Dual Programmable Air - Installation

Introduction

This procedure will show you how to install the Programmable Air Option [1] on the following machines and their variants:

VF-1/2/3/4/5/6/7/8/9
VM-2/3
DM-1/2
DT-1/2
MM
CM-1

Machine Requirements

NGC Software Requirements: 100.20.000.1200 or later.
Minimum Main IO firmware Version: 4.0 or higher.
93-1000878 - PROGRAMMABLE AIR DUAL FIELD INSTALL KIT
93-1000910 - PROGRAMMABLE AIR DUAL FIELD INSTALL KIT

Important: The Dual Programmable Air option is NOT compatible with the Single Programmable Air option or the E-vise option.

Important: The Dual Programmable Air option is NOT COMPATIBLE with machines with the TAB option built before June 2019.

IMPORTANT: Depending on the machine's built by date, seperate brackets may need to be ordered to make the machine compatible. The brackets that are sold seperately are 25-12138, 25-14177 & 25-12749. Refer to the below table to determine what brackets are needed for each machine:

Machine	Date	Part Number
VF-1/2	Built before 7/22/2022	25-12138 & 25-14177
VF-1/2	Built after 7/22/2022	25-15873 & 25-15875
VF-1/2YT	Built before 7/21/2022	25-12138 & 25-14177
VF-1/2YT	Built after 7/21/2022	25-15873 & 25-15875
VF-3/4	Built before 7/30/2022	25-12749 & 25-14177
VF-3/4	Built after 7/30/2022	25-15873 & 25-15875
VF-3YT/40	Built before 8/16/2022	25-12749 & 25-14177
VF-3YT/40	Built after 8/16/2022	25-15873 & 25-15875
VF-3YT/50	Built before 12/1/2022	25-12749 & 25-14177
VF-3YT/50	Built after 12/1/2022	25-15873 & 25-15875
VF-5/40/XT	Built before 9/20/22	25-12749 & 25-14177
VF-5/40/XT	Built after 9/20/22	25-15873 & 25-15875
VF-5/50/XT	Built before 10/16/22	25-12749 & 25-14177
VF-5/50/XT	Built after 10/16/22	25-15873 & 25-15875
VF-6/40/50	Built before 5/1/2022	25-12138 & 25-14177
VF-6/40/50	Built after 5/1/2022	25-15873 & 25-15875
VF-7/40/50	Built before 5/1/2022	25-12138 & 25-14177
VF-7/40/50	Built after 5/1/2022	25-15873 & 25-15875
VF-8/40/50	Built before 2/28/2022	25-12138 & 25-14177
VF-8/40/50	Built after 2/28/2022	25-15873 & 25-15875
VF-9/40/50	Built before 2/28/2022	25-12138 & 25-14177
VF-9/40/50	Built after 2/28/2022	25-15873 & 25-15875
VR-8/9	Built before 2/28/2022	25-12138 & 25-14177
VR-8/9	Built after 2/28/2022	25-15873 & 25-15875
VM-2/3	Built before 5/1/2022	25-12138 & 25-14177
VM-2/3	Built after 5/1/2022	25-15873 & 25-15875
DT/DM-1/2	Built before 1/28/2022	25-12138 & 25-14177
DT/DM-1/2	Built after 1/28/2022	25-15873 & 25-15875
TM-0	Built before 9/1/2022	25-12138 & 25-14177
TM-0	Built after 9/1/2022	25-15873 & 25-15875
TM-1	Built before 1/28/2022	25-12138 & 25-14177
TM-1	Built after 1/28/2022	25-15873 & 25-15875
TM-2	Built before 9/10/2022	25-12138 & 25-14177
TM-2	Built after 9/10/2022	25-15873 & 25-15875
CM-1	Built before 8/25/2022	25-12138 & 25-14177
CM-1	Built after 8/25/2022	25-15873 & 25-15875

Solenoid Installation

1

Attach the solenoid assembly [1] to the middle of the CALM cabinet door using the magnets in the kit.

Route the cable conduit [2] from the Dual Programmable Air manifold to the solenoid assembly using the magnets from the kit as shown [3].

The air lines [4] from the solenoid assembly [1] should be routed and connected in the CALM cabinet and install the push to connect fitting.

Refer to the Dual Programmable Air decal for push to connect fitting location.

The electrical cables for the solenoid assembly are wrapped under the electrical cabinet, remove the panel from under the electrical cabinet and route the cable [4] to the solenoid assembly [1] as shown.

2

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

The solenoid assembly [1] gets attached to the middle of the CALM cabinet door with magnets.

Air from the main manifold in the CALM cabinet will connect to the small air manifold located in the solenoid assembly [1].

The air supply for the vise's solenoids [4] and the air blast [3] is connected in the CALM cabinet [2] as shown.

The air blast black air hose coming from the Dual Programmable Air manifold [3] should be connected to the solenoid in the solenoid assembly [1].

Connect the Red (clamp) and Green (unclamp) hoses from vise 1 to the solenoid [5] with red and green zipties.

Connect the Purple (clamp) and Orange (unclamp) hoses from vise 2 to the solenoid [6] with purple and orange zipties.

Cable 33-1206 [7] connects to P36 and P50 on the IOPCB and to the vise's solenoids [5],[6]. If the machine is equipped with the coolant refill option, remove the cable from P36 and connect it to the pigtail [8] on cable 33-1206.

Cable 33-1207 [9] connects to the adapter from cable 33-0738 [10] at P13.
Note: If the machine is equipped with other options that utilize P13, connect it to the pigtail cable coming out of P13.

Cable 32-1390 [11] connects to the foot pedal at the front of the machine.

3

Make sure cable conduit covers the air lines from the solenoid assembly to the CALM cabinet [1] and the electrical cables to the electrical cabinet [2].

NOTE: Place magnets along the cable route [3].

Zip tie the solenoid and pressure switch cable to the side of Vise 2 solenoid [4].

Air Manifold Installation

1

Table Locations

DT-1/2 - DM-1/2 - VF-1/2 - MM

The programmable air manifold can be installed almost anywhere on the table. Verify that the conduit has enough slack and does not catch on the waycovers when at its travel limits.

VF-3/4/5

The programmable air manifold can be mounted to most locations on the table. Verify that the conduit has enough slack and does not catch on the waycovers when at its travel limits.

VF-5/40XT/50XT & VF-6/7/8/9

Install the programmable air manifold to the right side and middle of the table[1]. Verify that the conduit has enough slack and does not catch on the waycovers when at its travel limits.

VM-2/3

The programmable air manifold can be mounted to most locations on the table. Verify that the conduit has enough slack and does not catch on the waycovers when at its travel limits.

CM-1

The programmable air manifold can be installed almost anywhere on the table. Verify that the conduit has enough slack and does not catch on the waycovers when at its travel limits.

Note: These machines come standard with Table Auxiliary Air Supply. To install the programmable air manifold, a new location on the CALM air manifold will need to be used. Depending on the machine configuration an adapter will need to be made to add the programmable air solenoid.

2

The user supplied programmable vise's should be installed to the desired table locations [1],[2].

Use the included T-nut to attach manifold bracket to the table [3].

Install the cable clamp conduit [4] into the sheet metal panel [5] of the machine.

NOTE: The image shows for a VF-Small, on VF-Med and VF-Large machines the sheet metal panel opening for the conduit may be on the back of the right panel or the back right of the top panel.

Jog the table into the furthest corner from the cable clamp conduit to set the travel length of the cable.

Jog the table into the closest corner of the conduit cable clamp and verify that the conduit doesn't interfere with the Z-Axis waycover, OMI sensor, or WIFI camera if these options are installed.

Plug the user supplied vise and airblast into the air manifold on the table.

Red ziptie location for clamp on Vise 1.

Green ziptie location for unclamp on Vise 1.

Purple ziptie location for clamp on Vise 2.

Orange ziptie location for unclamp on Vise 2.

Black ziptie location for air blast on both Vise's

Note: On VF-Small's and DT/DM machines, it is best to place the vises so that the air connections are to the front of the machine. If the air connections are to the back of the machine, the hoses will hit the way covers.

Note: The hoses may be too short to reach the second vise on the table, there are extension hoses in the kit to use if this happens.

3

For VF-3 to VF-5 and VF-6 to VF-14

Attach the spring/magnet [1] assembly to the top panel of the machine as shown. Use it to help the droop of the cable conduit as shown in [2].

4

For CM-1/2 Machines

NOTE: Only applies to machines built BEFORE 1/1/2023.

Run the cable conduit up the machine. Secure the cable conduit inside the opening on top of the enclosure [1].

From outside the machine, route the cable conduit down the column and into the CALM cabinet.

Foot Pedal Cable - Installation

1

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 along the side skirt using the magnetic mounts to the front skirt of the machine to connect to the foot pedal.

Important: Use the next step if installing on a Mini Mill.

2

Mini Mill Install

On Mini Mills a sheet metal bracket [2] will need to be installed on the front of the machine for the foot pedal as shown with the magnet [1] given in the kit.

Route cable 32-1390 from P14 on the I/O PCB and install the cable to the bracket [2].

3

Connect the second foot pedal [2] to the first pedal [1] as shown.

Dual Programmable Air Activation

Turn on the machine.

Login to the HBC Portal.

Download the Dual Programmable Air option configuration patch files.

Note: The option files will appear on the configuration download page after the Dual Programmable Air Kit has been ordered. If the option does not appear contact the service department.

Load the option configuration patch file to the control. Refer to the NEXT GENERATION CONTROL - CONFIGURATION FILE - DOWNLOAD/LOAD procedure.

Setup

1

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

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

Verify the pressure switch's function by clamping the workholding and running the spindle in MDI: M03 S100;

Lower the air pressure to zero by turning down the regulator[1] 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.

M70/71 CLAMP/UNCLAMP

M116/M117 AIR BLAST ON/OFF

Repeat the above steps to set up Vise 2.

Note: Use M70 Pn / M71 Pn to clamp or unclamp the vises setup on the workholding page. The P code defines the vise number. The range is P1 - 8. For example M70 P1 clamps Vise 1 and M71 P1 unclamps it. The system will default to Vise 1, if no P-Code is specified with M70 or M71.

Note: If alarm 391: Feature Disabled is generated when commanding the workholding, the workholding has not been setup correctly on the Workholding tab. Perform the previous steps again.

Clamp/Unclamp can be operated from the Workholding tab or by commanding the Foot Pedal(s).

Air Blast can be operated from the Devices tab.