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This procedure tells you how to install these components on machines that have Classic Haas Control (CHC):

1. Optional Fourth-Axis and Fifth-Axis Drive
2. Rotary Scale Feedback
3. Secondary Mocon PCB
4. Expansion PCB

If you are installing a Fourth-Axis, only refer to the Fourth-Axis Installation section.

If you are installing Fourth-Axis and a Fifth-Axis at the same time, refer to the Fourth-Axis and Fifth-Axis Installation section.

Machine Compatibility:

• Mill that has brushless servo amplifiers.

Push [POWER OFF].

Set the main circuit breaker to the OFF position.

Find the (2) plugs [1] for the A-Axis receptacles. The plugs are on the side of the control cabinet. Push the plugs out of the holes.

Install the 7-pin power connector [2] into the receptacle that is labeled A-AXIS POWER. Then, use the (4) screws to secure the plug.

Install the 28-pin encoder connector [3] in the receptacle with the A-AXIS ENCODER label. Then, use the (4) screws to secure the plug.

Remove the I/O PCB and Maincon cover.

Find the location on the amplifier bank that has the A Axis label. Install the amplifier for the fourth-axis drive at this location.

Connect the fourth-axis servo cable wires to the high-voltage terminals on the amplifier:

• red to RED [1]
• white to WHT [2]
• black to BLK [3]

 Note: The cables have the labels A, B, and C. Make sure the labels are in the correct sequence.

Connect jumpers [4] from the fourth-axis drive to the nearest amplifier on each side:

• Connect the black wire to -H.V.
• Connect the red wire to +H.V.

 Caution: The fourth-axis servo cable has a shielded wire attached to the black jumper. Connect the shielded wire to -H.V. Do not connect it to the machine ground.

Put the cables in the cable tray.

Connect the 6-pin connector [1] on the A-Axis brake cable to P46 [2] on the I/O PCB.

Connect the 16-pin connector [4] on the encoder cable to P9 [3] on the Maincon PCB.

Connect the 10-pin connector [5] on the current command cable to the P5 connector [6] of the Maincon PCB.

Note: The image shows the 10-pin connector is being plugged into a stand alone Mocon where the P5 connector is horizontal. With machines with a Maincon/Mocon combination board, the P5 connector will be vertical. 

Connect the 8-pin connector [8] on the current command cable to the amplifier [7].

Push [POWER OFF].

Set the main circuit breaker to the OFF position.

Lock the main circuit breaker. Use an approved lock with an approved safety tag.

Find the plug [1] for the A-AXIS SCALE and B-AXIS SCALE receptacles. The plugs are on the side of the control cabinet. Pull the plugs out of the holes.

Connect the 28-pin connectors [2] from the rotary scale feedback cable to the A-AXIS SCALE and B-AXIS SCALE receptacles. Use the (8) 4-40 screws.

Remove the PSUP PCB cover.

Connect the 3-pin connector [3] of the A-AXIS rotary scale feedback cable to P34A [4] and the B-AXIS rotary scale feedback cable to P34B on the PSUP PCB.

Install the PSUP PSB cover.

Remove the Maincon PCB [2] cover.

Put a label on each cable to show its location for the installation. Disconnect the necessary cables. Remove the (5) standoffs [1]. Remove the Maincon PCB.

Find the (5) 1-1/4" standoffs [3] in the service kit. Install these standoffs onto the top of the (5) 1/2" standoffs [4] where the Maincon PCB was installed.

Remove the (6) screws from the expansion PCB [2] standoffs.

Connect P1 on the expansion PCB to P36 on the back of the Maincon PCB [1]. Make sure that you tighten the expansion PCB standoffs on the expansion PCB against the back of the Maincon PCB.

Attach the expansion PCB to the Maincon PCB. Use the (6) screws.

Connect the 11-pin connector [1] of the Fourth-Axis rotary scale feedback cable to P5A [2] on the expansion PCB.

Connect the 11-pin connector of the Fifth-Axis rotary scale feedback cable to P6A on the expansion PCB.

Install the combined PCB onto the 1-1/4" standoffs [3]. Be sure to connect all the cables. Install (4) standoffs onto the last PCB. Do not install the cover for the Maincon PCB at this time.

Install an electrical jumper [1] at JP2 on the second Mocon PCB.

A - If a battery [3] is installed near P1 [4] on the Maincon PCB, install the second Mocon PCB in front of the Maincon PCB.

B - If a battery PCB [5] is installed in the center of the Maincon PCB, you must install the second Mocon PCB behind the Maincon PCB.

Use the (4) standoffs to attach the second Mocon PCB to the Maincon PCB.

Connect the (2) 3/50 IDC ribbon cables [2] to the top of each PCB. Push the connectors into position until you hear a click.

Connect the Mocon PCB power cable to P15 [1] on Mocon PCB and P33 [2] on PSUP PCB.

Remove the electrical jumper from P7 [3] on the I/O PCB.

Connect cable 770 Mocon 2 Aux E-Stop to P34 [4] on the Mocon PCB and P7 on the I/O PCB. The labels at the end of the cable show the correct connectors.

A - If the machine has (1) large fan [1] under the amplifier block, the fan installation is not necessary.

B - On machines with (2) small fans, you must install a third fan [2] under the amplifier block.

• Remove the cables from the installed fans.
• Install the new servo fan cable to P6 on the PSUP PCB.
• Install the other end of the servo fan cable into the (3) fans. The labels at the end of the cable show the correct connectors.

Find the (2) plugs [1] for the A-axis and B-Axis sockets. The plugs are on the side of the control cabinet. Pull the plugs out of the holes.

Install the 7-pin power connectors [2] in the sockets labeled A-AXIS POWER and B‑AXIS POWER. Then, use the (8) screws to secure the plug.

Install the 28-pin encoder connectors [3] in the sockets labeled A-AXIS ENCODER and B-AXIS ENCODER. Then, use the (8) screws to secure the plug.

Find the amplifier bank locations with the A axis and B Axis labels. Then, install the amplifier for the fourth axis drive in the A axis slot and the amplifier for the fifth-axis drive in the B axis slot.

Connect the fourth-axis and fifth-axis servo cable wires to the high-voltage terminals on their respective amplifiers:

• red to RED [1]
• white to WHT [2]
• black to BLK [3]

 Note: The cables have the labels A, B, and C. Make sure the labels are in the correct sequence.

Connect jumpers [4] from both axis drives to the nearest amplifier on each side:

• Connect the black wire to -H.V.
• Connect the red wire to +H.V.

Put the cables in the cable tray.

Connect the 6-pin connector [1] on the A-Axis brake cable to P46 [2] on the I/O PCB.

Connect the 16-pin connector [4] on the A-Axis encoder cable to P9 [3] on the Maincon PCB.

Connect the 10-pin connector [5] on the A-Axis current command cable to the P5 connector [6] of the Maincon PCB.

 Note: The image shows the 10-pin connector is being plugged into a stand alone Mocon where the P5 connector is horizontal. With machines with a Maincon/Mocon combination board, the P5 connector will be vertical. 

Connect the 8-pin connector [8] on the A-Axis current command cable to the amplifier [7].

Connect the 16-pin connector on the B-axis encoder cable to the correct connector on the Maincon or secondary Mocon PCB. Refer to this table:

VMC, OM-1, HS, SMM-2 without SMTC, VS

• Maincon: P30 [1]
  

VF-2SS/3SS/4SS/5SS/6SS, SMM-2 with a SMTC, DT-1/2, MDC-500, EC

• Secondary Mocon: P9 [2]
  

Connect the 10-pin connector on the B-axis current-command cable to the correct connector of the Maincon or secondary Mocon PCB. Refer to this table:

VMC, OM-1, HS, SMM-2 without SMTC, VS

• Maincon: P32 [3]
  

VF-2SS/3SS/4SS/5SS/6SS, SMM-2 with a SMTC, DT-1/2, MDC-500, EC

• Secondary Mocon: P5 [4] 
•  Note: The image shows the 10-pin connector is being plugged into a stand alone Mocon where the P5 connector is horizontal. With machines with a Maincon/Mocon combination board, the P5 connector will be vertical. 

Connect the 6-pin connector on the B-Axis brake cable to P31 [1] on the I/O PCB.

Connect the 8-pin connector on the B-Axis current command cable to the B‑Axis amplifier [2].