Service Home TSC-300/1K - Troubleshooting Guide - NGC
Last updated: 11/16/2021

TSC-300/1K - Troubleshooting Guide - NGC

Introduction

The image shows the following components of the TSC system:

  1. TSC Auto-Clean Coolant Pump:
  2. Check Valve:
  3. Vacuum Generator:
  4. Precharge Solenoid (40-Taper belt-driven):

    or

    TSC Union Solenoid (50-Taper or inline):

Compensating TSC Union Basics

Symptom Table

Symptom Possible Cause(s) Corrective Action(s)
Compensating Union:  
Leaking Coolant from Union.		 The coolant union seal is damaged. Manually depress the piston or replace the cup seal, 93-3179, if flowing out the bypass. Replace the base seal 20-7908 if leaking on the motor.
The TSC Filter Icon stays on the screen. The TSC filter is clogged. Cycle the Tool changer a few times to actuate the AutoClean system on the TSC pump.
The vacumm sensor is not plugged in or the cable is damaged. See the Vacuum Sensor section.
The vacumm sensor has debris or is clogged.
The Auto-clean cylinder is leaking.

Alarm 151 LOW THROUGH SPINDLE COOLANT

 A short circuit in the pump motor or pump motor cable caused a fuse to blow or a circuit breaker to trip.

Check the circuit breakers and fuses on the power supply PCB.

Check for shorts in the TSC pump cable and the motor leads.
Incorrect Circuit Breaker size installed TSC 1K requiries 15 Amp Circuit breaker, verify correct size is installed.
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 TSC pressure sensor is defective. Some coolant flow may occur if this is the case. Troubleshoot the coolant pressure sensor.
The TSC auto clean cylinder is leaking air into the tank which will fill the auxilary filter with air. Remove the cylinder from the pump and place that end in the coolant, manually actuate the TSC purge solenoid a few times, once complete let it sit and see if any bubbles are present, if they are replace auto clean cylinder.
The Auxilary filter is draining from being used with the TSC pump. Replace muffler fitting with 58-2103 (FITG NPT1/4M X 1/8" THRU 90 BRASS) See section below.
The Auxilary filter is being drained, the tank lid is not leaking.
The TSC pump is cavitating.
The Auxilary Filter tank runs out of coolant periodically.
Pump head shaft misalignment causing shaft to seize and shear. Review pump head casting to see if it says "REV" or "REV C" report what is found to a service tech so we may keep record of the failed pump. Then replace the pump head and motor if the motor shaft has sheared if it has not sheared you may replace the pump head only. The correct pump head that should be installed should have "REV C" on the casting.
Alarm 552 TRIPPED CIRCUIT BREAKER Pump head shaft misalignment causing shaft to seize and shear. Review pump head casting to see if it says "REV" or "REV C" report what is found to a service tech so we may keep record of the failed pump. Then replace the pump head and motor if the motor shaft has sheared if it has not sheared you may replace the pump head only. The correct pump head that should be installed should have "REV C" on the casting.

Low coolant flow, no alarm.

Low coolant flow, the pump cavitates (cavitation sounds like heavy grit in the pump head, or a suction sound) or is otherwise noisy.

 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 coolant does not return to the coolant tank fast enough. Remove chip buildup from the coolant return path.
The pressure relief spring in the pump head is damaged. Inspect the pressure relief spring.
The TSC pump filter or intake strainer is clogged. Clean the filters. Remove chips from the coolant system.
The Auto-clean coolant pump filter does not work (if equipped). Test and troubleshoot the Auto-clean pump filter.
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.
TSC union solenoid does not turn off after running TSC. Faulty pressure sensor. Troubleshoot the TSC pressure sensor.
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.
The Auto-clean cylinder is leaking. Inspect the air cylinder for leaks into the coolant tank after it cycles. 
Tool Air Blast (TAB) causes coolant tank overflow. The coolant check valve has failed. Replace the coolant check valve.
Coolant fills the TAB air pneumatic line and blows out the muffler in the CALM cabinet. The TAB air check valve has failed. Replace the TAB air check valve.
TSC union is making squeeling noise while running. Motor shaft is pushed up causing the standoff height to be incorrect. Measure the height from the top of the motor shaft to the mounting surface, refer to Motor Shaft Reference Dimension Section for further instructions.

Vacuum Sensor

There is a vacuum sensor [5] on the TSC pump.  Go to DIAGNOSTIC> I/O> tab [1].  Type in TSC, press [F1] [2].  Look at the state of Input#48 TSC_VACUUM_SWITCH [3].   If the value of this input remains at 1 the TSC Filter ICON will appear on the screen.   

  • Make sure the vacuum sensor [4] is fully connected.
  • Check the vacuum sensor cable [5] for damaged.
  • Remove the sensor and make sure that it does not have any debris or plugged.
  • The Auto clean cylinder might be leaking.  Remove the cylinder from the pump and place that end in the coolant, manually actuate the TSC purge solenoid a few times, once complete let it sit and see if any bubbles are present, replace auto clean cylinder.

Fitting Replacement for Auxiliary filter

If your auxiliary filter is draining for any of the reasons in the symptom table above you will need to change the muffler fitting to fitting 58-2103 (FITG NPT1/4M X 1/8" THRU 90 BRASS) [1]. The orientation of hole [2] must face the opposite side of the threaded portion of the fitting as shown in the image.

Output Pressure Reference Chart

This graph shows approximate pressure vs. tool orifice diameters for Through Spindle Coolant.

This graph shows approximate pressure vs. tool orifice diameters for tool air blast.  (single orifce tools)

Flow Rate Reference Chart

This graph shows approximate Flowrates vs. tool orifice diameters. This data can be used to aid in the selection of an appropriate spindle speeder for your appliaction.

Short Circuit

1. Check for a blown fuse or a tripped breaker:

TSC-300 - On the power supply PCB: Make sure that the fuses at F1 and F3 are not blown. If there are blown fuses, check for shorts in the motor or motor cable in Step 2 before you replace the fuses.

TSC-1K - On the motor drive PCB: Make sure the circuit breaker [2] on the motor drive PCB is in the ON position.  Verify 15 Amp Circuit breaker is installed for TSC-1K

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

 Note: On pumps made before December, 2016, you must use water-based coolants with The TSC-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 [3] to ground [4] on the TSC power cable. If all leads [3] test open to ground [4], the pump and cable do not have a short.

If the motor cable leads [3] indicate a short, disconnect the cable from the motor. Measure the (3) cable leads [5] to ground [6]. If any lead tests short, the pump is at fault. If none of the leads [5] test short, the cable is at fault.

3. If all leads test OK:

Check the TSC 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 on the machine 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

Cutting abrasive materials causes premature wear on the coolant system, resulting in reduced pressure. Use additional filtration when you cut abrasive materials.

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.

Check the pressure relief spring in the pump head.

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

Motor Shaft Reference Dimension

1

Measure from the end of the motor shaft to the mating surface of the standoffs; these measurements should be as follows:

  • DT/DM built before 2018: 1.74 in (44 mm)
  • DT/DM built after 2018: 1.09 in (28 mm)
  • VF Inline: 1.29 in (33 mm)

If this reference height is incorrect, please contact your local Haas Factory Outlet for assistance. 

TSC Pressure-Sensor Failure

Pressure Switch:

Press [PARAM/DGNOS]. Go to the I/O diagnostics page.

Short the switch connector leads. The Low TSC Pressure bit state should change from 1 to 0.

If it does not change, then the cable or the I/O PCB is damaged. Measure for resistance at both ends of the cable. If the cable has resistance, refer to:

The pressure switch is connected to a bracket above the spindle. Replace the pressure switch if it is defective:

If the bit changes, use an inline pressure gauge to verify the pressure is correct. If the pressure is over 40 psi, replace the switch.

Pressure Sensor:

Check the TSC pressure gauge page in diagnostic when the pump is not running. It should read 0 PSI/BAR. If it reads pressure when the pump is off the TSC union solenoid will remain on after use. Replace the sensor on the check valve assembly.

Coolant Blockage

Remove all chips from the the auger trough [1], and the coolant return drain [2].

Clean the coolant filters and the filters in the coolant tank.

Press the plunger down (5) times to clean the filter. Make sure that the auto-clean plunger activates when the TSC pump shuts off. If it does not activate, troubleshoot the solenoid. Test the TSC purge solenoid.

Remove the filter tray from the bottom of the TSC assembly. Remove the tray lid from the filter. Use a brush to clean the filter. Install the filter tray to the bottom of the TSC pump assembly.

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

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, pull it tightly over the top of the chip basket. Make sure that the elastic band goes over the edge of the chip basket.

Tool Air Blast (TAB) causes coolant tank overflow

Coolant pressure can push the ball into the spring and trap it, causing the check valve to fail.  Without a functional check valve air from the TAB may flow backward through the coolant system and cause the coolant tank to overflow.

Corrective Action:

Disassemble and inspect the check valve. Replace the valve if it has failed.

Through Spindle Coolant (TSC) flow diagram.

Coolant fills the TAB air pneumatic line

When the TAB air check valve [1] fails and TSC is turned on, coolant from the TSC pump will back flow through the TAB air line to the solenoid and blow out the muffler.


CORRECTIVE ACTION:

Replace the TAB air check valve.

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.

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