Haas+Sohn HRT 160 Operator'S And Service Manual Download Page 61

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96-5047 rev L June 2005

Summary of Contents for HRT 160

Page 1: ...ertification 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...

Page 2: ...onnected to a AC DC servo motor through a timing belt and pulley set Odd number bolt circles and uneven hole spacing are easily handled with simple programming The table is equipped with a pneumatic brake HRT 450 uses air over oil A regular shop air line of approximately 100 PSI is all that is needed to activate the brake The HRT210SHS Super High Speed Table is unique from the other rotary tables ...

Page 3: ...ock and the fixture and support have less than 0 003 T I R then the weight might be able to be more than the rotary table weight Common sense and good fixturing technique will generally make it possible to machine larger parts The HRT210SHS Table was designed for lighter size parts which may require numerous tool changes and indexes so the speed is important to reduce the cycle time It has no brak...

Page 4: ...ces to be repeated up to 999 times saving programming time and memory space AUTOMATIC CIRCLE DIVISION Program a step that automatically divides a circle into any number of equal parts between 2 and 999 PROGRAMMABLE PARAMETERS Alter many of the basic features by performing your own basic programming PROGRAM STORAGE Store and recall from up to seven different programs MEMORY A non volatile memory re...

Page 5: ...Y Against any defects in materials or workmanship SYNTHETIC GEAR OIL Provides greater worm gear wear protection than conventional gear oils Except HRT210SHS see below FEATURES EXCLUSIVE TO THE HRT210SHS Harmonic Drive gear set 3 HPA C Servo Motor Variable feed rates from 001 deg sec to 270 deg sec with rapids to 360 deg sec ...

Page 6: ... 0 3 2 6 3 5 1 3 5 1 5 1 c e s c r a y t i l i b a t a e p e R 0 1 n i h t i w 0 1 n i h t i w 0 1 n i h t i w 1 0 1 n i h t i w 0 1 n i h t i w g e d n o i t u l o s e R 1 0 0 1 0 0 1 0 0 0 1 1 0 0 1 0 0 g e d n o i t u l o s e R x a M 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 0 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 n i a i D r a e G m r o W 7 4 3 6 4 9 4 9 5 3 1 5 3 1 R O T O M s s e l h s u r B o v r e S C A...

Page 7: ...4 63 6 000 0 001 5 25 Ø2 00 0 0005 12 4 HRT210SC 210mm 8 27 1 75 7 65 17 80 4 63 6 000 001 7 025 Ø2 00 0 0005 12 4 HRT 310 310 mm 12 20 2 00 7 82 22 80 6 88 9 000 0 001 7 875 Ø3 25 0 0005 17 7 HRT320FB The platter lifts 065 during positioning HRT310 Brush 310 mm 12 20 2 00 7 82 24 30 6 88 9 000 0 001 7 875 Ø3 25 0 0005 17 7 HRT450 450 mm 17 72 2 25 9 00 28 55 9 26 11 500 0 001 9 00 Ø7 50 0 00 22 4...

Page 8: ...0 W x 0 50 DP Front Rear Tie Down Slots MODEL DIMENSIONS A B C D E F G HRT 160SP 10 80 12 25 10 39 8 63 5 000 0 001 4 78 1 500 x 6 00 Depth HRT 210SP 12 28 13 77 12 39 10 64 6 000 0 001 5 26 2 000 x 7 000 Depth HRT 310SP 16 26 17 80 17 60 15 90 9 000 0 001 6 88 3 250 x 9 875 Depth ...

Page 9: ...8 96 5047 rev L June 2005 HRT210SHS MACHINE DIMENSIONS ...

Page 10: ...r Haas dealer to order Haas part number SCPB Installed Servo Control Bracket 1 8 HAAS TAILSTOCKS Tailstocks must be properly aligned to the rotary table before using Clean bottom surface of tailstock casting before mounting to mill table If there are any noticeable burrs or nicks on the mounting surface clean them with a deburring stone See the Haas tailstock manual 96 5000 for pneumatic tailstock...

Page 11: ...to Access Toe Clamp Pockets 1 2 13UNC T Nuts Studs Flange nuts and Washers Clamping Tool Assembly 2 Bottom View of Casting 1 2 13UNC T Nuts Studs Flange Nuts and Washers Toe Clamp Assembly 1 2 13UNC T Nuts Studs Flange nuts and Washers NOTE Toe Clamp Fasteners are not supplied Standard stud mounting front and rear For extra rigidity use additional Toe Clamps NOTE The HRT 310 can be secured as show...

Page 12: ... SCAN SCAN ZERO SET ZERO SET 7 4 1 5 2 0 6 3 8 9 RUN PROG RUN PROG MODE Note Your HAAS mill must have the 4th axis option to run full fourth and must be configured as brush or brushless to be compatible with your indexer Brush configuration uses one cable and one connection at the A axis port on the control Brushless uses two cables and two connectors at the A axis port HRT320FB cannot be run dire...

Page 13: ...xceed a length of 30 feet 9 Semi Fourth Axis Connect the remote interface lines See Interfacing to Other equipment section 10 Connect the table to a standard shop air line 120 PSI Max The line pressure to the brake is not regulated Do not exceed the maximum pressure NOTE HAAS recommends the use of an in line air filter regulator for all tables The air filter will keep contaminates from entering th...

Page 14: ... relay or any inductive load remem ber to install a snubber diode across your relay s coil in the opposite direction of coil current flow Failure to use this diode or other arc suppression circuitry on inductive loads no matter how small they may be will result in the contacts of the relay arcing together in a very short time To test the relay use an ohmmeter to measure the resistance across pins ...

Page 15: ... is transmitting the data will be garbled Be cause of this the axis selection code must be unique for each controller The serial interface may be used in either a remote command mode or as just an Upload Download path RS 232 Remote Command Mode Parameter 21 must be non zero for the remote command mode to operate as the controller looks for an axis select code defined by this parameter The controll...

Page 16: ...ill need a connector supplied by HAAS or one obtained from a local source that can be used to trigger the controller from any one of several sources The cable connector used is a male four pin DIN connector The Haas Automation part number is 74 1510 Amphenol part number is 703 91 T 3300 1 The The Haas Automation part number is 74 1509 for the panel receptacle in the control box is Amphenol part nu...

Page 17: ... automatic equipment with the controller The feedback lines provide a switch closure through a relay inside the Haas control box to let your machine know when the table has finished indexing The relay can be used to Feed Hold NC machine movements or it can be used to cancel the M function If your machine is not equipped with such an option another alternative may be to dwell for a period of time l...

Page 18: ...unless you want the control to start another mechanism such as an automatic drilling head The feedback pins 1 and 2 do not need to be connected for the control to operate Color coded remote interface cables are available as an option to help the users understand the M function hookup They are coded as follows 1 red 3 black 2 green 4 white 2 6 REMOTE OPERATION WITH CNC EQUIPMENT NOTE All Haas contr...

Page 19: ...5 DB25M DB25M null modem not required Radio Shack Catalogue no RSU 10524 114 see pinout below 5 Shielded M code relay cable Haas Automation Part Number CNC DB25 pinout 1 1 2 2 3 3 4 4 5 5 6 6 7 7 8 8 20 20 Not connected in the brushless control HAAS INTERNAL CNC INTERFACE CABLE Control Cable RS 232 Cable 4 Pin Din Connector Rear of Controller CNC MILL CNC MILL W FANUC CONTROL HAAS ROTARY CONTROL H...

Page 20: ...es Data bits as word length parity bit then set to 8 Stop bits 2 Required setting do not experiment Flow control XON XOFF Character Coding EIA ISO ISO Required setting EIA will not work DPRNT EOB LF CR CR CR is required lf is always ignored by Servo control DPRNT Leading zeroes as blanks off Initial settings Experiment with these settings only AFTER interface is functional NOTES 1 Be certain to se...

Page 21: ...carriage returns CR in your DPRNT statement DPRNT PROGRAM EXAMPLE The following is an Example of one way to program the FANUC O0001 G00 G17 G40 G49 G80 G90 G98 T101 M06 G54 X0 Y0 S1000 M03 POPEN OPEN FANUC SERIAL PORT DPRNT CLEAR RESET HAAS G04 P64 DPRNT ZG090 SERVO CONTROL STEP SHOULD NOW READ 00 G04 P64 DPRNT ZS000 000 LOADS STEP SIZE 000 000 INTO STEP 00 G04 P64 DPRNT ZF050 000 LOADS FEED RATE ...

Page 22: ...ograms sent or received by the controller have the following format Sample Only N01 G91 S045 000 F080 000 L002 N02 G90 S000 000 F080 000 N03 G98 F050 000 L013 N04 G96 P02 N05 G99 The must be found before the controller will process any input and it will always begin output with a The N code and G code are found on all lines and the remaining codes are present as required by the G code The N code i...

Page 23: ...uired for the 16C and 3J Make sure to supply tooling distributor with spindle drawbar details as shown in figure 1 b Figure 1 a A6AC collet closer shown mounted to an HRT A6 E F A MAX B MIN A MAX Tube Extended 100 psi line pressure 640 760 1 75 2 029 2 0300 A1 6 1 7 8 16 UN 2B 1 834 1 841 1 25 B MIN Tube Retracted C Spindle Type and Size E Draw Tube I D F Draw Tube O D G Spindle I D D Draw Tube Th...

Page 24: ...o the CLAMPED position This will be adjusted for maximum clamping force To reduce the clamping force back off further on the drawbar or regulate the air pressure down before adjusting Collet Sticking NOTE To prevent excessive wear and collet sticking make sure collets are in good condition and free from burrs A light coat of Molybdenum grease on the collet wear surfaces will extend the life of the...

Page 25: ... 3 feed rate indicated by a letter F 4 loop count indicated by a letter L 5 G code indicated by a letter G Successive pushes of the right arrow button will cause the display to cycle to the next register that is POSITION STEP SIZE FEED RATE LOOP COUNT G CODE POSITION etc In RUN mode the right arrow button can select among any of these five displays In PROGRAM mode all of these but the position may...

Page 26: ... to motor or table may result See Troubleshooting section NOTE It is normal for the LEDs to be illuminated during a rapid movement or high duty cycle F ZERO RETURN causes the servo to return to HOME position search for mechanical HOME delete a step or move forward to the mechanical offset G ZERO SET clears the entered data resets program to 0 or defines the present servo position as HOME H MINUS K...

Page 27: ...ery may have caused loss of your program parameters Press the front panel START switch once The panel should now indicate 01 no Ho This indicates that the motor is powered but the zero position is not yet defined 3 3 AUTOMATICALLY FINDING THE ZERO POSITION Press the ZERO RETURN button to start the automatic homing operation When the table stops the display will indicate 01 Pnnn nnn 3 4 MANUALLY FI...

Page 28: ...f tests is run and the results may indicate a controller fault Any of these could result in an En display of one of the following codes Blank front panel Program CRC failure bad RAM or cycle power if bad ROM to RAM program transfer E0 EProm EPROM CRC error FP Short Front panel switch closed or PIO fault rE Short Remote START switch closed and enabled E3 rAm RAM cannot store data E4 bAtt Saved prog...

Page 29: ...Z channel fault bad encoder or cable REncodEr Rotary scale Z channel fault bad rotary scale encoder or cable HRT210SC only Hi Curr Over current limit stalled or PCB fault EncodES Z channel missing bad encoder or cable rEncodES Rotary scale Z channel missing bad rotary scale encoder or cable HRT210SC only Hi VoLt Regen overheat high line voltage CABLE Break detected in encoder cable wiring rCABLE B...

Page 30: ...mode where commands are entered into memory The servo loop can be turned on in either mode and will hold the motor to a commanded position when at standstill When the controller is first turned on it is in RUN mode but the servo is turned off This is indicated by Por On Pressing any key will allow you to continue operation Some buttons have more than one function depending upon which mode you are ...

Page 31: ...the controller is in PROGRAM mode and at step number 01 To do this press the MODE button while the servo is NOT in motion The displays must be blinking Next push and HOLD the clear CLR key for five seconds You have now cleared the memory and are at step one and ready to begin programming 01 000 000 should be displayed Please note that you do not have to clear the memory each time you wish to enter...

Page 32: ...you enter a wrong number or one that is out of limits the control will display an error message Error To correct this push the CLR button and re enter the correct number If you are entering the correct number and Error still appears check Parameter 7 for memory protect When the last step has been entered an end code must be present at the following step Steps 2 through 99 are set to the end code w...

Page 33: ... is invoked by entering 96 into the G code After entering 96 you must DISPLAY SCAN over to the LOC short for location register to enter the step you wish to jump to The location register replaces the feed rate register and is only present on G96 steps After executing a G96 step the control will jump to the step called out in the LOC register execute that step and the ones following until it reache...

Page 34: ... in PROGRAM mode It will cause the next step and all following steps to be moved up by one All subroutine jumps are also renumbered 4 15 DEFAULT VALUES For all steps the default values are 000 000 step size zero F maximum feed rate defined by Parameters L 001 G 91 incremental If an entry is cleared or set to 0 by the operator the controller will be set to the default value All entries are stored w...

Page 35: ... time Insert a G94 into the control and the desired rotation and feed rate on the next step The control will execute G94 this pulses the MFIN relay and allows your CNC to proceed and the following step or steps as one step If you wish to do more than one step then insert the number into the L register By selecting a rotation feed rate and varying the mill feed rate any spiral is possible In order ...

Page 36: ...uld start moving at the same instant In the same manner a problem may exist at the end of the spiral but this can be eliminated by slightly altering the feed rate on your mill Don t adjust the feed rate on the HAAS control because your mill has a much finer feed rate adjustment than the HAAS control If the undercut appears to be in the X axis direction then speed up slightly 0 1 change in feed rat...

Page 37: ...itch on The power switch is located on the rear panel 2 Push the CYCLE START switch 3 Push the ZERO RETURN switch 4 Push the MODE button and release Displays must be blinking 5 Push and hold CLR button for five seconds 01 000 000 displayed 6 Enter 9 0 0 0 0 7 Push MODE button Steady displays 8 Push CYCLE START to index ...

Page 38: ...1 Enter 1 0 2 5 0 on the key pad Use CLR if you make a mistake 12 Push the DISPLAY SCAN button once 13 Enter 5 0 0 0 on the keypad 14 Push the DISPLAY SCAN button twice A G 91 will be displayed 15 Push the DOWN ARROW once You should be on Step 3 16 Enter 8 8 on the keypad 17 Push the UP ARROW twice You should be on Step 1 18 Push the MODE button Steady displays 19 Push the CYCLE START switch three...

Page 39: ...o been done using Circle Division STEP FEED RATE LOOP COUNT G CODE 01 080 000 4 98 02 080 000 5 98 03 080 000 1 99 Example 4 We want to index 90 12 degrees 90 12o start a seven hole bolt pattern and then return to the zero position STEP STEP SIZE FEED RATE LOOP COUNT G CODE 01 90 120 080 000 1 91 02 0 080 000 7 98 03 0 080 000 1 88 04 0 080 000 1 99 Example 5 We want to index 90 degrees 90o then s...

Page 40: ...pattern eight times you would save twelve program lines In the subroutine example only the loop count in Step 1 would be changed to increase the number of times you wish to repeat the pattern As an aid in programming subroutines think of the subroutine as a separate program and write it on a piece of paper Program the control using G96 when you want to invoke the previously written subroutine When...

Page 41: ...intended result There are several parameters however which give numbers to add such as 1 With these parameters start at zero and add the value for each option you would like Some of the parameters are protected from being changed by the user This is because they could result in unstable or unsafe servo operation If you need to change any of these parameters call HAAS Automation 6 1 SC 4 0 5 0 AND ...

Page 42: ...3002 which is of the magnetically sensitive transistor type When the control is shut down and restarted it will give a no home display requiring the user to press the zero return button The motor then operates slowly in a clockwise direction as viewed from the platter of a rotary table until the proximity switch is magnetically tripped and then backs up to the first Z pulse See parameter code opti...

Page 43: ...d position Clearing of parameters will set all of the gear compensation tables to zero To exit the gear compensation display press the MODE button this returns the control to RUN mode When a table is using gear compensation the values in Parameter 11 must be set to 0 6 3 PARAMETER LIST The following is a list of the programmable parameters If the brushless software ranges are different they will b...

Page 44: ...ch step 1 Continue all looped steps and stop before next step 2 Continue all programs until end code 99 or 95 3 Repeat all steps until stopped manually Parameter 11 Reverse Direction Option range 0 to 3 PROTECTED This parameter consists of two flags used to reverse the direction and the motor drive and encoder Start with a zero and add the number shown for each of the following selected options 1 ...

Page 45: ...current to achieve target This parameter set too high will often cause a hum Parameter 18 Acceleration range 0 to 30000 0 to 999999x100 PROTECTED This parameter defines how fast the motor is accelerated up to the desired speed The value used in par 18 100 in encoder steps second second The highest acceleration is thus 3000000 steps per second per second It must be greater than or equal to Paramete...

Page 46: ...parameter is factory set and is usually set from 25 to 40 depending on the product This auto shut off results in a display of Hi LoAd Warning Changes from HAAS recommended values will damage the motor Parameter 24 General Purpose Flags range 0 to 1023 0 to 4095 PROTECTED This parameter consists of 12 individual flags for controlling servo functions 1 Interpret Parameter 9 as twice entered value 2 ...

Page 47: ...Revolution 0 to 10000 0 to 99999 PROTECTED This parameter is used with the Z channel option to check the encoder accuracy If Parameter 27 is 2 or 3 this parameter is used to check that the correct number of encoder steps are received per revolution Only two numbers are used here 32768 for all brushless motors 8192 line encoder x quadrature 8000 for all brush motors 2000 line encoder x quadrature P...

Page 48: ...ncoder position and the ideal value when the Z channel is encountered The following parameters do not apply to brush motors Parameter 38 KDD 0 to 9999 Servo loop second differential gain Parameter 39 Phase Offset 0 to 9 Offset of encoder Z pulse to zero degree of phasing Parameter 40 Max Current 0 to 2047 Maximum peak current output to the motor Units DAC bits Warning Changes to this parameter fro...

Page 49: ...sed HRT210SC only Parameter 53 Rotary scale mulitplier 0 to 9999 HRT210SC only The rotary scale multiplier increases current in proportion to the proximity to the absolute rotary scale position The farther from the absolute rotary scale target the greater the current up to the maximum compensation value in parameter 56 In which alarm will be generated if exceeded see parameter 56 Parameter 54 rota...

Page 50: ...k continuity across the cycle start pins pins 3 and 4 Try not to short your test leads and pins against the shield of the male plug NOTE On rare occasions some machine builders provide a 12 to 24 volt signal on pin 4 to activate our unit If the continuity test fails check and see if there is a voltage present between pin 4 and the machine ground This is also a valid cycle start signal If there is ...

Page 51: ...ing a heavy load p Table is jammed q Check Parameter 25 r Head is jammed n Fixture or workpiece is distorted o Tailstock or workpiece support not properly aligned p Heavy Workload n Brake not operative n Excessive backlash o Excessive wormshaft play REMEDY n Check power cord line fuse and AC supply n Allow motor to cool down If this occurs often consult HAAS Service Dept o Make sure power is OFF a...

Page 52: ...a Molybdenum disulfide grease n Contact HAAS Service Dept Do Not use air gun around rear brake disc See section 8 5 n Check Air Pressure 60psi min o Check for platter clearance or excessive weight of workpiece n Air pressure should be between 40 and 120PSI PROBABLE CAUSES n Excessive spindle collet friction n Chips blown in between O ring and brake disc n Insufficient Air Pressure o Platter face p...

Page 53: ... Mount a magnet on the platter of the table Use a tenths indicator to measure the backlash Take your reading off the magnet at a 4 radius Use the aluminum bar to rock the platter back and forth Read the amount of backlash from the indica tor it should be between 0002 and 0006 Not applicable for the HRT210SHS Backlash In The System Connect the air to the table Index the table in the negative direct...

Page 54: ... remove the pipe plug from the lube fill port This is located on the top plate above the eye see Figure below Add Mobil SHC 630 oil until the proper level is reached Replace the fill port bolt and tighten Replace the oil every 2 years Oil Fill Port Eye Fill Port location for Rotary Table 8 5 CLEAN UP At the end of the workday or shift it is important to clean the rotary table The table should be f...

Page 55: ...54 96 5047 rev L June 2005 9 HRT ASSEMBLY DRAWINGS ...

Page 56: ...55 96 5047 rev L June 2005 Note All rotary tables use Polyurethane tubing for all air lines Specifications are 1 4 O D x 160 I D 95A Durometer ...

Page 57: ...10 32 X 3 8 SHCS 8 32 X 1 3 4 BHCS 20 X 1 2 WASHER 8 SEALING S S GASKET ENCLOSURE COVER GASKET MOTOR ENCLOSURE MSHCS M12 X 45 TOP COVER 1 40 1630 SHCS 20 X 5 16 24 40 1500 SHCS 5 16 18 X 1 4 45 0039 WASHER BRASS Ø 328 I D X Ø 562 O D 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 3 17 16 12 24 13 36 31 1 14 32 25 21 23 28 7 15 19 22 9 33...

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Page 60: ... 68 1 58 3105 PIPE PLUG 1 4 NPT 69 1 58 3618 1 4 STREET ELBOW 90DEG 70 1 58 3710 QUICK RELEASE FTG MALE 71 1 59 2055 3 8 STEEL BALLS 72 1 69 18101 MAGNET MICROSWITCH 73 4 45 1850 WASHER FENDER PLT 74 4 46 1625 NUT 20 HEX BLK 75 1 28 4278 SIGHT GLASS PRESS GUAGE 76 1 57 4279 GASKET SIGHT GLASS 77 1 58 2262 AIRMUFFLERCENTEREDBRO 78 2 58 16732 1 8X1 8 MALE HEX JOINT 79 4 57 0057 O RING 2 007 VITON 80...

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Page 65: ...P 28 1 28 1 58 3065 1 4 MUFFLER 1 4 MUFFLER 29 2 29 2 58 1677 ANCHOR 4FP ANCHOR 4FP BODY 30 1 30 1 58 3710 QUICK RELEASE FITTING QUICK RELEASE FITTING MALE RN MALE RN 31 1 31 1 58 1677 ANCHOR 4FP ANCHOR 4FP NUT 32 1 32 1 58 3680 STR 6 STR 6 TUBE 4 MP TUBE 4 MP 33 1 33 1 58 1676 CROSS 1 8 CROSS 1 8 34 1 34 1 58 1676 ANCHOR 4FP ANCHOR 4FP NUT 35 1 35 1 58 1677 ANCHOR FP ANCHOR FP NUT 36 1 36 1 58 30...

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