets.
  3. When re-installing the collet closer, use a strap wrench and tighten to approximately 30 ft-lb.

Haas Manual Draw Tube (HMDT)

The HMDT is used for standard and tilt multi-head 5C units in place of pneumatic closers, where a through hole is required or space constraints exist. The HMDT fits within the body of the 5C unit and has a 1.12" (28 mm) through hole. The collet is tightened using a standard 1-1/2" (38 mm) socket and a torque wrench for consistency.

Collect Sticking

NOTE: To prevent excessive wear and collet sticking, make sure collets are in good condition and free from burrs. A light coat of molybdenum grease (Haas p/n 99-0007 or Mobil p/n CM-P) on the collet wear surfaces extends the life of the spindle/collet, and helps prevent sticking.

When using the AC25, releasing a collet is accomplished by removing the air supply. The collet is then pushed out by a heavy spring inside the air collet.

The AC100 uses shop air to move the drawbar forward and release the collet. Increasing the air pressure can help free the collet when it sticks; however, do not exceed 150 psi.

The AC125 uses shop air to pull in the drawtube, and a heavy internal spring to push out the drawtube and release the collet. If, after repeated use, the spring does not push out the collet, use one of the following methods to remove the collet and lubricate the outside of the collet with a light grease before re-inserting:

  1. If the three-way air valve becomes clogged, exhaust airflow may be restricted, causing the collet to stick in the taper. Leave the valve clamped, and connect and disconnect the air supply several times.
  2. If the above procedure does not free the collet, switch the valve to the unclamped position, then gently tap the back end of the drawtube with a plastic-faced mallet.

A6AC Air Collet Closer (HRT)

The A6AC is a 1-3/4" diameter through-hole type closer, adjustable from the rear. It holds parts using spring force to provide up to 0.125" of longitudinal movement and up to 5000 lb of draw force at 120 psi.

The A6AC collet closer bolts to the back of the HRT A6 (See the following illustration).

The drawbar and collet adapters are designed to mate with the Haas A6/5C spindle nose. The optional A6/3J and A6/16C can be obtained from a local tooling distributor. Failure to follow the A6AC installation instructions may result in throughst bearing failure.

A special drawtube adapter is required for the 16C and 3J. Be sure to supply the tooling distributor with spindle/drawbar details as shown.

A6AC Collet Closer Mounted To An HRT A6

Drawtube and Spindle (Extended/retracted)

Drawtube To Spindle Dimensions (Extended/retracted) @ 100 psi Line Pressure

Reference Name Value (extended/retracted)
[A] MAX. (Tube Extended) .640
[B] MIN. (Tube Retracted) .760
[C] Spindle Type and Size A1-6
[D] Draw Tube Thread Data
1 - Diameter of Thread (internal) 1 7/8 - 16 - UN - 2B
2 - Pitch  1.834/1.841
3 - Thread Length 1.25
[E] Draw Tube I.D. 1.75
[F] Draw Tube O.D. 2.029
[G] Spindle I.D. 2.0300
     

To adjust the collet closer:

  1. Align a collet with the keyway, push the collet into the spindle, and turn the draw bar clockwise to pull the collet in.
  2. To make final adjustments, place a part in the collet, and turn the air valve to the Unclamped position.
  3. Tighten the draw bar until it stops, then loosen it 1/4-1/2 turn, and turn the air valve to the Clamped position (adjusted for maximum clamping force).
  4. To reduce clamping force, loosen the draw bar or reduce the air pressure before adjusting.

TRT Rotary - Air Clamp Provision - Installation

AD0524

Introduction

1

This procedure will explain how to install the Rotary air union on the following units:

  • TRT160 built after 8/16/2019
  • TRT210 built after 03/16/2020
  • TRT310 built after 10/01/2021

NOTE:  The TRT160, TRT210, and TRT310 must have the motor cover with the AUX 1 and AUX 2 port on the rotary axis.

Machine Requirements:

  • Next Generation Control
  • Auto Vise Software Requirements: 100.20.000.1200 or later. 
  • Minimum Main IO firmware: version 4.0 or higher. 

This procedure applies to the following kits:

TRT160

  • AIR-CLAMP-PROV-160 Air Clamp Provision only.
  • AIR CLAMP AUTO 160 Automatic Air Clamp Provision kit.  This kit comes with a foot pedal switch.
  • 93-1000427 AIR CLAMPING PROVISION TRT160 - Manual Air Clamp Provision kit.  This kit comes with a manual switch

TRT 210

  • AIR-CLAMP-PROV-210    Air Clamp Provision kit only.
  • AIR CLAMP PRO-MANU Manual Air Clamp Provision kit.  This kit comes with a manual switch
  • AIR-CLAMP-PRO-AUTO   Automatic Air Clamp Provision kit.  This kit comes with a foot pedal switch.

TRT310

  • AIR CLAMP MANU 310 Manual Air Clamp Provision kit.  This kit comes with a manual switch
  • AIR CLAMP AUTO 310 Automatic Air Clamp Provision kit.  This kit comes with a foot pedal switch.
  • 100MM AIR VISE-MNL 100mm air vise to use with manual switch
  • 100MM AIR VISE-AUT 100mm air vise to use with foot pedal switch. 

Air Clamp Provision - Installation

1

 Warning: Zero return the unit before installing the air clamp union assembly [1].

Use the SHCS 10-32 [2] to install the assembly onto the unit. 

NOTE: The TRT160 will have x4 10-32 screws, while the TRT210 and TRT310 will have 3.

 

2

TRT160 and TRT210

The air clamp union should be installed in the correct orientation as shown. Auxiliary port 1 is denoted as [1] and auxiliary port 2 as [2]. 

3

TRT310

The air clamp union should be installed in the correct orientation as shown. Auxiliary port 1 is denoted as [1] and auxiliary port 2 as [2]. 

4

For TRT160's with equally spaced platter bolts, use the shown orientation with the aux 1 denoted as [1] and aux 2 denoted as [2].

5

Move the NPT plugs from the auxiliary ports below the unit [1] to the ports shown in position [2].

6

Install the copper lines and fittings as shown.

[1] COPPER TUBE 2 PORT UNION AUX 2 TRT210

[2] FITG LUBE COMP NUT BIJUR-M 5/32 (2x)

[3] FITG LUBE COMP SLEEVE 5/32 BRASS

[4] FITG LUBE BIJUR-F NPT1/8M STR BRASS

7

Remove the plugs [1].

Install 90° compression fittings [2] where the plugs were removed from.

Note: If the TRT is removed from the machine, plug ports with 1/8 NPT plugs to prevent contamination of the air system.

Manual - Air Clamp Provision

1

Follow this step for the Manual Air Clamp Provision Option.

Install the air switch [1], the switch can be mounted on the inside or outside of the machine via magnet.

Connect the air supply [3] to the air switch [1]. 

Connect the air lines from the switch [1] to the unit [2].

Note: The AUX 1 port will act as clamp and the AUX 2 port will act as unclamp.

Automatic - Air Clamp Provision - Installation

1

Follow these steps for the Automatic Air Clamp Provision Option.

Connect the SS braided hoses [1] from the solenoid assembly to the 90° compression fittings [2] at AUX 1 and AUX 2.

Note: The red zip tie denotes clamp and the green zip tie denotes unclamp.

2

Solenoid 30-13112 UNCLAMP/CLAMP:

Warning: E-Stop and turn off the machine before any electrical installation

Remove a NPT plug from the air manifold inside the lubrication cabinet and install the solenoid[1] to the air manifold into the location APC DOOR INTERLOCK/PROGRAMMABLE AIR shown on the AIR - LUBRICATION SYSTEM - PICTORIAL.

Connect the red hose at the location with the red zip tie and connect the green hose at the location with the green zip tie.

Note: The ports that these hoses are installed to will determine if the vise remains clamped when power is cut to the machine. Test at end of installation.

Plug cable 33-0631 in at P50 on the I/O board. Plug the other end of the cable into the APC Door Interlock/Programmable Air location on the solenoid bracket.

Plug the solenoid into 33-0631 at the APC Door Interlock/Programmable Air Molex connector.

Connect cable 33-0732 onto the pressure switch on solenoid 30-13112. Plug cable 33-0738 into P13 on the I/O PCB and connect the other end to cable 33-0732.

3

Foot Pedal Installation

VF/VM Models

Install the fool pedal cable on the hole located on the front skirt of the machine.

Note: If the foot pedal cable hole is not present, drill a 5/8" hole in the front skirt to install the foot pedal cable.

Route cable 32-1390 from P14 on the I/O PCB to the front skirt of the machine to connect to the foot pedal.

Note: To install the Pneumatic Vise, refer to the TRT Pneumatic Vise - Installation procedure. 

TRT Pneumatic Vise - Installation

AD0525

Introduction

This procedure outlines how to install the TRT Pneumatic Vise.

Minimum Requirements:

Installation

1

Remove the port plugs [1].

Install the 2-013 o-rings [2].

Note: If the vise is ever removed, plug the ports with 1/8 npt plugs to prevent contamination of the air system.

2

Verify the orientation of the vise ports [1] and the union ports [2] line up with each other.

Note:  The vise has two ports with different holes to ease with identification.  It is important to have proper orientation for correct clamp/unclamp action.

3

Install the vise bolts [1] and torque them to 60 ft-lbs or 80 N-m.

Manual Air Clamp Provision - Verification

1

Perform this step if you have the Manual - Air Clamp Provision.

Toggle the air switch and make sure the vise actuates correctly.

Note: The AUX 1 port will act as clamp and the AUX 2 port will act as unclamp.

Automatic Air Clamp Provision - Verification

1

Perform these steps if you have the Automatic - Air Clamp Provision.

Press SETTING and set Setting 276 Workholding Input Monitor to 15.

The clamp force of the Pneumatic Vise can be adjusted by adjusting the Air Regulator[1] on the Clamp/Unclamp solenoid. The higher the pressure, the greater the clamp force.

Verify the pressure switch functions by running the spindle in MDI: M03 S100;

Lower the air pressure all the way by turning down the regulator until the machine alarms with Alarm 180 Fixture Not Clamped. Adjust the pressure back to the desired pressure.

2

Press [CURRENT COMMANDS] and navigate to Devices > Workholding > Vise 1.

Press [ALTER] to setup the vise.

Press [E-Stop] and select 3. Custom Pneumatic Vise.

Press [ALTER] to go back to the vises view.

Press [F2] to clamp/unclamp the vise, make sure the vise actuates correctly.

 

Rotary - Zero Point - Install

AD0658

Applies to TRT units built with the Zero Point work holding option

Introduction

A TRT160 or TRT210 ordered with the Zero Point work holding option will require some assembly before it can be used. 

This procedure goes over how to set up a new TRT with a zero-point option. 

Note: This option is not field installable. 

This document does not go over how to install the air clamp provision. Instructions for that can be found on AD0524 TRT Rotary - Air Clamp Provision - Installation. 

Instructions for setting up programable air and automatic work holding on NGC can be found on AD0473 Programmable Air - Installation.

The instructions for installing a rotary can be found on AD0005 Rotary - Installation.

The instructions for managing rotary cables can be found on AD0530 Rotary Cable Management Kit - Installation.

Required tools

  • 59-1844 - Zero Point Clamp
  • 59-1867 - Zero Point Plate or other work holding with Zero Point pull stud. 
  • Indicator with a mag base
  • Torque wrench with 5 mm hex bit
  • Grease

Machine requirements

  • 100.20.000.1200 version or Higher
  • Minimum Main IO firmware: version 4.0 or higher

Installation

1

 Warning: The air clamp provision must be installed before starting this procedure. If it is not installed, follow the instructions on AD0524 TRT Rotary - Air Clamp Provision - Installation.

Place the TRT in the machine and plug it into the machine and connect it to an air source.  

Blow air thru both ports located on the rear of the unit marked Aux 1 and Aux 2 to ensure the plumbing to the union/plate is free of debris.

If the TRT has the manual clamp, flip the switch to blow air through the TRT. 

If the TRT has the auto clamp, use the foot petal or M codes M70 and M71. 

The air will come out of the top of the rotary axis [1].

2

The image shows the bottom side of the Zero Point chuck. In the three noted grooves, install O-rings as shown on the vise. Use grease to hold o-rings in place.

3

Orient the vise as shown and carefully insert it into the bore. It’s a close fit, so be careful.

Position #1 [1] should be between the two air outlets [2].

4

Use a torque wrench with a 5 mm bit to torque down the eight bolts to 8 ft-lbs or 104 in-lbs or 11.8 Nm.

Use an indicator to check the runout of the chuck. It should be NTE 0.0005 inches or 0.0127 mm. 

5

Place a work holding plate on the rotary and test that it clamps and unclamps correctly. 

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