VC-400 Installation

Introduction

This procedure tells you how to install an VC-400. If installing a pallet pool refer EC-400 Pallet Pool - Installation.

Tools required:

Precision Machinist Level, 0.0005" Division
T-2192 SERVICE TOOL, LEVELING ADAPTER
Precision Spindle Test Bar, 8" Long

Leveling Screws Hardware

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 Rust Inhibitor

For ease of removal, first use a plastic scraper to remove most of the rust inhibitor and then use either a heavy duty citrus cleaner or Simple Green 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 using a shop towel. It is recommended to apply mineral spirit or WD-40 to all exposed metal surfaces for rust proofing.

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.

Note: The product is not hazardous and can typically be disposed of similarly to used oil.

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

Rust Inhibitor - Safety Data Sheet (SDS)

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 Installation

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.

Shipping Brackets Removal

Remove the rear panel.

Remove the column shipping bracket [1].

Remove the chip conveyor brackets [2].

Remove the operator door shipping bracket [3].

Reach in through the operator door and remove the red shipping bracket that is bolted to the rotary and H-frame [4].

Remove the load station door bracket [5].

Remove the load station pallet bracket. Remove the pallet plug that is bolted to the bracket. Place the plug in the center hole of the pallet and tap it in place with a mallet [6].

Machine Leveling

1

Zero return each axis one at a time or press [POWER UP]. Go through the leveling process.
Repeat these steps to achieve correct machine level.

2

Set the machine height using the four corner leveling bolts [1,2,7,8] to 3" (76.2 mm) above the floor. Turn each screw so they have equal tension.

Turn the four middle leveling screws [3,4,5,6] up off the middle pads.

Jog the X and Y axis to the middle of the travel.

Position the level at the center of the pallet, parallel to the X-axis.

Position the level at the center of the pallet, parallel to the Y-axis.

Adjust the corner leveling bolts [1,2,7,8] until both levels read +/- 0.0005"

Position the level at the center of the pallet, parallel to the X-axis.

Jog the Y axis towards the spindle and then away from the spindle and adjust the front left bolt [7] until the level reads +/- 0.0005"

3

Jog the X and Y axis to the middle of the travel.

Bring down the center leveling screws [3,4,5,6] with equal pressure.

Position level at the center of the pallet, parallel to the Y-axis.

Jog the Y axis towards the spindle and then away from the spindle. Adjust the leveling screws [5,6,7,8] until the level reads +/- 0.0005"

4

Install tool T-2192 on the spindle.

Mount the bubble level on top of T-2192.

Jog the X-axis from left to right and adjust the leveling screws [3, 4] if necessary until the level reads +/- 0.0005"

Spindle Sweep

Tools Required:

Test Indicator with a magnetic mount.
pH-neutral cleaner
Degreaser
Abrasive pad
Gauge Block (optional)

1

Clean the table surface to remove any corrosion
Jog the spindle down to the middle of the z-axis travel and attach the magnetic base to the spindle
Adjust the indicator to measure a 10" diameter circle
Position the table so that the indicator will remain on the table as the spindle rotates
Move the Z-axis so that the indicator makes contact with the table and zero the indicator
Sweep the spindle and take measurements every 90 degrees. Make sure the measurement locations are parallel to their respective axis
The total indicator for all four positions should not exceed 0.0005"

2

Spindle Sweep Adjustment

Note: Only the front and back sweep values can be effectively changed by adjustment of the middle leveling screws

If the values from the front to back differ by more than 0.0005", make small and equal adjustments to the middle leveling screws.
If the spindle sweep values come back into tolerance with only small adjustments to the leveling screws then there is no need to recheck the twist and bow.

For a more in depth guide on how to perform a spindle sweep test on your VMC please see:

VMC Spindle Sweep

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.

Machine Operation

Verify that all machine functions are operational:

Connect the coolant pump and TSC pump.
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
Calibrate the probe. Refer to: Probe Calibration (VPS) - NGC