ST-20/25/30/35/30L/35L, DS-30 - HPC-300/1K Installation - NGC

Introduction

This procedure will show you how to install HPC-300/1K field install kit on a ST-20/25/30/30L/35/35L, DS-30 lathes and their Y/LY variants with the Next Generation Control (NGC).

Important: The illustration shows the two types of NGC ST models:

ST with the angled door (Non-Reboot)
ST with the flat door (Reboot).

Verify you have the correct HPC kit see the list below:

Non-Reboot ST

93-1000213 ST-20 thru ST-35, DS-30 HPC-300 Field Install Kit
93-1000209 ST-20 thru ST-35, DS-30 HPC-1K Filed Install Kit

Reboot ST

93-1000214 ST-20 thru ST-35, DS-30 HPC-300 Field Install Kit
93-1000210 ST-20 thru ST-35, DS-30 HPC-1K Field Install Kit
93-1000569 ST-30L/35L HPC-300 Field Install Kit
93-1000568 ST-30L/35L HPC-1K Field Install Kit

Tools Required

Service USB key

HPC Motor Drive PCB - Installation

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: If the vector drive voltage indicator light is on, do not touch the electrical components. Wait for the voltage indicator LED on the vector drive to go off completely.

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

2

Do this step if you do not have a door panel installed in the control cabinet.

Open the control cabinet. Remove the cover for the I/O PCB.

Install these parts:

Use (2) screws [2] to install the top hinge plate [1].
Use (2) screws [3] to install the bottom hinge plate [4].
Use (4) screws [5] to install the (2) door brackets [6].
door panel [7]

3

Install these parts on the door panel:

(2) spacers [1]
motor-drive PCB [G]
(2) socket-head cap screws (SHCS) [2]

Connect the 33-1974 cable [H] to these locations:

P2 [3] on the motor-drive PCB (put the cable [H] through the left cable-carrier channel).
P10 [4] on the I/O PCB.

4

Note: This fan is only required on HPC-1K Kits. Skip this step for HPC-300 Kits.

Install the bracket [2] for the fan assembly. Use the (2) 1 x 1/4" Phillips pan-head screws (PPHS) [1]. Make sure the arrows [3] on the fan assembly point in the correct direction.

Install the fan assembly [4] to HS6 [3] on the I/O PCB. Use the (2) 1/4" PPHS [5].

Connect the fan-assembly cable [7] to P11 [6] on the I/O PCB.

5

Connect the 33-0987B cable [I] to these locations:

P4 [1] on the motor-drive PCB (put the cable [I] through the top and right cable channels).
Connections 77, 78, and 79 [2] on the transformer (each wire has an identification label).

Connect the HPC extension cable [C] to P1 [3] on the motor-drive PCB.

Put the cable [C] through the top and right cable channels.

ST-20/25 with an Angled Door - HPC - Installation

The following section applies to the following kits:

93-1000213 ST-20/25 HPC-300 Field Install Kit - (Angled Door)
93-1000209 ST-20/25 HPC-1K Filed Install Kit - (Angled Door)

1

Remove the back panel.

Route the HPC extension [1], vacuum sensor [2] cables.

Connect the HPC extension cable to P1 on the HPC motor-drive PCB [1].

Connect the vacuum sensor to P28 on the I/O PCB [2].

Remove the HPC plugs from the coolant receptacle bracket.

Install the receptacle end of the cable to the receptacle bracket. Use the twist lock mount and the screws [3].

Install the vacuum sensor cable to the receptacle bracket [4].

2

Remove the plug [1] next to the standard coolant check valve.

Remove the plug on the back of the coolant manifold.

Install the HPC check valve and flare fitting [2].

Install the coolant pressure sensor on the back of coolant manifold.

Connect the M12 coolant pressure connector to the sensor [3].

Important: The coolant hose [4] installed must be rated to handle 1000 PSI if not contact the service department.

3

Turn off the air to the machine. [1]

Remove the plug from the air manifold. Install the solenoid assembly [2].

Connect the cable for the solenoid [3] to the connector panel label "HPC Auto Clean".

Connect the purple tube [4] to the air solenoid.

Trim the purple tube to the correct length [5].

4

Install the HPC pump into the coolant tank.

Connect the HPC hose [1] from the HPC check valve to the HPC pump.

Connect the purple hose [2] to the air fitting.

Connect HPC filter sensor [3] to the HPC pump.

ST-20/25/30/30L/35/35L With a Flat Door - HPC Installation

The following section applies to the following kits:

93-1000214 ST-20/25/30/35 HPC-300 Field Install Kit - (Flat Door/Reboot)
93-1000210 ST-20/25/30/35 HPC-1K Field Install Kit - (Flat Door/Reboot)
93-1000569 ST-30L/35L HPC-300 Field Install Kit - (Flat Door/Reboot)
93-1000568 ST-30L/35L HPC-1K Field Install Kit - (Flat Door/Reboot)

1

Remove the back panel, and also the panel on top of the electrical cabinet.

Route the HPC extension [1], vacuum sensor [2] cables.

Connect the HPC extension cable to P1 on the HPC motor-drive PCB [1].

Connect the vacuum sensor to P28 on the I/O PCB [2].

Remove the HPC plugs from the coolant receptacle bracket.

Install the receptacle end of the cable to the receptacle bracket. Use the twist lock mount and the screws [3].

Install the vacuum sensor cable to the receptacle bracket [4].

Route the purple hose from the lube panel to the coolant tank area as shown [5].

Note: Make sure ther is enough slack on the hose at this time.

2

Turn off the air to the machine. Assemble the solenoid assembly [1].

Remove the plug from the air manifold. Install the solenoid assembly [2].

Trim the purple tube to the correct length. Connect the purple tube [3] to the air solenoid.

Connect the cable for the solenoid [4] to the connector panel label "HPC Auto Clean".

3

ST-20/25/30/35 Machines

Remove the plug [1] from the coolant manifold.

Install the check valve for the high pressure hose into the manifold.

Route the high pressure hose along the coolant hose [2].

Use the same hose brackets as the coolant hose [3].

Connect the HPC hose to the check valve at the manifold.

4

ST-30L/35L Machines

Remove the plug [1] from the coolant manifold.

Install the check valve for the high pressure hose into the manifold.

Install the HPC cable carrier along the standard coolant cable carrier.

Route the HPC hose through the cable carrier and along the coolant hose.

Connect the HPC hose to the check valve at the manifold.

5

Install the HPC pump into the coolant tank.

Connect the HPC hose [1] from the HPC check valve to the HPC pump.

Connect the purple hose [2] to the air fitting.

Connect HPC filter sensor [3] to the HPC pump.

HPC Option - Activation and Test

Turn on the machine.

Login to the HAAS SERVICE PORTAL.
Download the HPC option configuration patch files.
Note: The option files will appear on the configuration download page after the HPC 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.

In [MDI] command: M88; (this m-code will turn on the HPC pump).

Note: To learn more about this M-code go to the Service section on www.haascnc.com.

Verify that the HPC pump turned on and that coolant comes out of the turret.

Check for leaks at the coolant manifold, coolant pressure sensor and hose fittings.

Install the covers.