Service Home Alarm Search: 134 H-5AX Single Yoke Spindle Head - Troubleshooting Guide
Last updated: 08/15/2024

H-5AX Single Yoke Spindle Head - Troubleshooting Guide

Introduction

Important: Download and fillout the Spindle Inspection Report Checklist below before replacing any parts.

Warning: The machine should be stopped and powered off immediately is signs of coolant or chiller fluid is seen leaking from between the spindle and spindle mount plate.

Warning:  Breaking the DON'T REMOVE seal on the spindle without contacting Haas Service will VOID the warranty. Contact Haas Service before proceeding with any adjust

 

H-5AX Service Request Form

This page will assist you in troubleshooting the H-5AX Spindle Head found on the VR series machines and the GM-2-5AX machine.

For more information on geometry and head alignment please refer to the following procedures for their respective machines:

Geometry Guide - VR Series

GM-2-5AX Head Alignment Procedure

NOTE: Haas is requiring that the serrated/small steel washers be replaced with hardened thick washers. Order part number 93-3769 HSD C-AXIS MOUNTING HARDWARE SVC KIT for the proper hardened washers and longer bolts. 

Symptoms Table

Symptom

Probable Cause

Solution
Alarm 130 Tool Unclamp Tool Holder is not properly seated in the taper Verify double arm alignment to the spindle, refer to Side-Mount Tool Changer - HSK - Double Arm - Replacement - NGC
 Head Alignment Refer to the following procedures for their respective machines: Geometry Guide - VR Series / GM-2-5AX Head Alignment - Procedure
 A63 Tool Holder orientation Refer to the HSK tool loading section in the HSK - Spindle - Troubleshooting Guide
Air Pressure

Verify that the TRP pressure is set to 145 PSI in the lube panel cabinet. Verify that the Spindle Purge pressure is set to 45 PSI.

Verify customer’s air lines are not contaminated (moisture) 
Draw Bar push out / switch adjustment Verify the clamping cone push out before adjusting TRP sensors.  See H-5AX Sensor Wiring section for images
Alarm 134 Tool Unclamp  Fualt Spindle Air Solenoid has the .040 ORIFICE installed in the wrong location

Reconfigure the Air Solenoid fitting, Move the restrictor orifice from before 90° fitting to before the Tee Brass fitting. (see Spindle Air Solenoid)
Note: No parts required for corrective action.

HSG-A 02/16/2023

Tool Sticking in the Taper

Incorrect push out

Air escaping from the Air Regulator Knob
Spindle was replaced and spindle load is very high. Commanded RPM are incorrect as well. Motor may have been wired incorrectly during replacement. 

Check the motor configuration to see if the motor is wired correctly. See Motor Wiring section for more details.

If the spindle was not replaced and the machine is experiencing this issue please follow the VECTOR DRIVE TROUBLESHOOTING GUIDE for further troubleshooting.
Spindle noise is present while running the spindle at lower RPM's.  Damaged cables or missing ferrite filters can cause this issue. 

Troubleshoot the vector drive using the VECTOR DRIVE TROUBLESHOOTING GUIDE, verify all feedback cables at the maincon have ferrite filters, verify cables in the spindle are in good condition (see Connection port section for more details, verify the spindle power cable is tight, verify all connections to the signal distribution junction are tight. See Connection Locations section for reference. 

If the issue persists contact Haas Service for further instructions. 
Alarm 4.9003 Insuficient Spindle Coolant Chiller Flow occurs Flow sensor on the spindle chiller may need to be adjusted to read correct flow.  Adjust the flow sensor using the slotted holes on the sensor, move the sensor towards the motor side until the bit changes. The slots on the sensor might not be enough adjustment, if so open the slots further to get the adjustment needed. Contact Haas Service if this issue continues to persist. 
Air may be introduced into the system via chiller lines not being fully plugged into the manifold or seals that are broken and sucking in air.  Replace any broken seals and make sure the lines are fully plugged into the manifold. Prime the lines and make sure the no air bubbles are present in the lines. 
Coolant tank chiller issues with less than normal pressure or an over-heated pump

The correct placement of the 3” return tube. 

A 6’’ tube (58-3728) being used rather than the 3” tube (58-0742). The 6” tube was bottoming out and cause a major flow restriction. See Coolant Tank Chiller section for images
Alarm 4.103  S (SPINDLE) AXIS SERVO ERROR TOO LARGE Control showing 1000 rpms on the spindle speed with the spindle stopped. Verify the spindle encoder or enocder cable is not shorted to ground. See Encoder Connection section for more details.
Alarm 4.9932  S (SPINDLE) SPINDLE STALLED 
Alarm 4.9922  S (SPINDLE) MOTION CHANNEL FAULT DETECTED 
Alarm 4.182  S (SPINDLE) AXIS ENCODER CABLE FAULT
Alarm 4.224  S (SPINDLE) AXIS TRANSTION FAULT
Alarm 7.217 C (5th AXIS) AXIS PHASING ERROR
Alarm 7.9959 C (5th AXIS) SERIAL ENCODER DISCONNECT
Alarm 6.103  B (4TH Axis) AXIS SERVO ERROR TOO LARGE

Brake does not disengage before commanding a movement resulting in high loads on the axis.

Brake air hoses are not connected properly.

Check the brake manifold and make sure the air lines are routed to the correct port. See Brake Manifold section for more details. 

Verify parameter 76 Low Air Pressure Delay has not been changed (30.000 sec) and verify proper air to machine. 
Alarm 7.103  C (5TH Axis) AXIS SERVO ERROR TOO LARGE
Concentricity of the head is not staying within specification after being established during alignment.  The incorrect washer is installed on the C-axis mounting surface. {icon:fa fa-file-text} NOTE: Haas is requiring that the serrated/small steel washers be replaced with hardened thick washers. Order part number 93-3769 HSD C-AXIS MOUNTING HARDWARE SVC KIT for the proper hardened washers and longer bolts. 

Brake Manifold

1

To access the brake air manifold remove the spindle head sheet metal [1]. THe air manifold can be found mounted on the rear sheet metal.

The air brake manifold is the top manifold [2] not mounted on the stand off's.

Follow the bottom right image for the correct hose orientation. The B-axis brake solenoid hoses [3] will connect to the A-AXIS RELEASE/LOCK ports and the C-axis brake solenoid hoses will connect to the C-AXIS RELEASE/LOCK. ports.

Motor Wiring

1

Check the motor wirings and make sure they are wired in the delta configuration [1] shown in the image.

The barrel connector going to the vector drive [2] is also provided to ensure the cable is pinned correctly.

H-5AX Sensor Wiring

1

Verify Spindle Clamping Collet push out is correct and all TRP sensor are properly adjusted.

Check the barrel connectors going to the T-Signal Connector are tight and the connector at P2 on the 5AX Interface PCB is seated correctly.

(1) TRP Sensors

(2)  T Signal Connector

(3) B Axis Sensor Cable

(4)  5AX Interface PCB

Identifying the sensors for ES779 and ES789

S1+S4 - Clamping cone locked in the correct position (DRAWBAR CLOSED)

S2  - Clamping cone open tool-holder ejected, Draw Bar forward (DRAWBAR OPEN) 

S3 - Not Used

S5** - TRP backward at upper end stop (TRP PISTION RETRACTED) in series with S4 (DRAWBAR CLOSED)

** Present in certain versions only.

Coolant Tank Chiller

1

The 6” return tube is bottoming out and cause a major flow restriction.

2

Corrective Action:  Install a 3" return tube (58-0742)

Encoder Connection

1

Test to see if the encoder is shorted to ground.

Using a multimeter, check continuity between the barrel connector case to spindle nose and pins to spindle nose.

Results should be continuity of 0.2 ohms at the barrel connector case to the spindle nose and all pins open to the spindle nose.

2

Test to see if the encoder cable is shorted to ground.

If results show continuity between the pins and spindle nose, open the Encoder inspection window on the side of the ES779 or ES789 spindle body and disconnect the encoder terminals.

Recheck for continuity between the pins of the barrel connector to the encoder connectors.  

Connector 3 pin 3 should be the only lead Closed to the Barrel Case showing 0.2 ohms and pin to pin should not be open.

3

Testing if the encoder is shorted to ground.

Using a multi meter, verify the pin are open to the Encoder Body. Connector 3 pin 3 should be the only pin closed to the encoder body showing 0.2 ohms. If any of the other pins show continuity, the encoder is shorted internally and will need to be replaced. 

It should also be noted if the encoder passes this test, this does not mean that the encoder is functioning properly, only that it is not shorted internally. Proceed to the next step to confirm the encoder is funcitoning properly.

NOTE: Some encoder have a separate ground cable that is secured to the encoder 

For encoder replacement procedure refer to AD0558 GM / VR H-5AX Spindle Shaft - Replacement Guide  

H-5AX Spindle Chiller Fluid

Spindle Chiller tank uses a 50/50 mix of DOWFROST HD INHIBITED PROPYLENE GLYCOL (Not Sold by Haas) and deionized water. The tank capacity is 5 gallons.  Any over the counter Propylene Glycol product can be used, but will require to flush out the system prior to fillling. 

IMPORTANT: Mix the glycol and deionized water outside of the chiller tank before adding to the mixture already in the tank.

Warning:  Don’t mix with Ethylene-glycol product.  If Ethylene-glycol is the only substitute to be found then the system must be flushed prior to filling.

Warning: Do not mix the glycol product with anything other than deionized water.

Spindle Air Regulator

Reconfigure the Air Solenoid fitting, Move the restrictor orifice from before 90° fitting to before the Tee Brass fitting. 

Note: No parts required for corrective action.

Setting the Tool Change Offset

1

Reset the grid offset, by zeroing parameters 6.140 B-AXIS GRID OFFSET and 7.140 C-AXIS GRID OFFSET and then zero returning each axis and pressing the axis B/C and pressing [F4].

Set the Tool change offset for the B-Axis by sweeping the side of the test bar so it reads zero to zero over the entire length of the test bar [B].

Set the Tool change offset for the C-Axis by sweeping the front side of the test bar so it reads zero to zero over the entire length of the test bar [C].

NOTE: This is NTE 0.0005 in (0.0127 mm), but it is recommended to get this value as close to zero as possible. If the machine is experiencing issues getting it closer to zero, complete the backlash compensation section and return to set the tool change offset.

Setting Backlash Compensation

1

B-Axis Backlash

After resetting the tool change offset re-zero the B and C-Axis set up the test bar [1] as shown in the image and place an indicator at the high spot 20 inches away from the test bar [2]. 

NOTE: If the test bar is not larger than 20 inches place it approximately an inch away from the end of the test bar.

2

B-Axis Backlash

With the indicator set up and B at 0 degrees and C at zero degrees [1] press [POSITION] and navigate to the operators page and set the Y-Axis and B-Axis position to zero.

Move the Y-axis enough to clear the indicator [2]

Rotate the B-Axis -10 degrees and return back to B zero position [3].

Move the Y-Axis back to the zero position on the operators page. 

Record the error value on the indicator.

3

B-Axis Backlash

With the indicator set up in the same starting position verify that the  Y-Axis and B-Axis position are zero on the operators page.

Move the Y-axis enough to clear the indicator [2]

Rotate the B-Axis +10 degrees and return back to B zero position [3].

Move the Y-Axis back to the zero position on the operators page. 

Record the error value on the indicator.

Add both error values from this step and the previous and input double the amount of error into Parameter 6.042 B-AXIS BACKLASH COMPENSATION. (Example total backlash observed : 0.004 inches,  Parameter 6.042 value: 0.008 deg)

This value is NTE 0.0003 in (0.0076 mm).

4

If the backlash value switched direction then the compensation was set too high. 

For example before the compensation value was set the negative motion value read [A] red, and the positive motion the value read [B] blue.

After the compensation value was set the negative motion value read [A] blue, and the positive motion the value read [B] red.

The B & C-Axis backlash  is NTE 0.0003 in (0.0076 mm)

5

C-Axis Backlash

After resetting the tool change offset re-zero the B and C-Axis set up the test bar [1] as shown in the image and place an indicator at the high spot 20 inches away from the test bar [2]. 

NOTE: If the test bar is not larger than 20 inches place it approximately an inch away from the end of the test bar.

6

C-Axis Backlash

With the indicator set up and B at -90 degrees and C at zero degrees [1] press [POSITION] and navigate to the operators page and set the Z-Axis and C-Axis position to zero.

Raise the Z-axis enough to clear the indicator [2]

Rotate the C-Axis -10 degrees and return back to C zero position [3].

Lower the Z-Axis back to the zero position on the operators page. 

Record the error value on the indicator.

7

C-Axis Backlash

With the indicator set up in the same starting position verify that the  Z-Axis and C-Axis position are zero on the operators page.

Raise the Z-axis enough to clear the indicator [2]

Rotate the C-Axis +10 degrees and return back to C zero position [3].

Lower the Z-Axis back to the zero position on the operators page. 

Record the error value on the indicator.

Add both error values from this step and the previous and input double the amount of error into Parameter 7.042 C-AXIS BACKLASH COMPENSATION. (Example total backlash observed : 0.004 inches,  Parameter 7.042 value: 0.008 deg)

This value is NTE 0.0003 in (0.0076 mm).

8

If the backlash value switched direction then the compensation was set too high. 

For example before the compensation value was set the negative motion value read [A] red, and the positive motion the value read [B] blue.

After the compensation value was set the negative motion value read [A] blue, and the positive motion the value read [B] red.

The B & C-Axis backlash  is NTE 0.0003 in (0.0076 mm)