Haas VF Series Operation Manual v7

HAAS AUTOMATION INC. 2800 STURGIS ROAD OXNARD, CA 93030

TEL. 888-817-4227 FAX. 805-278-8561

www.HaasCNC.com

9 6 - 8 0 0 0 r e v J

Mill Operators

Manual

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No part of the contents of this CD may be reproduced without the prior written permission of Haas Automation, Inc.

All copyrights will be strictly enforced.

805.278.1800

PHONE FAX

805.278.8540

JANUARY

2004

Haas Automation, Inc. 2800 Sturgis Road Oxnard, CA 93030

Operators, Service & Reference Manuals

Haas Automation, Inc.

Ver t ica l

Turn ing Centers

Hor izonta l

Rotary

EC1600EC 300

EC 500

Mill Operators Manual J U N E 2 0 0 4

Haas Technical Publications

This content is for illustrative purposes.

Historic machine Service Manuals are posted here to provide information for Haas machine owners.

Publications are intended for use only with machines built at the time of original publication.

As machine designs change the content of these publications can become obsolete.

You should not do mechanical or electrical machine repairs or service procedures unless you are qualified and knowledgeable about the processes.

Only authorized personnel with the proper training and certification should do many repair procedures.

HAAS SERVICE AND OPERATOR MANUAL ARCHIVE

WARNING: Some mechanical and electrical service procedures can be extremely dangerous or life-threatening. Know your skill level and abilities.

All information herein is provided as a courtesy for Haas machine owners for reference and illustrative purposes only. Haas Automation cannot be held responsible for repairs you perform. Only those services and repairs that are provided by authorized Haas Factory Outlet distributors are guaranteed.

Only an authorized Haas Factory Outlet distributor should service or repair a Haas machine that is protected by the original factory warranty. Servicing by any other party automatically voids the factory warranty.

VF Series Operators Manual 96-8000 RevJ English June 2004

96-8000 rev J June 2004

1Safety

VF-Series

HAAS SAFETY PROCEDURES

All milling machines contain hazards from rotating parts, belts and pulleys, high voltage electricity, noise, and compressed air. When using CNC machines and their components, basic safety precautions must always be followed to reduce the risk of personal injury and mechanical damage.

DONT GET CAUGHT

UP IN YOUR WORK

T H I N K S A F E T Y !

Safety Contents USES AND GUIDELINES FOR PROPER MACHINE OPERATION ........................................................................................... 4 MODIFICATIONS TO THE MACHINE .............................................................................................................................. 4 SAFETY PLACARDS ................................................................................................................................................. 4 AUTOMATIC EQUIPMENT ........................................................................................................................................... 4 MACHINE GUARDING .............................................................................................................................................. 4 ROTATING PARTS .................................................................................................................................................... 4 CHIP AUGERS ....................................................................................................................................................... 5 DANGEROUS VOLTAGES ........................................................................................................................................... 5 JOB SET-UP ......................................................................................................................................................... 5 HOT AREAS .......................................................................................................................................................... 5 MACHINE AWARENESS ............................................................................................................................................ 5 PROPER ATTIRE .................................................................................................................................................... 5 TOOLING .............................................................................................................................................................. 6 EYE-SAFETY .......................................................................................................................................................... 6 ELECTRICAL SERVICE ............................................................................................................................................. 6 SPILLS ................................................................................................................................................................ 6 FIXTURES ............................................................................................................................................................. 6 KEEP CLEAR ......................................................................................................................................................... 6 DECLARATION OF WARNINGS, CAUTIONS, AND NOTES ................................................................................................... 7 SAFETY WINDOWS ................................................................................................................................................. 7

Important This machine to be operated only by trained personnel in accordance with the Operators manual and intructions for safe operation of machine.

Back

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Only authorized personnel should work on this machine. Untrained personnel present a hazard to themselves and the machine, and improper operation will void the warranty.

Check for damaged parts and tools before operating the machine. Any part or tool that is damaged should be properly repaired or replaced by authorized personnel. Do not operate the machine if any component does not appear to be functioning correctly. Contact your shop supervisor.

Use appropriate eye and ear protection while operating the machine. ANSI-approved impact safety goggles and OSHA-approved ear protection are recommended to reduce the risks of sight damage and hearing loss.

Do not operate the machine unless the doors are closed and the door interlocks are functioning properly. Rotating cutting tools can cause severe injury. When a program is running, the mill table and spindle head can move rapidly at any time in any direction.

The Emergency Stop button (also known as an Emergency Power Off button) is the large, circular red switch located on the Control Panel. Pressing the Emergency Stop button will instantly stop all motion of the machine, the servo motors, the tool changer, and the coolant pump. Use the Emergency Stop button only in emergencies to avoid crashing the machine.

The electrical panel should be closed and the three latches on the control cabinet should be secured at all times except during installation and service. At those times, only qualified electricians should have access to the panel. When the main circuit breaker 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, extreme caution is required. Once the machine is installed, the control cabinet must be locked and the key available only to qualified service personnel.

DO NOT modify or alter this equipment in any way. If modifications are necessary, all such requests must be handled by Haas Automation, Inc. Any modification or alteration of any Haas Milling or Turning Center could lead to personal injury and/or mechanical damage and will void your warranty.

It is the shop owners responsibility to make sure that everyone who is involved in installing and operating the machine is thoroughly acquainted with the installation, operation, and safety instructions provided with the machine BEFORE they perform any actual work. The ultimate responsibility for safety rests with the shop owner and the individuals who work with the machine.

READ BEFORE OPERATING THIS MACHINE:

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3Safety

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This machine is automatically controlled and may start at any time.

This machine can cause severe bodily injury.

Do not operate with the doors open.

Avoid entering the machine enclosure.

Do not operate without proper training.

Always wear safety goggles.

Never place your hand on the tool in the spindle and press ATC FWD, ATC REV, NEXT TOOL, or cause a tool change cycle. The tool changer will move in and crush your hand.

To avoid tool changer damage, ensure that tools are properly aligned with the spindle drive lugs when loading tools.

The electrical power must meet the specifications in this manual. Attempting to run the machine from any other source can cause severe damage and will void the warranty.

DO NOT press POWER UP/RESTART on the control panel until after the installation is complete.

DO NOT attempt to operate the machine before all of the installation instructions have been completed.

NEVER service the machine with the power connected.

Improperly clamped parts machined at high speeds/feeds may be ejected and puncture the safety door. Machining oversized or marginally clamped parts is not safe.

Windows must be replaced if damaged or severely scratched - Replace damaged windows immediately.

Do not process toxic or flammable material. Deadly fumes can be present. Consult material manufacturer for safe handling of material by-products before processing.

OBSERVE ALL OF THE WARNINGS AND CAUTIONS BELOW:

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USES AND GUIDELINES FOR PROPER MACHINE OPERATION

All milling machines contain hazards from rotating cutting tools, belts and pulleys, high voltage electricity, noise, and compressed air. When using milling machines and their components, basic safety precautions should always be followed to reduce the risk of personal injury and mechanical damage. READ ALL APPRO- PRIATE WARNINGS, CAUTIONS, AND INSTRUCTIONS BEFORE OPERATING THIS MACHINE.

MODIFICATIONS TO THE MACHINE

DO NOT modify or alter this equipment in any way. If modifications are necessary, all such requests must be handled by Haas Automation, Inc. Any modification or alteration of any Haas machining center could lead to personal injury and/or mechanical damage and will void your warranty.

SAFETY PLACARDS

Some or all of these warnings may be on your machine. Be aware of the possible dangers.

If a sticker is missing from the machine, or an extra one is needed to remind employees of the need to work safely contact the Haas factory

Automatic Equipment As this machine equipment is programmable it may start unexpectedly. Operators and other shop personnel need to be aware of this. Keep the doors closed at all times other than loading or unloading parts and tools.

Machine Guarding Some guarding and access panels may close unexpectedly due to machine operation. Ensure all guarding and panels are closed and if possible, secured. Personal injury will result if the guarding falls or the access panels swing closed.

Rotating Parts If it is necessary to work on the machine, ensure the power is disconnected before servicing the machine. Rotating parts within the machine can cause serious or fatal injuries.

DANGER

THIS EQUIPMENT

STARTS AUTOMATICALLY

PINCH POINT

KEEP CLEAR

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5Safety

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CAUTION

BROKEN TOOLS, LOOSE CHUCKS

OR LOOSE PARTS WILL BE

EJECTED WITH DEADLY FORCE

DOORS ARE TO PROTECT OPERATOR

FROM CHIPS AND COOLANT ONLY

Chip Augers The chip augers can be programmed to start and stop automatically. Keep all body parts out of these as they may rotate unexpectedly. Keep out of the discharge tubes as well. The collected chips will cut you.

Dangerous Voltages Potential lethal voltages and currents are present within the system. Service should be done only by qualified personnel.

Job Set-up Incorrect tooling, machining practices, or improperly clamped workpieces or fixtures will create devastating results. Double check your set-up before beginning any machining operations.

Hot Areas This warning is on areas of the machine that have a lot of heat associated with it. Serious burns will result if personnel come in contact with these areas.

Machine Awareness Most areas of the machine are not designed to support the weight of the operator.

Proper Attire Watch for loose clothing and other personal belongings. These may become entangled in the machine and cause personal injury.

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Tooling Do not slow, or try to stop the rotating tools. These are extremely sharp and will cut or cause extensive bodily harm.

Eye-Safety Always wear safety glasses or a face mask during machine operation. Flying hot chips will cause injury.

Electrical Service Electrical shock is possible with any machine. Only authorized certified personnel should service the machine. Do not open the control cabinet or any other electrical guarding.

Spills Clean up spills immediately. Liquids, such as machine coolant will be slippery and will cause a hazardous work environment.

Fixtures Improperly clamped workpieces can be thrown from the fixture with deadly force.

Keep Clear Do not put anything between the tool and the workpiece. Severe personal injury can occur.

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DECLARATION OF WARNINGS, CAUTIONS, AND NOTES

Throughout this manual, important and critical information is contained in the following styles/formats; Warn- ings, Cautions and Notes:

Warnings are used when there is an extreme danger to the operator and/or to the machine. Take all steps necessary to heed the warning given. Do not continue if you cannot follow the warning instructions. An example warning is:

WARNING!

NEVER PUT HANDS BETWEEN TOOL CHANGER AND SPINDLE HEAD.

Cautions are used when there is the potential for minor personal injury or mechanical damage. An example of a caution is:

CAUTION! Power down the machine before performing any maintenance tasks.

Notes are used to give additional information to the operator about a particular step or procedure. This informa- tion should be taken into consideration by the operator as he/she performs the step or procedure to ensure there is no confusion. An example of a note is:

NOTE: If machine is equipped with the optional extended Z-clearance table, follow these guidelines: Avoid extreme loads on the center of table or far end of table. The weight of the part should be distributed evenly over the table or one pad. Flatness of part should be within 0.002".

Safety Windows Improperly clamped work pieces may be thrown through the windows; serious personal injury may occur. Use care and proper machining techniques during all operations. Replace windows immediately if they are damaged or show signs of wear. Contact the Haas Service Depart- ment for Replacement parts.

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9Maintenance June 2004 96-8000 rev J

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1. MAINTENANCE

1.1 GENERAL REQUIREMENTS

GENERAL REQUIREMENTS

Operating Temperature Range 41F to 104F (5 to 40C) Storage Temperature Range -4F to 158F (-20 to 70C) Ambient Humidity: 20% 95% relative humidity, non-condensing Altitude: 0-7000 ft.

ELECTRICITY REQUIREMENTS

ALL MACHINES REQUIRE: AC input power is three phase Delta or Wye power, except that the power source must be grounded (e.g. leg or center leg for delta, neutral for Wye) Frequency range of 47-66 Hz Line voltage that does not fluctuate more than 10% Harmonic distortion not to exceed 10% of the total RMS voltage

20-15 HP System Voltage Requirements High-Voltage Requirements STANDARD VF and 10K (195-260V) (354-488V) Power Supply 1 50 AMP 25 AMP Haas Circuit Breaker 40 AMP 20 AMP If service run from elec. panel is less than 100' use: 8 GA. WIRE 12 GA. WIRE If service run from elec. panel is more than 100' use: 6 GA. WIRE 10 GA. WIRE

40-30 HP System Voltage Requirements High-Voltage Requirements2

50 TAPER, 10K (50T), and HT10K (40T) (195-260V) (354-488V) Power Supply1 100 AMP 50 AMP Haas Circuit Breaker 80 AMP 40 AMP If service run from elec.panel is less than 100' use: 4 GA. WIRE 8 GA. WIRE If service run from elec. panel is more than 100' use: 2 GA. WIRE 6 GA. WIRE

WARNING! A separate earth ground wire of the same conductor size as the input power is required to be connected to the chassis of the machine. This ground wire is required for operator safety and for proper operation. This ground must be supplied from the main plant ground at the service entrance, and should be routed in the same conduit as the input power to the machine. A local cold water pipe or ground rod adjacent to the machine cannot be used for this purpose.

Input power to the machine must be grounded. For wye power, the neutral must be grounded. For delta power, a central leg ground or one leg ground should be used. The machine will not function properly on ungrounded power. (This is not a factor with the External 480V Option.)

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96-8000 rev J

VF-Series The rated horsepower of the machine may not be achieved if the imbalance of the incoming voltage is beyond an acceptable limit. The machine may function properly, yet may not deliver the advertised power. This is noticed more often when using phase converters. A phase converter should only be used if all other methods cannot be used.

The maximum leg-to-leg or leg-to-ground voltage should not exceed 260 volts, or 504 volts for high-voltage machines with the Internal High Voltage Option.

1 The current requirements shown in the table reflect the circuit breaker size internal to the machine. This breaker has an extremely slow trip time. It may be necessary to size the external service breaker up by 20-25%, as indicated by power supply, for proper operation.

2 The high-voltage requirements shown reflect the Internal 400V configuration which is standard on Europeon machines. Domestic and all other users must use the External 480V option.

AIR REQUIREMENTS

The VMC requires a minimum of 100 psi at 4 scfm at the input to the pressure regulator on the back of the machine. This should be supplied by at least a two-horsepower compressor, with a minimum 20-gallon tank, that turns on when the pressure drops to 100 psi.

NOTE: Add 2 scfm to the above minimum air requirements if the operator will be using the air nozzle during pneumatic operations.

The recommended method of attaching the air hose is to the barb fitting at the back of the machine with a hose clamp. If a quick coupler is desired, use a 3/8" for 40 taper machines, or a 1/2" for 50 taper machines and machines with the side mount tool changer option.

NOTE: Excessive oil and water in the air supply will cause the machine to malfunction. The air filter/regulator has an automatic bowl dump that should be empty before starting the machine. This must be checked for proper operation monthly. Also, excessive contaminants in the air line may clog the dump valve and cause oil and/or water to pass into the machine.

NOTE: The nipple between the air filter/regulator and the oil lubricator (See illustration in Air Connection" section) reservoir tank below the control box on the back of the machine is for the optional rotary table. DO NOT use this as a connection for an auxiliary air line. Auxiliary connections should be made on the left side of the air filter/regulator.

WARNING! When the machine is operating and the pressure gauge (on the ma- chine regulator) drops by more than 10 psi during tool changes, insuf- ficient air is being supplied to the machine.

11Maintenance June 2004 96-8000 rev J

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1.2 MAINTENANCE SCHEDULE

The following is a list of required regular maintenance for the HAAS VF Series Vertical Machining Centers. Listed are the frequency of service, capacities, and type of fluids required. These required specifications must be followed in order to keep your machine in good working order and protect your warranty.

INTERVAL MAINTENANCE PERFORMED DAILY !Check coolant level each eight-hour shift (especially during heavy TSC usage).

!Check way lube lubrication tank level. !Clean chips from way covers and bottom pan. !Clean chips from tool changer. !Wipe spindle taper with a clean cloth rag and apply light oil.

WEEKLY !Check Through the Spindle Coolant (TSC) filters. Clean or replace element if needed.

!Check for proper operation of auto drain on filter regulator. !On machines with the TSC option, clean the chip basket on the coolant tank.

Remove the tank cover and remove any sediment inside the tank. Be careful to disconnect the coolant pump from the controller and POWER OFF the control before working on the coolant tank. Do this MONTHLY for machines without the TSC option.

!Check air gauge/regulator for 85 psi. Check the spindle air pressure regulator for 17 psi. For 15K-spindle machines, check spindle air pressure regulator for 20 psi.

!For machines with the TSC option, place a dab of grease on the V-flange of tools. Do this MONTHLY for machines without the TSC option.

!Clean exterior surfaces with mild cleaner. DO NOT use solvents. !Check the hydraulic counterbalance pressure according to the machines

specifications.

MONTHLY !Check oil level in gear box. For 40 taper spindles: Remove inspection cover beneath spindle head. Add oil slowly from top until oil begins dripping from overflow tube at bottom of sump tank. See section 1.4. For 50 taper spindles: Check oil level in sightglass. Add from side of gearbox if necessary. See section 1.5.

!Inspect way covers for proper operation and lubricate with light oil, if neces- sary.

!Place a dab of grease on the outside edge of the guide rails of the tool changer and run through all tools.

SIX MONTHS !Replace coolant and thoroughly clean the coolant tank. !Check all hoses and lubrication lines for cracking.

ANNUALLY !Replace the gearbox oil. Drain the oil from the bottom of the gearbox. Remove inspection cover beneath spindle head. Add oil slowly from top until oil begins dripping from overflow tube at bottom of sump tank. For 50 taper spindles, add oil from the side of the transmission.

!Check oil filter and clean out residue at bottom of filter. !Replace air filter on control box every 2 years. !Check SMTC oil level in sight glass, (see Side Mount Tool Changer Oil Level

in this section).

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1.3 TSC MAINTENANCE

The TSC pump is a precision gear pump and will wear out faster and lose pressure if abrasive particles are present in the coolant.

Check the dirt indicator on the 100-micron mesh filter with the TSC system running and no tool in the spindle. Change the element when the indicator reaches the red zone.

Clean the pump intake filter when indicator is in the red zone. Reset indicator with button. All intake filters can be cleaned with a wire brush.

After changing or cleaning filter elements, run TSC system with no tool in spindle for at least one minute to prime system.

Coolant will be used more quickly when the TSC system is in use. Make sure to keep the coolant level up and to check the level more frequently (check after every eight hour shift). Premature wear of the pump can result from running with a low coolant level in the tank. The spindle will shut off automatically if the coolant level gets too low.

TSC Coolant Pump Assembly. Cleaning the Intake Filter. Gate Filter

Warnings Use of coolants with extremely low lubricity can damage the TSC coolant tip and pump.

Shortened pump life, reduction of pressure and increased maintenance are normal and to be expected in abrasive environments and are not covered by warranty. A special filter, in addition to the standard filter should be used; contact HAAS for recommendations.

Machining of ceramics and the like voids all warranty claims for wear and is done entirely at customer's risk. Increased maintenance schedules are absolutely required with abrasive swarf. The coolant must be changed more often and the tank thoroughly cleaned of sediment on the bottom. An auxiliary coolant filter is recommended.

To Clean the Gate Filter: 1. Turn off the coolant pump. 2. Remove the filter. 3. Clean and reinstall filter.

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VF-Series

1.4 LUBRICATION CHART

METSYS SCITAMUENPDNAEBULYAW NOISSIMSNART KNATTNALOOC

NOITACOL ehtforaerehttalenaplortnocehtrednU enihcam

eldnipsehtevobA daeh

enihcamfoediS

NOITPIRCSED .emitelcycetunim03htiwpmupnotsiP gninrutsieldnipsnehwnoylnosipmuP

.gnivomsisixanehwro

SETACIRBUL eldnipsdnastunllab,sediugraeniL ylnonoissimsnarT

YTITNAUQ elytspmupnognidneped.stq5.2-2 zo43repat04 zo15repat05

snollaG04 11-6FVsnollaG08

TNACIRBUL 2#artcaVliboM 52ETDliboM liocitehtnyselbulos-retaW desabcitehtnysrodesab

*.tnacirbul/tnalooc .sdiuqiLelbammalFoN

* Mineral cutting oils will damage rubber components throughout the machine. Do not use pure water as a coolant; machine components will rust.

WARNING! The TSC pump is a precision gear pump and will wear out faster and lose pressure if abrasive particles are present in the coolant.

Use of coolants with extremely low lubricity can damage the TSC Cool- ant tip and pump.

When machining castings, sand from the casting process and the abrasive properties of cast aluminum and cast iron will shorten pump life unless a special filter is used in addition to the 100-micron mesh suction filter. Contact Haas Automation for recommendations.

Machining of ceramics and the like voids all warranty claims for wear and is done entirely at the customers risk. Increased maintenance schedules are absolutely required with abrasive swarf. The coolant must be changed more often, and the tank thoroughly cleaned of sediment on the bottom. A larger coolant tank is recommended.

Shortened pump life, reduction of pressure and increased mainte- nance are normal and to be expected in abrasive environments and are not covered by warranty.

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VF-Series SIDE MOUNT TOOL CHANGER GEARBOX OIL

Check the oil level in the SMTC

View the Oil level sight glass in the location shown. The proper level is half way on the sight glass. If more oil is needed, fill the gear box to the proper level at the oil fill/breather where shown.

SMTC Oil Types Mobilgear 632 or equivalent, for standard tool changers Mobil SHC 630 or equivalent, for high speed tool changers

1.5 VF-1 THROUGH 6 / 40T - TRANSMISSION OIL

There is no visible indicator for the level of transmission oil in the VF 1-6/40T models.

To add transmission oil, remove the access panel located directly behind the spindle head. This will expose the Transmission Oil Overflow Pipe. Place a container on the table, beneath this outlet. Manually jog the Z axis to its full -Z travel. Power down the machine. Locate the Transmission Oil Fill Cup, accessed from the top of the motor housing (see figure below). There is a cut-out provided in the top of the motor housing sheetmetal for filling. Slowly pour in Mobil DTE 25 oil until oil starts to come out of the overflow pipe. This overflow indicates your transmission oil reservoir is full. Close the Transmission Oil Fill Cup. Wipe off the overflow pipe and replace the access cover. Consider any overflow oil to be used and dispose of properly.

VF 1-6/40T Transmission Oil Fill Cup

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1.6 VF-6 THROUGH 11 50T - TRANSMISSION OIL

CAUTION! Power down the machine before performing any maintenance tasks.

Oil Level Check The VF 6 through 11 50T machines provide a means to check the transmission oil level. The transmission oil level sight glass is located behind an access panel secured to the right side of the spindle housing (as viewed from the front; see figure below). To visually check the oil level, remove the 6 BHCS securing the access panel to the spindle housing sheetmetal. Remove the access panel. The transmission oil level sight glass will be visible. The oil level should reach the middle of the sight glass.

Transmission

Fill Plug (2)

Transmission

Sight Glass

Access Port

VF 6 through 11 50T Oil Level

If additional oil is necessary, remove the fill port plug located just to the left of the sight glass. Add Mobil DTE 25 oil until the proper level is reached. Replace the fill port bolt and tighten. Securely reattach the access panel.

Oil Change 1. Remove the sheet metal from the spindle head. 2. Remove the encoder and the encoder mounting plate. 3. Remove the oil drain plug. When the oil drains, check the magnet for metal particles. 4. Replace the oil drain plug and fill the gear case with 1 liters of Mobil DTE 25 gear oil at the

fill cup on top. 5. Replace the oil overflow plug, put a small amount of thread sealant on the threads. (Do not use

loctite) install encoder and insure that the spindle orientation is correct. 6. Install the sheet metal and run a spindle warm up and check for leaks.

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1.7 CHIP AUGER

MAINTENANCE During normal operation, most chips are discharged from the machine at the discharge tube. However, very small chips may flow through the drain and collect in the coolant tank strainer. To prevent drain blockage, clean this trap regularly. Should the drain become clogged and cause coolant to collect in the machines pan, stop the machine, loosen the chips blocking the drain, and allow the coolant to drain. Empty the coolant tank strainer, then resume operation.

1.8 LUBRICATION SYSTEM

All machine lubrication is supplied by the external lubrication system. The reservoir is located on the lower rear of the machine (see figure below). Current lube level is visible in the reservoir. If additional lube needs to be added, remove the cap from the fill port and add lube to the proper level.

External Lubrication System

WARNING! DO NOT ADD LUBE ABOVE THE HIGH LINE MARKED ON THE RESERVOIR. DO NOT ALLOW THE LUBE LEVEL TO GO BELOW THE LOW LINE MARKED ON THE RESERVOIR AS MACHINE DAMAGE COULD RESULT.

To lubricate the system, pull up on the primer pull-tab located next to the fill port. The primer will automati- cally send 3 cc of lube through the system.

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VF-Series SPINDLE AIR PRESSURE

Verify Spindle air pressure using the gauge located behind the Air Regulator panel. VF machines should show 17 psi. Adjust if necessary.

15K Spindle The air pressure for the 15K Spindle is 20 psi. The 15K Spindle requires higher pressure to slightly reduce the amount of oil and speed the delivery of the oil to the bearings.

1.9 SIDE MOUNT TOOL CHANGER OIL LEVEL CHECK

1

13 12 11

10

9

8 7

6 5

4

3

2

23 22

21

20

1 99

1 8

1 7

1 6

1 5

1 4

24

Carousel

Number Disc

Disc Mounting

BHCS (6)

Oil Fill Level

The SMTC is factory filled with the appropriate level of oil and does not need to be changed under normal conditions. As a precaution, check the oil level annually. Oil will not need to be added as long as the level remains viewable in the sight glass as shown above. Should the level drop below the sight glass, call the HAAS service department.

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1.10 PERIODIC MAINTENANCE

A periodic maintenance page has been added to the control, it is found on the Current Commands screens titled SCHEDULED MAINTENANCE and accessed by pressing PAGE UP or PAGE DOWN which allows the operator to activate and deactivate a series of checks (see list below).

An item on the list can be selected by pressing the up and down arrow keys. The selected item is then activated or deactivated by pressing ORIGIN. If an item is active, the remaining hours will be displayed to the right. If an item is deactivated, will be displayed instead. Items are tracked either by the time accumulated while power is on (ON-TIME) or by cycle-start time (CS-TIME). When power is applied, and every hour thereafter, the remaining time for each item is decremented. When it reaches zero (or has gone negative) the message MAINTENANCE DUE is displayed at the bottom of the screen. A negative number of hours indicates the hours past expiration. The maintenance item can have its time adjusted by using the left and right arrows. One hour is added or subtracted for each keypress, upto a maximum of 10,000 hours, and a minimum of 1 hour. Pressing the Origin key will reinstate the default time.

This message is not an alarm and does not interfere with machine operation in any way. The intent is to warn the operator that one of the items on the list requires attention. After the necessary maintenance has been performed, the operator can select that item on the SCHEDULED MAINTENANCE screen, press ORIGIN to deactivate it, then press ORIGIN again to reactivate it, and the countdown begins again with a default number of hours remaining (this value is determined by the software and cannot be altered by the operator.) Items available for checking are:

COOLANT - needs replacement 100 ON-TIME AIR FILTER in control enclosure - replace 250 ON-TIME OIL FILTER - replace 250 ON-TIME GEARBOX OIL - replace 1800 ON-TIME COOLANT TANK - check level, leakage, oil in coolant 10 ON-TIME WAY LUBE SYSTEM - check level 50 CS-TIME GEARBOX OIL - check level 250 ON-TIME SEALS/WIPERS missing, torn, leaking - check 50 CS-TIME AIR SUPPLY FILTER - check for water 10 ON-TIME HYDRAULIC OIL - check level 250 ON-TIME

1.11 WINDOWS / GUARDING

Polycarbonate windows and guarding can be weakened by exposure to cutting liquids and chemicals that contain amines. It is possible to loose up to 10% of the remaining strength annually. If degradation is suspected, window replacement should occur at no more than a two year interval.

Windows and guarding should be replaced if damaged or severely scratched - Replace damaged windows immediately

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1.12 INTERIOR WORKLIGHT

Bulb Replacement 1. TURN OFF power to the machine at the main breaker.

2. Remove the light lens by bowing it over the lower light tabs and pulling it down.

3. Remove the light bulb and replace.

4. Replace the light lens and restore power to the machine.

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2. OPERATION

The Information contained in this manual is constantly being updated. The latest updates and other helpful information can be downloaded in .pdf format from the Haas website. Go to www.HaasCNC.com and click on Manual Updates under the Customer Services drop-down menu on the navigation bar.

Additional technical information is available in the Haas Reference Manual. The Reference Manual contains definitions of param- eters and alarms, machine installation instructions, and explanations of the machines mechanical and electrical subassemblies.

The Haas Reference Manual is available online as a free download in .pdf format (go to www.HaasCNC.com and click on Manual Updates under the customer services drop-down menu in the navigation bar), or may be purchased through the Haas Service Department.

2.1 BASIC INTRODUCTION

This section provides the basic programming and operation principles necessary to begin operating the ma- chine. The remainder of this manual is divided into more detailed Programming and Operation sections.

In an NC (numerically controlled) machine, the tool is controlled by a code system that enables it to be operated with minimal supervision and with a great deal of repeatability. CNC (computerized numerical control) is the same type of operating system, with the exception that the machine tool is monitored by a computer.

The same principles used in operating a manual machine are used in programming an NC or CNC machine. The main difference is that instead of cranking handles to position a slide to a certain point, the dimension is stored in the memory of the machine control once. The control will then move the machine to these positions each time the program is run.

The operation of the VF Series Vertical Machining Center requires that a part program be designed, written, and entered into the memory of the control. The most common way of writing part programs is off-line, that is, away from the CNC in a facility that can save the program and send it to the CNC control. The most common way of sending a part program to the CNC is via an RS-232 interface. The HAAS VF Series Vertical Machining Center has an RS-232 interface that is compatible with most existing computers and CNCs.

In order to operate and program a CNC controlled machine, a basic understanding of machining practices and a working knowledge of math is necessary. It is also important to become familiar with the control console and the placement of the keys, switches, displays, etc., that are pertinent to the operation of the machine.

This manual can be used as both an operators manual and as a programmers manual. It is intended to give a basic understanding of CNC programming and its applications. It is not intended as an in-depth study of all ranges of machine use, but as an overview of common and potential situations facing CNC programmers. Much more training and information is necessary before attempting to program on the machine.

The programming section of this manual is meant as a supplementary teaching aid to users of the HAAS Vertical Machining Center. The information in this section may apply in whole or in part to the operation of other CNC machines. Its use is intended only as an aid in the operation of the HAAS Vertical Machining Center.

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VF-Series

2.2 THE COORDINATE SYSTEM

The first diagram we are concerned with is called a NUMBER LINE. This number line has a reference point that is called ABSOLUTE ZERO and may be placed at any point along the line.

Horizontal number line.

The number line also has numbered increments on either side of absolute zero. Moving away from zero to the right are positive increments. Moving away from zero to the left are negative increments. The +, or positive increments, are understood, therefore no sign is needed.

We use positive and negative along with the increments value to indicate its relationship to zero on the line. In the case of the previous line, if we choose to move to the third increment on the minus (-) side of zero, we would call for -3. If we choose the second increment in the plus range, we would call for 2. Our concern is with distance and direction from zero.

Remember that zero may be placed at any point along the line, and that once placed, one side of zero has negative increments and the other side has positive increments.

The next illustration shows the three directions of travel on a vertical machining center. To carry the number line idea a little further, imagine such a line placed along each axis of the machine.

The first number line is easy to conceive as belonging to the left-to-right, or X, axis of the machine. If we place a similar number line along the front-to-back, or Y, axis, the incre- ments toward the operator are the negative increments, and the increments on the other side of zero away from the operator are the positive increments.

VF-1 showing X, Y, and Z-axis lines.

The final axis of travel on our machine is the up-and-down, or Z, axis. When we place a number line on the Z travel, the positive increments are up above zero and the negative values are down below zero.

Remember, when we are moving the machine, we are concerned with positioning the spindle. Although the machine table is the moving part, we have to keep in mind our coordinates are based on our theoretical spindle movement.

Keep in mind that the zero position may be placed at any point along each of the three number lines, and in fact will probably be different for each setup of the machine. It is noteworthy to mention here that the Z axis is usually set with the machine zero position in the full upward position, or the tool change position. This will place all the Z moves in a negative range of travel. However, the work zero in the Z axis is usually set at the top of the part surface, and this will be entered in the tool length offset as a negative value.

0 1 2 3-1-2-3

0

1

2

3

-1

-2

-3

V e r t i c a l

n u m b e r

l i n e

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VF-Series The diagram shows a top view of the grid as it would appear on the machine tool. This view shows the X and Y axes as the operator faces the machine tool. Note that at the intersection of the two lines, a common zero point is established. The four areas to the sides and above and below the lines are called QUADRANTS and make up the basis for what is known as rectangular coordinate programming.

OPERATOR

-X, +Y +X, +Y

-X, -Y +X, -Y

1 2 3-1-2-3

1

2

3

-1

-2

-3

View of X,Y grid from above.

Whenever we set a zero somewhere on the X axis and somewhere on the Y axis, we have automatically caused an intersection of the two lines. This intersection where the two zeros come together will automatically have the four quadrants to its sides, above, and below it. How much of a quadrant we will be able to access is determined by where we placed the zero within the travel of the machine axis.

2.3 MACHINE HOME

The principle may be seen when doing a manual reference return of all machine axes. When a zero return (ZER