Service Home Haas Control Surge Protector - Troubleshooting Guide
Last updated: 03/28/2023

Haas Control Surge Protector - Troubleshooting Guide

Introduction

The Haas Control Surge Protector protects machines against lightning strikes and power surges.

Replacement Surge Protector Assembly:

Machine Requirements:

  • Software Version 100.22.000.1015 or higher
  • Three Phase Machines only.
  • Not installable on Pre-Reboot UMC Machines built 06/15/2018 and later. P65 is used on the I/O PCB for cable 33-0476 for the redundant door lock.
  • Not installable on Desktop Mills or Desktop Lathes.

Haas Control Surge Protector - System Overview

The Haas Control Surge Protector has the following behavior:

  • This device uses six surge protection units. In the event of a voltage spike or transient, the surge protectors will absorb the energy and the fuse will open triggering a fault and warning. At this time, Input 27 will change from 0 to 1. 
  • When Input 27 is a 1, True. The Surge Fault icon will display on the control display, the LED status light will be red, and System Message & Notification 20026 SURGE PROTECTOR FAULT HAS BEEN DETECTED is logged in the Alarm History. If Input 27 is a 0, False. The Surge Fault icon will clear, the LED status light will be green, and System Message & Notification 20026 SURGE PROTECTOR FAULT HAS BEEN REPAIRED is logged in the Alarm History.
  • If Input 27 is a 1, the LED Status Light is Red, and the Surge Protector Icon is displayed. A Pop-Up will display when a program is run by pressing [CYCLE START].

Surge Protector Fault has been detected.
The electronics are capable of being damaged due to any electrical surge.
Do you want to proceed?

Press [CYCLE START] to continue or [CANCEL] to Exit.

  • Alarm 9000 is generated when Input 27 is a 1 only at power up. The alarm is resettable but if Input 27 stays a 1, the LED status light is red and the Surge Fault icon is displayed. The machine is no longer protected in the event of an electrical surge event. The machine electronics are capable of being damaged.

Electrical Safety

 Caution: When you do maintenance or repair on CNC machines and their components, you must always follow basic safety precautions. This decreases the risk of injury and mechanical damage.

  • Set the main circuit breaker to the [OFF] position.

 Danger: Before beginning any work inside the control cabinet the High Voltage indicator light on the 320V Power Supply / Vector Drive must have been off for at least 5 minutes.

Some service procedures can be dangerous or life-threatening. DO NOT attempt a procedure that you do not fully understand. If you have any doubts about doing a procedure contact your Haas Factory Outlet (HFO) and schedule a service visit.

WARNING: Before preceding the following must be done.

  • All incoming power to the CNC Machine must be turned off Lockout-Tagout at the source prior to installing the surge protector.
  • The machine main circuit breaker must be in the [OFF] position.
  • Always check the incoming lines with an AC Voltage detector to make sure power has been disconnected.

Symptom Table

Symptom Possible Cause Corrective Action
Alarm 9000 Enhanced Surge Protector Fault Detected The Enhanced Surge Protector Device has detected a fault. The machine must have Software Version 100.22.000.1015 or higher. This alarm is generated at power up. Try to clear the alarm by pressing [RESET]. The device fuse takes time to stabilize, wait at least 10 seconds or more. Verify Input 27 is a 0 and the alarm clears. If Input 27 stays a 1, the LED Status Light is Red, and the alarm clears. The unit should be replaced to ensure the machine electronics are safe. Replace the Surge Protector with 93-3709A SURGE PROTECTOR FIELD INSTALL ASSEMBLY.
The machine must have Software Version 100.22.000.1015 or higher. This alarm is generated at power up. Try to clear the alarm by pressing [RESET]. The device fuse takes time to stabilize, wait at least 10 seconds or more. Verify Input 27 is a 0 and the alarm clears. If Input 27 stays a 1, the LED Status Light is Red, and the alarm does not clear. The unit should be replaced to ensure the machine electronics are safe. Replace the Surge Protector with 93-3709A SURGE PROTECTOR FIELD INSTALL ASSEMBLY.
System Message & Notification 20026 SURGE PROTECTOR FAULT HAS BEEN DETECTED/REPAIRED A Surge Protector Fault has been detected or repaired. This is an informational message only. No parts need to be replaced. This is an informational message only. No parts need to be replaced. If the System Message & Notification 20026 SURGE PROTECTOR FAULT HAS BEEN DETECTED/REPAIRED appears in the Alarm History consistently, the incoming power to the machine may need to be inspected.
The Surge Protector Icon is displayed. The Enhanced Surge Protector Device has detected a fault. Check the machine Alarm History for System Message & Notification 20026 SURGE PROTECTOR FAULT HAS BEEN DETECTED. If System Message & Notification 20026 SURGE PROTECTOR FAULT HAS BEEN REPAIRED is not generated after pressing [RESET]. Cycle Power the machine. If alarm 9000 is generated at power up. Try clearing the alarm. If the alarm clears and the LED Status Light is Red, and Input 27 is a 1. Replace the Surge Protector with 93-3709A SURGE PROTECTOR FIELD INSTALL ASSEMBLY.
Alarm 9000 ENHANCED SURGE PROTECTOR FAULT DETECTED at Power Up or the Surge Fault icon is displayed, the Status LED is Red, and Input 27 is a 1. N/A

For Machines Built before 2/2/2023:

See the Surge Protector Voltage Measurement section below.

HSG-A  02-15-2023

For Machines Built 2/2/2023 and later:

The machine must have Software Version 100.22.000.1015 or higher. This alarm is generated at power up. Try to clear the alarm by pressing [RESET]. The device fuse takes time to stabilize, wait at least 10 seconds or more. Verify Input 27 is a 0 and the alarm clears. If Input 27 stays a 1, the LED Status Light is Red, and the alarm clears. The unit should be replaced to ensure the machine electronics are safe. Replace the Surge Protector with 93-3709A SURGE PROTECTOR FIELD INSTALL ASSEMBLY.

HSG-A  02-15-2023
LED Status Light - Green
 Status Ok. N/A
LED Status Light - Red The cable labeled 77-79 230V IN PSUP P11 is disconnected or the cable labeled XMFR CBL is disconnected.

Check the connections and cables.
Circuit is open due to surge voltage. Verify Input 27 is a 1 and alarm 9000 does not clear. The device circuit is open and not resettable. The unit should be replaced to ensure the machine electronics are safe. Replace the Surge Protector with 93-3709A SURGE PROTECTOR FIELD INSTALL ASSEMBLY.
LED Status Light - Off Signal cable to I/O PCB is disconnected. Check and connect the cable labeled 33-1148 SURGE FLT I/O PCB P65 to the I/O PCB at P65. 

System Message & Notification 20026 SURGE PROTECTOR FAULT HAS BEEN DETECTED/REPAIRED

If the System Message & Notification 20026 SURGE PROTECTOR FAULT HAS BEEN DETECTED/REPAIRED appears in the Alarm History consistently, the incoming power to the machine may need to be inspected by an electrician. This is an informational message only. No parts need to be replaced.

Surge Protector Fault Detected Pop-Up

If Input 27 is a 1, the LED Status Light is Red, and the Surge Protector Icon is displayed. A Pop-Up will display when a program is run by pressing [CYCLE START].

Surge Protector Fault has been detected.
The electronics are capable of being damaged due to any electrical surge.
Do you want to proceed?

Press [CYCLE START] to continue or [CANCEL] to Exit.

 

Surge Protector Voltage Measurement

Machines Built before 2/2/2023 may see the following issue.

Problem: Machines with the Haas Control Surge Protector may generate Alarm 9000 ENHANCED SURGE PROTECTOR FAULT DETECTED at Power Up.

Corrective Action: If the alarm clears but the Surge Fault icon is displayed, the Status LED is Red, and Input 27 is a 1.

  1. Measure the voltage at connector J2 on the Surge Protector PCB. Leg to Leg (195-260VAC).
  2. Leg to Ground Cable Screw[4] (Screw where Surge Protector ground cable is connected to the PCB, Leg to Ground Cable Screw should be balanced and no more than +/- 10% of each measurement).
  3. Ground Cable Screw[4] to Chassis of Control Cabinet. (Should be 0VAC).
  • [1] to [2]
  • [2] to [3]
  • [1] to [3]
  • [1] to [4]
  • [2] to [4]
  • [3] to [4]
  • [4] to Chassis in Control Cabinet

If the voltage measurements are correct, the assembly should not be replaced. Attach the measurements and Error Report to Haas Service App. The Surge Protector monitoring can be disabled by changing Parameter 2252 to 0 or downloading and loading a new configuration file. The machine can continue operation. The machine will still be protected, but there will be not be any feedback from the machine that there has been a Surge Event.

If the Surge Protector assembly is damaged from a surge event, replace the Surge Protector Assembly with PN: 93-3709A. The Surge Protector monitoring can be enabled by loading machine configurations or changing Parameter 2252 to 1.

Electrical Diagram

Ground cable[1] labeled 33-1156 SURGE to control panel chassis. 

Cable[2] labeled 33-1148 SURGE FLT I/O PCB P65 to the I/O PCB at P65.

Cable[3] labeled 33-1148 SURGE +12V PSUP PCB P18 to the PSUP PCB at P18.

Cable[4] labeled 77-79 230V IN PSUP P11 and connect it to the cable labled 33-1167 XMFR CBL.

Cable[5] labeled 33-1167 PSUP P11 to the PSUP PCB at P11.