HPC-300/1K - Troubleshooting Guide - NGC

Introduction

Download and fill out the coolant pump Inspection Report Checklist below before replacing any parts.

Coolant pump Inspection Report Checklist

The image shows the following components of the HPC system.

HPC Auto-Clean Coolant Pump
Check Valve
HPC Pressure Sensor

Recommended Coolants:

Good cutting performance and long pump life rely on using the proper type of coolant. Always use a soluble oil or a semi-synthetic coolant, mixed to the manufacturer’s recommended concentration. Full synthetic coolants typically do not have adequate lubricity and don’t always have adequate rust preventative properties.

Good system performance and reliability also relies on adequate coolant filtration. If you are cutting cast materials or abrasive materials you need to use the Haas Auxiliary Filter assembly.

Symptom Table

Symptom	Possible Cause(s)	Corrective Action(s)
Alarm 8151 HPC LOW PRESSURE (HPC-300/1K)	A short circuit in the pump motor or pump motor cable caused the circuit breaker to trip on the motor drive PCB.	Check the circuit breaker on the motor drive PCB.
		Check for shorts in the HPC pump cable and on the motor leads.
	Incorrect power phasing - the pump motor is running backward.	Check the phasing indicators and change the incoming power cables, if necessary.
	Damage to the motor shaft key, shaft collar, or wear in other parts of the pump head assembly	Inspect the motor shaft / pump head assembly.
	The HPC pressure sensor is defective. Some coolant flow may occur if this is the case.	Troubleshoot the coolant pressure sensor. Refer to the HPC Pressure - Sensor Failure section below.
Low coolant flow, no alarm. (HPC-300/1K) Low coolant flow, the pump cavitates (cavitation sounds like heavy grit in the pump head, or a suction sound) or is otherwise noisy.	The Auto-clean coolant pump filter (if equipped) is clogged.	Test and troubleshoot the Auto-clean pump filter.
	The pressure relief spring in the pump head is damaged.	Inspect the pressure relief spring.
	Damage to the motor shaft key, shaft collar, or wear in other parts of the pump head assembly.	Inspect the motor shaft / pump head assembly.
	The pick-up hose can kink when the pump is running.	Replace the pick-up hose with the new version with a spring.
	The pickup hose fittings are loose.	Tighten the pickup hose fittings.
	Gear pump coupler misalignment.	Order kit 93-4195 Coolant Gear Pump Coupler Conversion. Follow the Pump Head Coupling - Flexible Coupling Replacement procedure.
The 230V system does not turn ON and the red LED on the motor drive PCB is OFF.	The jumper on the motor drive PCB is incorrectly located or defective.	Make sure that the motor drive PCB has a jumper installed on P3 inbetween pin 1 and 2 (the bottom two pins).
	There is no 12V input power.	Make sure that the 12V input power is connected to P2 on the motor drive PCB.
There is a delay before the coolant starts to flow.	The coolant check valve is defective.	Inspect the check valve for contamination and proper operation.
There is a delay before the coolant starts to flow.	The Auto-clean cylinder is leaking.	Inspect the air cylinder for leaks into the coolant tank after it cycles.
The HPC pump is running backwards when standard coolant is on.	There is no check valve installed on the coolant manifold.	Install a check valve and upgrade the coolant manifold.
Excessive noise from pump	Gear pump coupler misalignment.	Order kit 93-4195 Coolant Gear Pump Coupler Conversion. Follow the Pump Head Coupling - Flexible Coupling Replacement procedure.

Short Circuit

1. On the motor drive PCB:

Note: The PCB [2] on the HPC-1K has a fan. The HPC-300 PCB [1] does not.

Make sure that the circuit breaker is in the ON position.

If the circuit breaker has tripped, turn it back on. Test the HPC system. If the circuit breaker trips again, check for a short circuit in the HPC pump.

Note: You must use water-based coolants with the HPC-1K system. Thicker fluids like cutting oil will overload the pump and trip the breaker.

2. Check the pump for shorts:

Measure the (3) leads [1] to ground [2] on the HPC power cable. If all leads test open to ground, the pump and cabledo not have a short.

If the motor lead test indicates a short, disconnect the cable from the motor. Measure the (3) cable leads [3] to ground. If any lead tests short, the pump is at fault. If none of the leads test short, the cable is at fault.

3. If all leads test OK:

Check the HPC motor for binding that could cause an over amperage condition.

Incorrect Input-Power Phasing

The power supply PCB has a phase detect with neon indicators on the top center portion of the board. Make sure that the electrical power is phased correctly:

Green Light: The incoming power is phased correctly.
Orange Light: The incoming power is incorrectly phased.
Both Lights: A phase is missing (there is a loose cable in the system).

If the electrical power is phased incorrectly:

Set the main circuit breaker to the OFF position.

Lock the main circuit breaker. Use an approved lock with an approved safety tag.

Swap the #74 and #75 incoming power cables at the main transformer.

Coolant Pump Damage

Remove the pump from the tank. Rotate the pump motor fan [1] by hand clockwise. Make sure that the pump coupling [2] also turns.

If it does not turn, separate the pump from the motor. Check for a damaged key on the motor shaft.

HPC Pressure - Sensor Failure

Note: The HPC pressure sensor is mounted on a coolant block located behind the tool changer.

Machines with Analog HPC Pressure sensor:

Important: If the I/O page is displaying that pressure and alarm 151 is generated, the machine will stop.

Press [RESET] to reset the alarm and turn HPC back on. Carefully watch the gauge on the I/O page to see if it the gauge is stuck at 0 psi even when the HPC is on.

Cycle power the machine, turn HPC on, and watch the gauge on the I/O screen. If the gauge is operating correctly and the machine does not alarm out, it can continue to be used. If the gauge is still stuck at 0 or alarms out, continue troubleshooting.

Pressure Sensor:

Check the HPC check valve [1] to make sure is not stuck before replacing the sensor on the check valve assembly.

How to Test HPC Analog Pressure Sensor with Multimeter:

You will need to remove the rear sheetmetal to get to the analog pressure switch [2]. Make sure the cable connector is correctly threaded into the sensor.

The machine must be powered on and at idle.

On I/O PCB locate the HPC pressure sensor cable connected at P48. With the cable still plugged into sensor, use fine tip probes to check readings between pins.

Refer to the table below for the correct readings. If the values are not within range, the HPC sensor is likely to be faulty.

Red Multimeter Lead	Black Multimeter Lead	Expected Reading
Brown Wire (Pin 3, [+5VDC])	White Wire (Pin 7, [GND])	4.69VDC to 5.25VDC
Blue Wire (Pin 2, [HPC Signal])	White Wire (Pin 7, [GND])	0.490VDC to 0.510VDC (machine is at idle)

Coolant Blockage HPC-300/1K

Remove the filter tray from the bottom of the TSC assembly. Remove the tray lid [3] from the filter [4]. Use a brush to clean the filter.

Remove the chip basket and polyester mesh strainer (if the strainer is installed) from the chip tray. Remove all chips from the chip strainer basket.

To replace the mesh strainer [5], pull it tightly over the top of the chip basket [7]. Make sure that the elastic band [6] goes over the edge of the chip basket [7].

Make sure that the auto-clean plunger activates when the HPC pump shuts off. If it does not shut off, go to the solenoid troubleshooting guide. Test the HPC purge solenoid.

If the solenoid operates and it outputs air, check the air tube for kinks or breaks.

Do these steps for a damaged pressure relief spring.

Remove the HPC pump from the tank.
Remove the pressure relief plugs.
Inspect the spring and valve pin. Replace the spring if it is broken and the pin if it is pitted or worn.

Kinked Pick-up hose

The pick-up hose can kink when the pump is running. Replace the pick-up hose with the new version with a spring.

HPC Check Valve

When running the standard coolant pump, it may back drive the HPC pump.

The manifold block needs to be upgraded to add the check valve. Upgrade the manifold assembly with the following PNs:

1. 20-9118

2. 58-0287

3. 59-2229