Service Home How To Procedures IO PCB-AC - Replacement - CHC - AD0007
Last updated: 01/17/2022

I/O PCB-AC - Replacement - CHC

AD0007

This Procedure Applies to Machines Built From: Jan 1999 to Jan 2015

Introduction

This procedure tells you how to install the I/O PCB revision-AC. Revision-AC started in June, 2010. Revision AC is compatible with these lower versions: S thru AB.

The machine has "Smart" alarm functions if you have these software versions or higher: mill 17.04 or lathe 10.04

Service Kit:

  • 93-0619F  I/O PCB
Component Locations:
  1. R310
  2. P6, P7, P72, P81
  3. J1
  4. TP6 & TP7 at R122
  5. J2
  6. P57
  7. P87
  8. P77
  9. P15
  10. P83
  11. P9, P89
  12. P48, P50
  13. P20

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.

Danger: When the machine is off, wait at least 5 minutes before you work in the electrical cabinet. This lets power dissipate from the machine. When the voltage indicator LED on the vector drive to goes off completely, it is safe to work in the electrical cabinet.

Caution: When you touch a PCB that is not grounded, you must put on an Electrostatic Discharge (ESD) strap.

Remove or open the I/O PCB cover.

Record the I/O PCB version letter from the board.

Make sure all cable connections have the correct labels. Record the position of the push-on jumpers on the I/O PCB. Disconnect all cables.

Remove the I/O PCB. Put the removed I/O PCB in the bag from the replacement I/O PCB.

2

EMERGENCY STOP,  REMOTE INPUT, DOOR INPUTS AND COOLANT OVERHEAT JUMPERS

Install the new I/O PCB. Connect the cables and jumpers that you disconnected from the original I/O PCB.

Connect a jumper to any unused Emergency Stop input connectors (P6, P7, P72, P81) [2].
In addition, connect a jumper to these connectors if they are not used:

  • Second remote unclamped input (P20) [1]
  • Additional door switch inputs (P9, P89) [2]
  • Connectors P48 and P50 [3]

3

J2 JUMPER

The jumper at J2 [1] is for service only.

  • When replacing an I/O PCB-U/ through I/O PCB-AC, check to see if there is a jumper at J2. The new board must match the old board.

Caution: Incorrect usage of the jumper will result in a damaged connector, a tripped breaker, or unsafe, floating AC power.

4

MILL AND LATHE JUMPER SETTINGS

  • Set the jumpers at J1 [1] to MILL position when replacing an I/O PCB-S or I/O PCB-T for both mills and lathes.

  • When replacing an I/O PCB-U through I/O PCB-AC, set jumpers in the same position as on the old board.

5

TOOL CHANGER

If there is no cable connected to P57 [1], connect the TC jumper cable (33-0809A).

If P57 has a cable, connect the TC jumper cable (33-0809A) to P87 [2]. If the cable at P57 is too short, use the longer cable (33-8626A) provided in the service kit.

6

EC SERIES MACHINES:

  • Make sure that a detached regen resistor is connected to R310 [1] on the PCB with cable 33-0318. Polarity is not an issue. Mount the resistor using an existing hole in the back wall of the control cabinet to the left of the vector drive or on the I/O PCB cover if a location is available.

For all other machines, install the board without these modifications.

7

CHIP AUGER AND CONVEYOR

Use a digital ohmmeter between TP6 and TP7 at position R122 [1] to measure chip conveyor overcurrent.

  • Adjust the overcurrent to 3 kOhm +/-100 Ohm for single-phase, auger-style chip conveyors.
  • Adjust the overcurrent to 4.5 kOhm +/-100 Ohm for single-phase, belt-style lathe chip conveyors.

8

PROBES AND WIPS

If a cable is connected to P77 [1] on the old I/O PCB, find the cable number. Both adapters are provided with the service kit.

*for LPRO-R, you may need to swap the brown and brown/white wires of the probe interface. Refer to ST-10/20/30 Lathe Probe Installation or ST-40 Lathe Probe Installation for details.

Note: If the service kit has adapters 33-0607 and 33-0613, the black 8-pin connectors need to be reworked into 33-0607A and 33-0613A. Refer to 33-0607 VQCPS Probe Cable Adapter Reconfiguration or 33-0613 WIPS Probe Cable Adapter Reconfiguration to rework the cables. Update the adapter label with the new part number.

Cable Adapter Probe System
33-0615 33-0613A WIPS
33-0617 33-0607A VQCPS / MIPSl
33-0618 33-0607A/33-0613A PROMAC
33-0619 33-0607A LPRO-R*

9

BEACON AND WORKLIGHTS

  • When replacing an I/O PCB-S through I/O PCB-Y, install jumper 33-0807 at P83 [1].

  • When replacing an I/O PCB-W through I/O PCB-AC, install jumper 30-0807 at P83 unless there is a cable connected in that position.

Note: If the beacon light, worklight, or high-intensity light do not work, make sure that a jumper or cable is installed at P83.

HS-1/2 RP only - Replace cable 810B (from HOPT to I/O PCB) with 33-8626A from the service kit.

Verification

1

Do this steps to make sure the I/O-PCB operates correctly.

Set the main circuit breaker to the ON position. Push POWER ON.

Push POWER UP/RESTART.

Note: If the beacon light, worklight, or high-intensity light do not operate, make sure that a jumper or cable is installed at P83 [10].

2

  • Make sure that Parameter 209:23 MCD RLY BRD is set to 1. If the parameter shows “RESERVED” or “UNUSED”, do not adjust this parameter.
  • Make sure that Parameter 57:10 PH LOSS DET is set to 0. If the parameter shows “RESERVED” or “UNUSED”, do not adjust this parameter.

3

Do this step if you have an auger or chip conveyor.

Operate the auger or chip conveyor.

  1. If the motor will not turn forward continuously, measure the test points between TP6 and TP7 at position R122 [4] on the I/O PCB. Turn the small screw on the potentiometer to adjust the resistance a maximum of 1 kOhm.
  2. Block the auger or belt with a piece of wood. Make sure that the motor pauses before it changes direction.

    Note: The belt-style conveyor possibly will not change direction, but it will pause. This is normal operation.

  3. If the auger or belt will not pause, adjust the restance at R122 [4] a maximum of 1 kOhm.

4

Operate the spindle, tool changer, coolant, TSC, P-cool spigot, Emergency Stop, beacon, operator door, and all optional systems.

Make sure that all machine parts and systems operate correctly. If the Side-Mount Tool Changer operates slowly, cycle the power.