3.1 HDC-3-5AX - Spindle Chiller Operation

Introduction

The HDC-3-5AX comes with a spindle chiller unit located next to the column on the Tool Changer side of the machine. This spindle chiller helps regulate the temperature of the spindle. This section provides operation information specific to the spindle chiller.

Control Key Description

Main interface bottom: on-off controller

Main interface bottom: quick view of parameters; function setting mode: exit setting mode

Main interface bottom: enter the setting state; under the failure state: clear the fault

Increase settings

Decrease settings

Operation instructions for general temperature-control mode

1. Start and stop the chiller
        Press [ON/OFF] to start and then press it to stop.

2. Quick view of parameters
        Press [ENT] to quickly view the temperature state, compressor and pump current

3. Setting control temperature
        Press [SET] to enter the setting temperature state, then press [UP] to increase the set value; hold it down for about 1 second to increase the value quickly until the maximum set value.
        Press [SET] to enter the setting temperature state, then press [DOWN] to decrease the set value; hold it down for about 1 second to decrease the value quickly until the minimum set value.

Operation Instructions for function setting mode

1. Enter function setting mode
    In general (whether on or off), pressing and holding [ENT] and [SET] for about 3 seconds or long press [SET] will enter the password menu. Press up and down to enter the password 8888, and then press [SET].
    The temperature window displays functional options, such as [F01]. The settings window displays setting data, such as [50.0]
2. Press [UP] or [DOWN] to change the function options, e.g. F [01] to [F45]
3. Modify set value
NUMERICAL MODEL
    Press [SET] to flicker the settings window and press [UP] to increase the set value; hold it down for about 1 second to increase the value quickly until the maximum set value.
    Press [SET] to flicker the settings window and press [DOWN] to decrease the set value; hold it down for about 1 second to decrease the value quickly until the minimum set value.

Parameter Code Setting data description Factory Default Range Setting Unit Remarks
F01 Over-temperature alarm 50.0 30.0~60.0 ℃  
F02 Control by spindle temperature OFF  ON/OFF - ON: Control the machine by Spindle
F03 Fixed temperature max value  42.0 F04~50.0 ℃  
F04  Fixed temperature max value  22.0 5.0~F03 ℃  
F05 Temperture Difference max value 9.9 F06~9.9 ℃  
F06 Temperture Difference max value -9.9 -9.9～ F05 ℃  
F07 Compressor start temperature difference 2.0 F08+0.1～9.9 ℃ Start-up conditions
F08 Compressor stop temperature difference  0.0 -9.9～F07-0.1 ℃  
F09 Compressor delay time 90 0～250 sec Delayed start-up when the temperature reaches F07
F10 Energy deficiency alarming time 90 0～250 min No protection when set to 0
F11 Temperature control mode OFF ON/OFF/H -

OFF: Temperature setting mode, with set temperature as standard

ON: Differential temperature mode, set temperature difference + room temperature

H: Constant temperature mode, set temperature + bypass valve
F12 Power phase detection ON ON/OFF -

ON: Detection alarm;

OFF: No detection alarm
F13 Flow detection delay 60 0～250 sec Detect the flow when this delay is on, do not detect when set at 0
F14 Electric heating stop temperature difference -0.1 F15+0.1～0.0 ℃  
F15 Electric heating start temperature difference -0.4 -9.9～F14-0.1 ℃  
F16 startup OFF ON/OFF -

Cooler status when it is powered on:

ON = Cooler off

OFF = Cooler on
F17 Data reset OFF ON/OFF - ON: All parameters are restored to factory defaults
F18 Pump current overloading 2.0 0.0～10.0 A No protection when set to 0
F19 Compressor current overloading 4.0 0.0～10.0 A No protection when set to 0
F20 Spindle temperature function OFF ON/OFF -

ON: Detection alarm;

OFF: Nodetection alarm
F21 Over-Spindle temperature 38.0 20.0～50.0 ℃  
F22 Remote control OFF ON/OFF -

ON: Start remote;

OFF: Stop remote
F23 Flow detection signal OFF ON/OFF/--- -

ON: normally started, high-voltage alarm;

OFF: normally stopped, low voltage alarm;

---: No protection
F24 Compressor high voltage input signal selection --- ON/OFF/--- -

ON: normally started, high-voltage alarm;

OFF: normally stopped, low voltage alarm;

---: No protection
F25 Compressor low voltage input signal  selection --- ON/OFF/--- -

ON: normally started, high-voltage alarm;

OFF: normally stopped, low voltage alarm;

---: No protection
F26 Screen Saver delay 0 0～250 sec No protection when set to 0
F27 Start Delay of Compressor 90 0～250 sec  
F28 Compressor high pressure detection time 10 0～250 sec No detection when it is set to 0.
F29 Compressor high pressure detection time 120 0～250 sec No detection when it is set to 0.
F30 Over-oil pressure alarm --- ON/OFF/--- -

ON: normally started, high-voltage alarm;

OFF: normally stopped, low voltage alarm;

---: No protection
F31 Over-oil pressure detection delay 0 0～120 sec No detection when it is set to 0.
F32 Low-oil pressure delay --- ON/OFF/--- -

ON: normally started, high-voltage alarm;

OFF: normally stopped, low  voltage alarm;

---: No protection
F33 Low-oil pressure detection delay 10 0～120 sec No detection when it is set to 0.
F34 Compressor overload input signal selection --- ON/OFF/--- -

ON: normally started, high-voltage alarm;

OFF: normally stopped, low voltage alarm;

---: No protection
F35 Pumb overload input signal selection --- ON/OFF/--- -

ON: normally started, high-voltage alarm;

OFF: normally stopped, low voltage alarm;

---: No protection
F36 By-pass valve stop temperature difference 0.4 F36+0.1～9.9 ℃  
F37 By-pass valve start temperature difference -0.1 -9.9～F37-0.1 ℃  
F38 Fluid temperature correction 0.0 -9.9～9.9 ℃  
F39 Indoor temperature correction 0.0 -9.9～9.9 ℃  
F40 LOGO display ON ON/OFF - ON: Display; OFF: No Display
F41 Low temperature protection 5.0 -40.0～30.0 ℃ No protection at - 40.0
F42 Pump ON/OFF status when an alarm is generated ON ON/OFF  

ON: PUMP overloaded or the phase sequence is wrong, the PUMP stops running.

OFF: In case of an alarm, PUMP stops; (PUMP does not stop at over-temperature and low-temperature)
F43 Digital flow detection delay 0 0～240 sec  
F44 Low flow protection value 5.0 0.0～30.0 L/min  
F45 Model of digital flow-meter 383 0～999 PULSE  

Technical Data

SN Project Unit Parameter
1 Power supply system V/Hz 3ϕ220V/50-60Hz
2 Rated power kW 1.412
3 Rated current A 6.42
4 Customized cooling capacity kW 2.5
5 Compressor power kW 1.042
6 Fan air volume m³/h 1200
7 Pump power kW 0.37
8 Rated flow rate L/min 15
9 Maximum pressure Bar 1.5
10 Size of oil inlet and outlet   Oil outlet G 3/4", Oil inlet G 1"
11 Set range °C 22°C~40°C
12 Control accuracy °C ±2
13 Ambient temperature °C 5°C ~43°C
14 Fuel tank capacity L 26
15 Refrigerant kg 0.48 (R410A)
16 Controller type   LCD
17 Equipment appearance color   Black+White
18 Noise dB (A) 78
19 Electrical box protection level   IP44
20 Overall dimensions mm See exterior drawing
22 Applicable cooling medium Main spindle oil, cutting oil

Note: Due to product updates, parameters are subject to change without prior notice.

Refrigeration capacity table (60HZ ± 5%)

Outlet Temperature

Air Temperature

 25°C 35°C 40°C
25°C 92% 105% 113%
35°C 88% 2.5kW 110%
43°C 80% 90% 95%

 Note: The customized cooling capacity is measured at an oil temperature of 35°C and an ambient temperature of 35°C, using 5 #~32 # oil products under operating conditions.

Power Wiring

Rated load current (RAL) of power wiring: 6.42A@60Hz

Maximum operating current (MCC): 7.7A@50Hz

Signal Wiring

Alarm Signal

In the electrical control of the chiller, a passive alarm signal is provided for the machine tool host. When the chiller malfunctions for some reason, the equipment stops. At the same time, the passive alarm terminal COM/NC changes from closed to open, and COM/NO changes from open to closed. The alarm terminal is a completely independent contact, with a maximum driving capacity of 220V/3A.

Terminal Power Down Fault Normal Operation
COM/NO close close open
COM/NC open open close

Off board startup

The chiller provides a pair of remote control terminals for the machine tool host. When set to "external start" mode, short-circuit the operation of the external control terminal equipment. When this pair of terminals is open, the equipment stops and enters standby mode.

3.2 HDC-3-5AX - Spindle Chiller Maintenance

Introduction

This section provides details about the maintenance required for the HDC-3-5AX spindle chiller.

Maintenance

The Maintenance of the equipment must be shut down first, cut off the power supply, and work after 5 minutes, otherwise there will be a risk of electric shock.

When the ambient temperature is below 0°C and the shutdown is long, the internal water must be drained.

Spindle Chiller 
Maintenance Item Interval
Potential safety hazards from the operation status Daily
Check for Vibration/Noise Daily
Inspect/Clean Air filter Weekly
Check Fluid tank level Weekly
Fill Fluid tank As Required
Remove dust and decontamination from unit Weekly
Check noise and interface connection of the circulating pump Monthly
Check the fan and compressor Monthly
Replace the media Semi-annualy
Inspect/Clean Liquid tank Semi-annualy
Insepct/Clean condenser Annualy
Inspect pipeline connection for leaks Annualy
Clean inside and outside of unit Annualy
Inspect/Clean water tank Annualy
Test insulation resistance (≥ 5M Ω) Annualy
Check grounding resistance (≤ 4Ω) Annualy
Test capacitors (NTE 10%) Annualy

HDC-3-5AX Spindle Chiller Maintenance

1

This image shows the key components of the Spindle Chiller:

Front of Chiller:

  1. Chiller Fluid Inlet
  2. Chiller Fuild Outlet
  3. Access Panel
  4. Dispaly/Control Keypad
  5. Air Filter
  6. Chiller Fluid Tank Filler
  7. Chiller Fluid Level Gauge
  8. Drain Plug

Back of Chiller:

         9. Pressure Gauge
         10. Drain Value

2

Inspect the fluid tank level by looking at the fluid level gauge located on the front of the spindle chiller [7]. To add fluid to the tank, remove the cap to the inlet at the top of the unit, and fill the tank with a mixture of 30% ethylene glycol and 70% dionized water until the gauge reads the level is at the top of the NORMAL or at the FULL level.

3

To clean the air inlet filter, remove the grate to gain access to the filter unit. From there, remove the filter screen so that any dust or debris can be picked out of the filter. If necessary, wash the filter using water to get rid of contaminants. 

4

Make sure that the air outlets are clear of dust and debris. It is also recommended to allow a clear area of 12 inches directly behind the air outlet vents. This will allow for proper air circulation in the system.

Transportation Requirements

  1. When handling the chiller, do not overturn or over-tilt it, and avoid collision or impact.
  2. When transporting or moving the chiller, use the correct tools (forklift, cranes, etc.). Do not move the chiller by hand.
  3. Before transporting, please remove the power lines and the coolant from the system. 
  4. When using a forklift, make sure that the chiller is as balanced as possible and is not higher than 7.8 inches above the ground.
  5. When using a forklift to move chillers with casters, the casters must be removed or avoided. 
  6. When lifting with a crane: 
    • Choose a crane and rope that can support the weight of the chiller
    • All personnel must keep a safe distance from the crane
    • Please keep the balance of the chiller
    • The angle of the lifting straps should be ≤ to 45 degree

Note: The chiller itself is designed with lifting eye bolts, please use these lifting eye bolts.

Applicable oils

  1. This chiller is recommended to use mineral hydraulic oil and lubricating oil. Do not use the following liquids:
    • Ortho-ester oil pressure oil, chlorinated hydrocarbon oil pressure oil, water-ethylene glycol fermentation oil pressure oil and O/W, W/O emulsified oil pressure oil and other non-combustible as load oil:
    • Cutting oil grinding oil water and water soluble liquid;
    • Food, medicine and corrosive liquids; 
    • Gasoline, lamp oil and organic solvents;
  2. The viscosity of oil used for this chiller must meet the 4-300 cSt standard. When the oil viscosity used is excessive or the oil pressure loss of the oil piping outside the chiller is excessive, the pump may produce an abnormal sound. At this time, the oil piping outside the chiller should be shortened and oil with appropriate viscosity should be used.
  3. Refer to Figure 6 for the variation of oil viscosity and temperature as well as the applicable range of oil temperature/viscosity for this chiller.

Storage Requirements

When the chiller is not being used for an extended period, please pay attention to protect the interior of the machine and the condenser from dust and moisture adhesion. 
  1. Please drain the water in the equipment and use compressed air to drain the water in the pump, filter and pipeline. Steps of operation:
    • First shut down and cut off the power supply, and operate after 5 minutes.
    • Close the inlet and export ball valve and remove the connection pipeline between the equipment.
    • Drain the water purification/oil tank, water/oil pump, filter, plate change, water/oil inside the pipeline in turn.
    • Use compressed air to blow the internal residual liquid through each interface. It is best to blow it several times at intervals. When no liquid flows out of the interface, it is proved that it has been blown clean. Repeat until no liquid flows out of the interface.
    • Close the inlet and outlet ball valve and each drainage valve.
  2. Please place this machine away from the dust.
  3. Please wipe the surface of the body clean, and blow away the dust and oil from the inside with an air pump.
  4. A protective cover is put on the outside of the device to prevent dust and moisture from sticking.
  5. Store this machine in a flat ground, dry and ventilated place to avoid direct sunlight
  6. If the device is equipped with casters, please make sure that the casters are fixed or locked to avoid damage caused by sliding the casters.
  7. Ambient temperature requirements: 0`45 C degrees, ambient humidity requirements: ≤ 90%RH

Scrapping

When the equipment reaches its service life and is scrapped, please treat it as industrial waste, and ask professionals for guidance to classify the metal parts, plastic parts, electrical parts, refrigerants, etc. in the equipment according to regional environmental protection requirements. 

List of Main Parts

SN Name Model Brand Remarks
1 Compressor WHP03250ASV HIGHLY N/A
2 Capillary 2*ɸ 2.5*800mm Rucol N/A
3 Trochoid Pump VDP-SE-15A OMO N/A
4 Electrical Machinery 1/2HP4P Jia Sheng N/A
5 Fan Leaf ɸ300 SD N/A
6 Controller N/A Rucol N/A
7 Evaporator RCO-25-Z Rucol N/A
8 Condenser RCO-25-L Rucol N/A

Selection of power supply wire diameter

Power cable diameter mm² (copper wire) 1 1.5 2.5 4 6 10
Carrying current capacity (A) 10.3 13.5 18.3 24 31 44

Electrical specification of controller

  Specifications Remarks
Input power AC8-12V N/A
50~60Hz
3 groups of relay output 250VAC/10A 30VDC/10A N/A
Alarm output contacts 250VAC/5A 30VDC/5A N/A
250VAC/3A 30VDC/3A
Three phases detection input 180~400VAC N/A
50~60HZ
5 groups of alarm input contacts 15~30VDC/AC N/A
AC50~60HZ N/A
Temperature sensor 25C 10K K:3977
Temperature control range 40.0℃~100.0℃/-9.9℃~9.9℃ fixed temperature mode / differential temperature mode
Temperature sense range -45℃~110℃ N/A
Temperature resolution 0.1℃ N/A
Temperature accuracy ±0.1% Full range@25℃
Temperature stability ±0.5% 0℃~75℃

3.3 HDC-3-5AX - Spindle Chiller Troubleshooting

Symptom Table

Symptom

Probable Cause

Solution
Alarm 4.9003 Insuficient Spindle Coolant Chiller Flow Flow sensor on the spindle chiller may need to be adjusted to read correct flow.  Adjust the flow sensor using the slotted holes on the sensor, move the sensor towards the motor side until the bit changes. The slots on the sensor might not be enough adjustment, if so open the slots further to get the adjustment needed. Contact Haas Service if this issue continues to persist. 
Air may be introduced into the system via chiller lines not being fully plugged into the fittings or seals that are broken and sucking in air.  Replace any broken seals and make sure the lines are fully plugged into the fittings. Prime the lines and make sure the no air bubbles are present in the lines. 
Coolant tank chiller issues with less than normal pressure or an over-heated pump.

The correct placement of the 3” return tube. 

A 6’’ tube (58-3728) being used rather than the 3” tube (58-0742). The 6” tube was bottoming out and cause a major flow restriction. See Coolant Tank Chiller section for images

Fault Alarms

Fault Code Cause of alarm Control output F42 = ON Control output F42 = OFF Remarks
Pump Compressor Alarm Lamp Pump Compressor Alarm Lamp
AL0 Three-phase loss OFF  OFF ON OFF OFF ON Manual Recovery
AL1 AL1 Three-phase inversion OFF OFF ON OFF OFF ON Manual Recovery 
AL2 Oil deficiency OFF OFF ON OFF OFF ON Manual Recovery
AL3 Compressor high pressure overload ON OFF ON OFF OFF ON Manual Recovery
AL4 Compressor low pressure overload ON OFF ON OFF OFF ON Manual Recovery
AL5 Energy deficiency ON OFF ON OFF OFF ON Manual Recovery
AL6 Indoor temperature sensor breakdown ON OFF ON OFF OFF ON Automatic Recovery
AL7 Fluid temperature sensor  breakdown ON OFF ON OFF OFF ON Automatic Recovery
AL8 Over temperature alarm ON ON ON ON ON ON Automatic Recovery
AL9 Low temperature alarm ON OFF ON ON OFF ON Automatic Recovery
AL10 Pump overload OFF OFF ON OFF OFF ON Manual Recovery
AL11 Compressor overload ON OFF ON OFF OFF ON Manual Recovery
AL12 (Communication failure) ON ON OFF ON ON OFF Automatic Recovery
AL13 Thermostat malfunction ON ON ON ON ON ON Automatic Recovery
AL14 Over-spindle temperature alarm ON ON ON ON ON ON Automatic Recovery
AL15 High oil pressure alarm OFF OFF ON OFF OFF ON Manual Recovery
AL16 Low oil pressure alarm OFF OFF ON OFF OFF ON Manual Recovery