Service Home How To Procedures UMC-1600-H Installation

UMC-1600-H Installation

5.2 UMC-1600-H

Last updated: 03/14/2023

UMC-1600-H - Installation

Revision 1

Introduction

1

This procedure shows how to level a UMC-1600-H. Use this procedure any time you move the machine.

Use the numbers shown to identify which foot to adjust at each step of the leveling process

Prerequisites:

Adjust the corner leveling screws until the bottom of the leveling pads are 4.0" above the ground. Only pegs 1, 5, 7, and 11 should be supporting the machine

Leveling Screws Hardware

1

 Note: The washers [1] and nuts [2] are installed during shipping and should be saved for installation and not be discarded.

 Note: The washer orientation [3] is important.  The conical part of the washer should be against the casting,  see illustration.

Remove Shipment Blocking

1

  • Remove control blocking bracket.

2

  • Remove all three door brackets.
  • There are 2 on the front loading doors keeping them closed (shown) and one keeping the operator door open.
  • Do not attempt to open/close any doors without removing blocking. Damage may occur.

3

  • Remove rear enclosure panel
  • Inside the column, find 2 blocking pins bolted in place with 1" bolts.
  • Remove the bolts and blocking pins

4

Remove X-axis table blocking bracket [1]

5

  • If the rotary came blocked in the position shown, remove the blocking brackets [2].
  • Leave the WIPS tool setter bracket in the position shown [1].

6

  • If the rotary came blocked in the position shown, remove the WIPS tool setter bracket [1] and blocking brakets [2].
  • Then mount the WIPS tool setter in the position shown in Step 5.

Removal of Rust Inhibitor

For ease of removal, first use a plastic scraper to remove most of the rust inhibitor and then use WD-40 or another PH neutral degreaser to spray all the way covers and other non-painted surfaces that have been coated with rust inhibitor. Let it soak for a few minutes before removing it. Then use shop towels to remove it. For thick applications of rust inhibitor use a plastic scraper to remove it.

https://vimeo.com/haasautomation/review/171129636/7c2a5127f9

 Important: Do not use scotch-brite or metal scrapers, these will scratch the way covers. Furthermore, to avoid any contamination of the way cover seals with the sticky residue. Do not move any of the axes until all the rust inhibitor has been removed.

Air Connection

Connect the air supply at the lube panel.

 Note: For air requirements refer to the decal that is located on the lube cabinet door.

Follow the Air Gun and Hose Installation procedure to install or replace the Air Gun.

 Note: Some installation kits will come with a spare air gun assembly.

Electrical Connections

Danger: WORKING WITH ELECTRICAL SERVICES REQUIRED FOR A CNC ARE EXTREMELY HAZARDOUS. ALL POWER TO CNC MUST BE TURNED OFF LOCKOUT-TAGOUT AT THE SOURCE PRIOR TO CONNECTING THE LINE WIRES TO CNC. HOWEVER, IF THIS NOT THE CASE OR ARE NOT SURE HOW TO DO THIS, CHECK WITH APPROPIATE PERSONNEL OR OBTAIN THE NECESSARY HELP BEFORE CONTINUING. ALWAYS CHECK THE INCOMING LINES WITH AN AC VOLTAGE DETECTOR TO MAKE SURE POWER HAS BEEN DISCONNECTED.

1

Initial Control Inspection

Danger: At this point, there should be no electrical connection to the machine. Electrical panel must be closed and secured. When main switch is on, there is HIGH VOLTAGE throughout the electrical panel (including the circuit boards and logic circuits) and some components operate at high temperatures. Therefore, exercise extreme caution when working in the panel.

  • Set the main breaker switch at the upper right of the electrical panel on the back of the machine to OFF.
  • Using a screwdriver, unlock the two latches on the panel door, unlock the cabinet with the key and open the door.
  • Take sufficient time to check all the components and connectors associated with the circuit boards. Look for any cables that have become disconnected, look for any signs damage and loose parts in the bottom of the panel box. If there are any signs that the machine was mishandled, call the factory before proceeding.

2

1-Phase Machines: Insert each power lead into the wire cover.  Connect the two power leads to L1 and L3 terminals on top of the main circuit breaker.

3-Phase Machines: Insert each power lead into the wire cover.  Connect the three power leads to L1, L2 and L3 terminals on top of the main circuit breaker.

Connect the separate ground line to the ground bus to the left of the terminals.

Refer to Haas Main Circuit Breaker - Torque Specifications for what value to torque the circuit breaker power leads.

 Note: Make sure that the leads actually go into the terminal-block clamps . (A poor connection will cause the machine to run intermittently or have other problems, such as servo overloads.) To check, simply pull on the wires after the screws are tightened.

3

After the line voltage is connected to the machine, make sure that main circuit breaker (at top-right of rear cabinet) is OFF . Remove the Lockout / Tagout and Turn ON the power at the source. Using a digital voltmeter and appropriate safety procedures: 

1-Phase Machines: Measure the AC voltage across L1 & L3 at the main circuit breaker.  The AC voltage must be between 220 - 250 volts .
Note: Lower or higher than this voltage can generate low/high voltage alarms.

3-Phase Machines : Measure the AC voltage between all three pair phases at the main circuit breaker. 

The AC voltage must be between 195 and 260 volts (360 and 480 volts for high voltage option).

SMinimill - Reboot: The AC voltage must be between 198 and 242 volts for machines without a high voltage transformer.  Refer to the Minimill/SMinimill - Identification document.

 Note: Wide voltage fluctuations are common in many industrial areas; minimum and maximum voltage supplied to a machine while it is in operation must be known. U.S. National Electrical Code specifies that machines should operate with a variation of +5% to -5% around an average supply voltage. If problems with line voltage occur, or low line voltage is suspected, an external transformer may be used. If you suspect voltage problems, voltage should be checked every hour or two during a typical day to be sure it does not fluctuate more than +5% or -5% from an average.

4

Important: With the main circuit breaker turned OFF.

Check the transformer taps at the bottom-right corner of the rear cabinet.

1-Phase Machines: The input voltage cable must be moved to the connector which corresponds to the average voltage measured in the above step.

3-Phase Machines:  The input voltage cables labeled 74, 75, and 76 must be moved to the terminal block triple which corresponds to the average voltage measured in the above step.

5

Transformer T5 supplies 24VAC used to power the main contactor. There are two versions of this transformer for use on a 240 and 400V machines. The 240V transformer has two input connectors located about two inches from the transformer, which allow it to be connected to either 180-220V or 221-240V.

Users that have 220V-240V RMS input power should use the connector labeled 221-240V, while users with 190-220V input power should use the connector labeled 180-220V. Failure to use the correct input connector will result in either overheating of the main contactor or failure to reliably engage the main contactor.

The 480V (option) T5 transformer has three input connectors, labeled 340-380V, 381-440V and 441-480V.

Users with 340-380V 50/60Hz power should use the 340-380V connector while users with 380V-440V 50/60Hz power should use the 381-440V connector.

Important: Set the main circuit breaker to ON. Check for evidence of problems, such as the smell of overheating components or smoke. If such problems are indicated, immediately set the main circuit breaker to OFF and call the factory before proceeding.

After the power is on, measure the voltage across the bottom terminals on the main circuit breaker. It should be the same as the measurements where the input power connects to the main breaker. If there are any problems, check the wiring.

6

Apply power to the control by pressing the Power-On switch on the front panel.

Check the DC Voltage and AC Line Voltage gauges in Diagnostics. The DC Voltage gauge must read between 310 - 360V. The AC Line Voltage must be between 90 and 105 percent. If the voltage is outside these limits, turn off the power and recheck steps 2 and 3. If the voltage is still outside these limits, call the factory.

7

Electrical power must be phased properly to avoid damage to your equipment. The Power Supply Assembly PC board incorporates a "Phase Detect" circuit with neon indicators. When the orange neon is lit (NE5), the phasing is incorrect. If the green neon is lit (NE6), the phasing is correct. If both neon indicators are lit, you have a loose wire; check the connections. Adjust phasing by setting the source power to off and then swapping L1 and L2 of the incoming power lines at the main circuit breaker.

Danger: ALL POWER TO CNC MUST BE TURNED OFF LOCKOUT-TAGOUT AT THE SOURCE PRIOR TO ADJUSTING PHASING. ALWAYS DOUBLE CHECK THE INCOMING LINES WITH AN AC VOLTAGE DETECTOR.

Turn off the power and set the main circuit breaker to OFF. Close the door, lock the latches, and turn the power back on.

Remove the key from the control cabinet and give it to the shop manager.

8

Activation

When the machine is properly placed and connected to both air and electrical power, it is ready for final installation (removing shipping blocks, leveling, spindle sweep, etc.) and software activation. The HFO service technician does this. Contact the local HFO to schedule the work.

Leveling

1

  • Rotate the rotary assembly to the position shown (0°)
  • Attach the precision bubble level (T-2181A) to the UMC Leveling Adapter (T-2192)
  • Attach leveling assembly to the ground surface on the side of the rotary casting.
  • Attach a mag base to the spindle head and run an indicator along the bottom of the precision level until it is flat.

2

  • Screw down pegs 4 and 8 until they touch the ground.
  • Without moving the rotary or the leveling assembly, jog the X-axis back and forth to check for roll in the X-axis.
  • Use pegs 5 and 7 to correct roll in the X-axis within specification.

3

  • Place the machine level on granite in the back of the column as shown
  •  Jog the Z-axis back and fourth checking for roll.
  • Adjust pegs 1 and 11 to correct for Z-axis roll until within specification
  • Place level back onto rotary and verify X-roll is still within specification
  • Touch down pegs 3 and 9
  • Then Touch down pegs 2 and 10
  • Verify Z-axis roll again.

4

  • Add the wedge jack in the position shown and torque to 8 ft-lbs.
  • Verify X-axis and Z-axis roll

5

  • With the rotary at 0° run an indicator vertically along the platter surface to check the platter parallelism to the Y-axis.
    • Always zero the indicator on the bottom of the platter, then jog up in Y-axis 25" to record the deflection at the top of the platter.
  • Adjust pegs 5 and 7 until parallel within ±.001"TIR
  • Touch down peg 6. 
    • If applicable small corrections up to ±.0005" TIR can be made by adjusting peg 6.

6

  • Rotate platter -90° run an indicator vertically along the platter surface for 25" (starting from the bottom) to verify the platter is parallel to the Y-axis in this position within ±0.002" TIR

7

  • Rotate platter +90° run an indicator vertically along the platter surface for 25" (starting from the bottom) to verify the platter is parallel to the Y-axis in this position within ±0.002" TIR

Rear Chip Auger

1

Remove the cover frm the auger-motor assembly.

Pull the augers [1] out of the EC-1600.

Do this until they extend more than the end of the machine.

Connect the augers to the auger-motor assembly [2].

Attach the cover for the auger-motor assembly.

2

Attach the cover [1] for the rear pan to the top of the auger-motor assembly.

Apply construction sealant (Sikaflex) to the surfaces of the auger-motor assembly that touch the enclosure.

Attach the auger-motor assembly [2] to the machine.

Put the auger power cable into the bottom of the control cabinet.

Connect the power cable [3] to P24 on the I/O PCB.

MRZP WIPS Offset Settings

1

This tells you how to set Machine Rotary Zero Point (MRZP) Offsets. The MRZP Offsets are settings in the Haas CNC control that tell the control these distances:

  1. the distance of the tilt axis (B axis) centerline from the X-Axis home position
  2. the distance of the tilt axis (B axis) centerline from the Z-Axis home position
  3. the distance of the table rotary axis (C axis) centerline from the Y-Axis home position

This procedures shows images that use both calibration assemblies.

 Important: The spindle probe must be calibrated before doing this procedure. This makes sure the accuracy of the probe to the machine position is correct. Refer to the Next Generation Control - Probe Calibration (VPS) procedure, in the diy.haascnc.com

2

Press [Setting] and navigate to Machine Setup. Check setting 255, 256, and 257. The values should not be zero. If they are perform the following procedure.

MRZP A-C or B-C Axis Rough Set

3

[ZERO RETURN] [ALL] axes.

Go to Features tab in [DIAGNOSTIC] and make sure the VPS Editing is on.

Put the work probe in the spindle.

Push [EDIT] button.

Select VPS .

Push the [DOWN] cursor arrow to PROBING [1].

Select CALIBRATION [2]. Push the [RIGHT] cursor arrow.

Select MRZP CALIBRATION [3].

4

 Select MRZP UMC-1600H

  

5

Select the tooling ball type by typing either M or S then ENTER 

6

If selecting M, fixture the tooling ball in one of the two positions shown.

7

Jog the probe until in the approximate position "above" the fixture's ball.

8

Position the probe aligned with the axis of the tooling ball rod approximately 0.4" (10mm) away.

9

Enter the diameter of the tooling ball [2].

 Important: Always measure the tooling ball with a calibrated micrometer to ensure the correct ball diameter.

 Note: If you are in metric mode make sure you enter the ball size in millimeters. If you are in inch mode enter the ball size in inches

10

If selecting S, fixture the tooling ball in the position shown.

Jog the probe until in the approximate position "above" the fixture's ball.

11

Position the probe aligned with the axis of the tooling ball rod approximately 0.4" (10mm) away.

12

Enter the diameter of the tooling ball [2].

 Important: Always measure the tooling ball with a calibrated micrometer to ensure the correct ball diameter.

 Note: If you are in metric mode make sure you enter the ball size in millimeters. If you are in inch mode enter the ball size in inches

13

The probe measures many positions on the B and C axes at different degrees.

The program puts values in macro variables 10121, 10122, and 10123. Record those values.

14

Put the recorded values in these settings:

  • Enter the value for macro variable 10121 in setting 255; MRZP X Offset.
  • Enter the value for macro variable 10122 in setting 256; MRZP Y Offset.
  • Enter the value for macro variable 10123 in setting 257; MRZP Z Offset.

If you think that you entered are possibly incorrect numbers, start the MRZP FINISH SET program again. The values that the program puts into the variables must be within five counts or less of the setting numbers.

 Note: Setting 9 determines if the values are shown in inches or millimeters.

Lubrication Verification

1

Run the spindle run-in program.

 Note: For 10K spindles and above use a balanced tool holder

Examine the sight glass, make sure the correct number of drops are fall through the sight glass.

Examine the fittings [1,2] on top of the oil pump tank.

The oil collects on top of the oil pump tank [3] either behind or in front of the sight glass bracket, underneath the leaking fitting.

Tighten any leaking fittings.

2

Go to the Maintenance tab.

Press [F2] to cycle an axis lubrication test.

Inspect the gauge on the lubrication system.  Make sure it holds pressure.

Coolant Tank Installation

1

Power off the machine.

Install coolant tank handle [1], tank lids [2], and chip tray [3]. 

 

Position coolant tank under the left side of machine (when viewing from the front). Ensure that the chip tray [3] is directly under the machine's drain slots, to ensure that coolant flows into the tank. 

2

Insert the coolant pump assembly in the position shown. Connect the coolant hose to the coolant filter [1].

Connect the coolant pump power cable to the socket labeled Low Pressure Coolant. 

Fill the coolant tank with coolant. Install the coolant float sensor into the coolant tank. Refer to Coolant Float Sensor - NGC - Installation or Coolant Float Sensor - CHC - Installation for more information. 

3

TSC Option: 

Insert the TSC pump assembly into the coolant tank in the position shown. 

Connect the TSC pressure sensor [1] into the socket labeled Coolant Filter Sensor. Connect the TSC power cable [2] into the socket labeled High Pressure Coolant. 

Connect the purple air hose from the TSC pump assembly's cylinder [3] and into the lube cabinet. 

Connect the coolant hose [4]. Ensure that the connection between the coolant hose and TSC pump assembly is firmly torqued. 

Note: Improper tightening of the TSC coolant hose will cause leaks. 

 

 

Machine Operation

Verify that all machine functions are operational:

  • Connect the coolant pump and TSC pump.
  • Connect Auxiliary Filter.
  • Test the tool changer.
  • Test the pallet changer.
  • Test the spindle RPM..
  • Test the coolant operation
  • Test the chip auger.
  • Test the remote jog handle.
  • Test the door interlocks.