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I/O PCB - Replacement - NGC - AD0413

8.2 I/O PCB - Replacement

Last updated: 03/22/2023

I/O PCB - Replacement - NGC

AD0413

Introduction

This procedure will show you how to replace the I/O PCB on an NGC machine.

Download and fill out the NGC I/O PCB Inspection Report Checklist below before replacing any parts. It can be found at the I/O and TC PCB troubleshooting guide. 

This procedure applies to these kits:

  • 93-32-3490C IO PCB, SIO-C NGC

Machine Compatibility:

  • P/N 93-32-3490C is fully backwards compatible with P/N 93-32-3490B, 93-32-3490A, 93-32‑3480A, 93-32-3480C, and 93-32‑3482C
  • Note: If replacing an earlier version I/O PCB some connectors have changed location. Some cables will need to have more slack pulled from the cable channel or from the enclosure. 
  • You will also need to order a 93-32-5502 Tool Changer CCA kit if the machine is equipped with DC-Motor tool changer or a bar feeder.

Replacement

1

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.

Caution: When you handle a PCB, you must wear an Electrostatic Discharge (ESD) strap.

2

Record the position of the push-on jumpers [1] on the PCB.

Put an identification label on each cable that is attached to the PCB. This makes the installation easier. Disconnect these cables.

Remove the I/O PCB and place it next to the replacement PCB [2].

Remove the push-on jumpers [1] from the removed PCB and put them onto the replacement PCB [2].

Note: The jumpers shown in the image are at P2, P12, and JP1 on the I/O PCB. Boards can have these as well as other jumpers depending on the options the machine has.

Caution: Carefully compare the two I/O PCBs to make sure you install each jumper in the correct position. If you do not correctly install each of the jumpers, the I/O PCB cannot operate correctly.

3

Note: If the machine is equipped with a tool changer that has a brush motor or bar feeder: Install the (4) standoffs [1] on the I/O PCB. Do not install the Tool Changer PCB until after the I/O is installed.

Install the I/O PCB in the electrical cabinet.

If equipped with a brush motor TC or bar feeder: Mount the 93-32-5502 Tool Changer PCB to the standoffs. Connect wires:

  • Connect cable P/N 33-0413 from J1 [2] on the TC PCB to P74 [3] on the I/O PCB.
  • Connect cable P/N 33-0412 from P55A [4] on the TC PCB to P55 [5] on the I/O PCB.
  • Connect cable P/N 33-0349 from P4 on PSUP PCB to the P55 [7] on the TC PCB.
  • Connect the tool changer/bar feeder cable to P58 [6].
  • For EC models, connect the external resistor at P57 [8].

4

Connect all cables.

Note: If updating from an earlier version I/O PCB some plug locations have changed.

  • The plugs on top of the I/O [1] will need to have slack pulled from the channel. 
  • Rotary axis brakes [2] have moved up on the left side of the I/O, these cables will need to be routed differently. 
  • The coolant and TSC plugs [3] have moved to the bottom of the I/O. Some slack will need to be pulled from the channel or from the enclosure to reach the new location. 
  • P28 [4] for the TSC Vaccum Sensor has moved. Some slack may need to be pulled from the strain relief on the enclosure to reach the new location. 
  • The tool changer output cable moves to P58 and cable 33-0349 to P55A on the Tool Changer PCB.

5

 IMPORTANT: When replacing 34-349XA/B I/O PCB with 34-3490C, do not reinstall the SIO filter board [1] and remove any single [2] or dual [3] solenoid filters in the CALM cabinet. The new I/O PCB board has these filters built into the board. 

6

IMPORTANT: When replacing 34-349XA/B I/O PCB with 34-3490C and VFD ADAPTER PCB is installed, do not re-install the VFD ADAPTER PCB into the 34-3490C I/O PCB as this VFD ADAPTER PCB is now built in.

Operation Test

1

Power on the machine with your Haas Control Key.

You get an alarm that you cannot stop until the Main Crc and Factory Crc numbers [3] are the same. Do these steps to stop the alarm:

Press [DIAGNOSTIC].

Use the CURSOR arrows to go to I/O Config [2] in the Diagnostics tab [1].

Press [F3] to Update Config Table[4].

Press [RESET] to continue.

If the alarm does not stop, push [POWER OFF], and then push [POWER ON].

 Note:  After installation, make sure the SIO Version and I/O TC Version are up to date. Refer to I/O Firmware Compatibility chart for the most current versions. If not, update the firmware to the correct version. 

2

Operate the spindle, tool changer, coolant, through-spindle coolant (TSC/HPC), P-cool spigot, Emergency Stop, beacon, operator door, barfeeder, and all optional equipment.

Make sure that all machine parts and installed options work correctly. If the Side Mount Tool Changer operates slowly, cycle power.

In an EC series machine, make sure the external resistor you connected to P57 does not heat up while the machine is idle.