Haas 5c Indexer Manual
1 Haas Technical Publications ManualArchiveCoverPage Rev A June 6, 2013 HAAS SERVICE AND OPERATOR MANUAL ARCHIVE HA5C Series Operators Manual J RevJ English 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. 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. 2 Back Ha5c-Series 1.
INTRODUCTION TO THE HAAS HA5C 1.1 DESCRIPTION The HAAS HA5C digital indexing head is a fully automatic, programmable, rotary positioning device. The unit is made up of two parts: the mechanical head that holds the workpiece and the electronic unit that controls the rotation of the spindle. Positioning of the workpiece is accomplished by programming the angular movements into the memory of the control and then pushing the CYCLE START switch on the front panel. The unit was specifically designed for rapid positioning of small parts in secondary operations such as milling, drilling, and tapping. The device is especially suited to automatic machines such as NC mills and automatic production machines. The control can be remotely activated by your equipment and does not require human assistance, resulting in fully automatic operation.
Furthermore, one unit can be used on several different machines, thereby eliminating the need for multiple units. SPINDLE Positioning of the spindle is accomplished through a specially ground and heat treated, self-locking worm and worm gear. The worm is connected to a servo motor. You are no longer restricted to a 24 or 48 position indexing plate. Odd number bolt circles and uneven hole spacing are easily handled with simple programming. CONTROL The control can be programmed to rotate the spindle in either direction (clockwise or counter-clockwise) with step sizes from.001 to degrees.
Aug 13, 2015 - I have an old Haas Model 5C Indexer. I did all 93 steps. And it appears to have finished exactly where I started! I can't believe.
There can be 99 different steps stored in memory. Additionally, each step can be repeated (or looped) up to 999 times. The memory in the controller is non-volatile so that your program is retained even when the power is turned off. You may store seven separate programs (Prog 0- Prog 6). The spindle can be programmed to rotate at a feed rate of.001 degree per second up to 270 degrees per second (for rapid positioning).
A ZERO RETURN function, which returns the spindle to its original starting position, can be either programmed or manually activated. The optional RS-232 interface can be used to upload, download, enter data, read position, start, and stop motor operation.
1.2 SELF L OCKING - DEFINITION Good machining practice dictates rigidly held parts and setups. The Model HA5C is engineered to provide this in three ways. Locking is provided by the close tolerance worm and worm gear, the large bearing area between spindle and body, and the servo motor. The worm gear is considered to be self locking because while the worm can drive the worm gear the reverse is not true. The principle here is the same as if you tried to turn the handle on your milling machine by trying to push the table. The locking motion is further guaranteed by the servo motor that prevents any small movements of the worm by being electronically stopped. Even the heaviest of cuts that would destroy the indexing head would not be able to cause the spindle to rotate.
1 3 1.3 MACHINABLE P ART S IZE The Model HA5C was designed for indexing small parts that normally fit in standard 5C collets, step collets, and small fixtures. Parts two inches in diameter and under made of common alloys can be machined easily without undue concern. Larger parts may require special fixtures or chucks and consideration should be given to the weight of the part and fixture and the rate of material removal. The HA5C can be used on milling machines, CNC machines, EDM s, broaching machines, and just about anything that needs to index a part. It can be used in both the vertical and horizontal positions. It can be used as a slave to your CNC machine or the master control unit in dedicated drilling operations.
Generally you will have to use your own judgment what size part you can successfully machine on the HA5C. We have seen enormous parts machined but they also required a reduction in metal removal rates to accomplish it. If you are familiar with a typical indexing head, here is a good rule of thumb to use: if you can do the job on the manual head, the HA5C can do it without a problem. 1.4 FEATURES RIGID DESIGN Large bearing surfaces support heavy cutting forces on large or small parts. HARDENED AND GROUND SPINDLE For higher accuracy. ALUMINUM BRONZE WORM GEAR For longer life.
HARDENED AND GROUND WORM Made from 8620 Chromium-Nickel-Molybdenum steel. AC SERVO DRIVE Closed loop, 3 / 4 HP AC servo motor brushless, (or a 1 / 2 HP DC servo motor brush).
VARIABLE FEED RATES Variable from.001 deg./sec. To 270 deg./sec. RESOLUTION Standard resolution of.001 degrees. PROGRAMMING Absolute or incremental programming. Up to 99 different steps can be stored in memory, and each step can be looped 999 more times. The ease and flexibility of programming the Haas control enables a single unit to serve you in many ways.
SIMPLE EDITING Edit a program by simply writing over existing steps, or inserting or deleting a line (or several lines) between steps, with automatic program line re-numbering. SUBROUTINES Allows you to repeat sequences up to 999 times saving programming time and memory space. AUTOMATIC CIRCLE DIVISION You can program a step that automatically divides a circle into any number of equal parts (between 2 and 999). PROGRAMMABLE PARAMETERS You can alter many of the basic features by performing your own basic programming. 2 4 PROGRAM STORAGE Store and recall from up to seven different programs. MEMORY A non-volatile memory retains your program even when power is turned off.
It also remembers the current spindle position and step number. INTERFACING Most CNC mills can be interfaced with the HA5C quickly and easily by using a spare M function which provides a switch-closer as a signal between your mill and the HA5C. EMERGENCY STOP/FEED-HOLD You can use the EMERGENCY STOP to feed-hold spindle movement without losing position on restart.
ZERO RETURN An automatic home position returns the spindle to its original starting position from any point. LINEAR & SPIRAL MILLING For semi fourth-axis capability. FAST SET-UPS All connectors are quick-disconnect, ensuring fast and easy set-ups. STANDARD POWER Operates on 115V AC 15 Amps. RS-232 INTERFACE For computer control of sending and receiving programs. 12-MONTH WARRANTY Against any defects in materials or workmanship. REPLACEABLE COLLET KEY A broken collet key can be easily replaced through the access hole in the front of the casting.
3 5 1.5 SPECIFICATIONS SPINDLE Height Torque Runout Backlash Speed ± from spindle center to base 60ft.-lb. Brushless, 20 ft-lb. HA5CSB (45 ft.-lb., brush) T.I.R. 40 arc seconds Feed rate selectable from.001deg/sec to 330 deg/sec.
For HA5CSB.001 deg/sec to 800 deg/sec. (.001 deg/sec to 270 deg/sec, brush type) Nose Thread 2 3/16-10 Collets INDEXING Indexing Accuracy Repeatability Resolution MOTOR Horsepower Gear Ratio Standard 5C +/- 30 seconds in one direction Within 10 arc seconds degrees 3 / 4 HP AC servo motor brushless ( 1 / 2 H.P. DC servo motor, brush) 60:1 self locking worm gear (33:1 HA5CSB) OPERATING SPECIFICATIONS Power Requirements 120V AC +/ amps Oil Requirements Mobil SHC 630 (synthetic) GENERAL R EQUIREMENTS Operating Temperature Range 41 F to 104 F (5 to 40 C) Storage Temperature Range -4 F to 158 F (-20 to 70 C) Ambient Humidity: 20% 95% relative humidity, non-condensing Altitude: ft. 4 6 1.6 MACHINE D IMENSIONS HA5C- Single Spindle SPINDLE NOSE DIMENSIONS 5 7 HA5C2,3,and 4 6 8 1.7 OPTIONAL S ERVO C ONTROL B RACKET Designed to work specifically with the Haas line of CNC mills. This bracket keeps the Servo Control in easy reach of the operator.
Allowing for easy joint programming between the Haas mill and Rotary table. Contact your Haas dealer to order.
(Haas part number: SCPB) Installed Servo Control Bracket 1.8 HAAS T AILSTOCKS 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 ( ) for pneumatic tailstock s operating pressure. When using Servo 5c Indexers, Haas Automation recommends using LIVE CENTERS ONLY!
Haas 5c Indexer Control Box Manual
SETTING UP THE INDEXING HEAD AND CONTROL 2.1 GENERAL S ETUP 1. Fill out your warranty card and mail it in. (Very Important). Place the indexer on your machine. Route the cable from the head such that it avoids tool changers and table edges. Cable slack must be provided for your machine s movements. If the cable is cut, the motor will fail prematurely; replace a damaged cable immediately.
Secure your HA5C Indexer to your machine s T-Slot table as shown below: 1/2-13UNC Flange Nuts (2) 1/2-Inch Washers (2) 1/2-13UNC T-Nuts (2) 1/2-13UNC Studs (2) 3. Place the indexer in an area free from chips and coolant where air can circulate freely. Do not let chips pile up over the motor enclosure, as this would prevent proper cooling. CAUTION: Never connect or disconnect this cable with the power on; instant failure will result. Connect the indexer to run as a full-fourth or semi-fourth axis. See the following figure. For fullfourth axis, the indexer is connected directly to the Haas mill control at the connector labeled 4th axis, and is the desired connection.
Note: The HAAS mill must have the 4th axis option to run full-fourth axis and must be configured as brush or brushless axis to be compatible with your indexer. Brushless axis uses two cables and two connectors at the 4th axis port.
Brush axis uses one cable and one connection at the 4th axis port on the control. 8 10 SEMI-FOURTH AXIS OPERATION 4TH AXIS TO MILL RS232 PORT OR INTERFACE CABLE PORT SERVO CONTROLLER FULL-FOURTH AXIS OPERATION 4TH AXIS TO MILL 4TH AXIS PORT 5.
Route the cable over the back of the mill sheetmetal and install the cable clamp. The bottom plate of the clamp assembly must be removed and discarded before installing the clamp to the mill. Assemble the clamp to the mill as shown Shipping Plate 6. If adding an indexer to a Haas mill the settings must be set for the specific unit. Refer to the instructions in the mill manual or call the Haas service department. Semi-Fourth Axis: Secure the servo control in servo pendant bracket (Haas part number SCPB) as seen at the end of the introduction section. Do not cover any surface of the control as it will quickly overheat.
Do not place the unit on top of other hot electronic controls. Connect the large black cable from the indexer to the controller. CAUTION: Never connect or disconnect this cable with the power on!
Instant failure will result! Semi-Fourth Axis: Connect the AC line cord to a 120V AC grounded receptacle.
Haas Indexing Head
The cord is a three-wire ground type, and the ground must be connected. Power is 120VAC.
The power service must supply a minimum of 15 amps continuously. Conduit wire must be 12 gauge or larger and fused for at least 20 amps.
If an extension cord is to be used, use a three-wire ground type and the ground line must be connected. Avoid outlets that have large electric motors connected to them. Use only heavy duty 12 gauge extension cords capable of 20 amp load. Do not exceed a length of 30 feet. Semi-Fourth Axis: Connect the remote interface lines. See Interfacing to Other equipment section.
Check the oil level. If it is low, add oil. Use MOBIL SHC-630 synthetic gear oil (Viscosity Grade ISO 220). For the HRT210SHS use Mobil SHC-626 synthetic gear oil (Viscosity Grade ISO 68).
Save the packing materials in case you need to ship the unit. At the end of the workday or shift, it is important to clean the rotary indexer. The indexer should be free of any chips or grime. Clean with a chip brush and apply a coat of a rust preventative.
Do not use air gun around front or rear seals. Chips may damage seal if blown in with an airgun. Turn on the mill (and servo control, if applicable) and home the indexer by pressing the zero return button. All Haas indexers home in the clockwise direction as viewed from the spindle. 10 12 2.2 INTERFACING T O O THER E QUIPMENT Interfacing is an unfriendly word that inspires fear in most non-electrical people. In reality, you are interfacing objects all the time. Hooking up a stereo, computer, or VCR requires many connections, or interfaces.
Plugging a lamp into the wall and turning the switch on is really interfacing a 100 watt incandescent lamp up to a 15 Megawatt generating plant. While there are hundreds of connections between your lamp and the power company, it is really a simple process. The HAAS controls are just as simple. The control can be installed to communicate with your mill two different ways: RS-232 Interface or CNC Interface Cable. These connections are detailed in the following sections.
Semi-Fourth Axis Operation The HAAS control has two signals: one input and one output. Your equipment tells the HAAS control to index (an input), it indexes, and then sends a signal back to your equipment that the index (an output) has been completed. These signals are simply switch closures, or in mechanical terms, relays. A switch (relay) is closed inside your machine that tells us to index, we index and then close a switch (relay) inside our control to tell your machine that we are done.
This interface requires four wires; two for each signal. They are from the remote input on the back of the HAAS control and from your equipment or CNC (Computer Numerically Controlled) machine. 2.3 THE R ELAY IN THE HAAS CONTROL The relay inside the Model HA5C has a maximum rating of 2 amps at 30 volts D.C./ 120V AC.
It is programmed as either a normally closed or a normally open relay, closed during cycle or after cycle (see Parameters). It is intended to drive other logic or small relays. It will not drive other motors, magnetic starters, or loads exceeding 100 watts. If you use the feedback relay to drive another D.C. Relay (or any inductive load), remember 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 1 and 2. With the control off, the reading should be infinite. If a lower resistance is measured, the contact points have failed and the relay must be replaced. Radio Shack sells a relay that can be used as a replacement (Cat.
# ) but it should only be replaced by a qualified technician. Automatic Drilling Applications A common application for the HA5C head is in dedicated drilling operations where the controller is the master unit. This utilizes the remote input. The cycle start lines are connected to a micro switch that closes when the drilling head retracts and the finish lines are connected to the start lines of the drilling head.
Here the operator pushes the CYCLE START on the controller to start the cycle. The HA5C indexes, and when in position, the feedback relay closure is used to trigger the drilling head to drill the hole. The micro switch mounted on the top of the drilling head will then trigger the HA5C to index when the drilling unit retracts. This results in an endless loop of the HA5C triggering the drill unit and the drill unit triggering the HA5C. In order to break the cycle, a G code of 97 is inserted in the last step of the HA5C control.
The G code 97 is a No Op code that tells the control not to send the feedback relay closure so the cycle can be stopped. 11 13 2.4 THE R EMOTE I NPUT The CNC Interface Cable provides a basic method of communication between a non-haas mill and Haas Servo Control/Rotary Head. Since most CNC machine tools are equipped with spare M-codes, Semi-fourth axis machining can be achieved by connecting one end of the CNC Interface Cable to any one of these spare relays (switches), and the other to a Haas Servo Control unit.
Indexing commands for the rotary unit are stored only in the Servo Control s memory, and each pulse of the host machine s relay triggers the control to index to its next programmed position. After finishing the index, the Servo Control signals that it has finished and is ready for the next pulse. A remote socket is provided on the back panel of the control unit. The remote input consists of a cycle start line and a cycle finish line. To connect to the remote, you will need a connector, supplied by us or 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 (Amphenol part number is T ).
The The Haas Automation part number is for the panel receptacle in the control box is (Amphenol part number T ). Cycle Start Figure 4 shows the connector as viewed while looking at the rear panel of the control unit.
When pins 3 and 4 are connected together, the control will index the head one cycle or step. Pins 3 and 4 must be connected for a minimum of 0.1 seconds.
To index again, pins 3 and 4 must be opened for a minimum of 0.1 seconds. Under no circumstances should power be applied to pins 3 and 4. A relay closure is the safest way to interface the control to your equipment. The following explains the electrical details of how a cycle start is implemented: Pin 3 supplies a positive 12 volts at 20 milliamps and pin 4 is connected to the diode of an opto-isolator that grounds to chassis. Connecting pin 3 to pin 4 causes a current to flow through the diode of the opto-isolator triggering the control.
If the control is used around high frequency equipment such as electric welders or induction heaters, you will need to use shielded wire to prevent false triggering by radiated EMI (electromagnetic interference). The shield should be attached to earth ground.
12 14 Cycle Finish Figure 4. A typical CNC interface. If your application is in an automatic machine, such as an CNC mill, the feedback lines (pins one and two) should be utilized. Pins one and two are connected to the contacts of a relay inside the control and have no polarity or power on them. They are used to synchronize the automatic equipment with the controller. The feedback lines provide a switch closure through a relay inside the Haas control box to let the machine know when the HA5C 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 longer than it takes the control to index the head. The relay will trigger for all cycle start closures except a nooperation code 15 2.5 REMOTE O PERATION W ITH M ANUAL E QUIPMENT The remote connection is used when you wish to index the unit other than by the START switch on the front panel. This frees the operator from having to touch the control to start indexing.
For example, using our optional remote quill switch (Part# RQS) for Bridgeport milling machines, every time the quill handle is retracted it touches a micro switch on the clamp, the indexing head will rotate automatically, thereby eliminating the need to remove your hand from the quill. Production is increased dramatically using this time saving procedure. Using a magnetic base, an aluminum bracket, and a micro-switch you can get the unit to index almost anywhere you wish. Use the switch to index the unit when you are milling. Every time the table comes back to a certain position, a simple bolt on the table can close the switch, thereby indexing the unit. Refer to Figure 4.
By simply connecting pins 3 and 4 together, the control will index. Be careful that you do not apply power to these lines (3 and 4 only). You do not need to hook up the feedback pins 1 and 2 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, and are coded as follows: 1 = red 3 = black 2 = green 4 = white 2.6 REMOTE O PERATION W ITH CNC EQUIPMENT NOTE: All Haas controls come standard with 1 CNC interface cable. Additional CNC interface cables can be ordered (Haas P/N CNC). CNC machines have Miscellaneous functions called M functions. These control external switches (relays) that turn things on or off (i.e., spindle, coolant, etc.,). Most CNC controls provide some degree of access to the M functions with most late model machines providing several spare relays just for this purpose. Our remote cycle start line is hooked into the normally open contacts of a spare M function relay.
The remote feedback lines are then connected to the M function finished line (MFIN) which is an input to the CNC control to cancel the M function and proceed onto the next block of information. On late model CNC machines, interfacing the unit is relatively simple if you know where to make the connections. Your machinery dealer is the best source for this information.
14 16 2.7 THE RS-232 INTERFACE There are two connectors used for the RS-232 interface. They are both DB-25 connectors, one male and one female. Multiple controllers are connected by daisy-chaining the boxes. The cable from the computer connects to the female connector. Another cable can connect the first box to the second by connecting the male connector of the first box to the female connector of the second. This can be repeated for up to nine controllers.
Since the RS-232 connector on the back of most PC's is a male DB-9, only one type of cable is required for connection to the controller, or between controllers. This cable must be a DB-25 male on one end and a DB-9 female on the other. Pins 1, 2, 3, 4, 5, 6, 7, 8, and 9 must be wired one-to-one. It cannot be a Null Modem cable, which inverts pins 2 and 3. To check cable type, use a cable tester to check that communication lines are correct. The controller is DCE (Data Communication Equipment).
This means that it transmits on the RXD line (pin 3) and receives on the TXD line (pin 2). The RS-232 connector on most PC's is wired for DTE (Data Terminal Equipment), so no special jumpers should be required. The Down Line (RS-232 out) DB-25 connector is only used when more than one controller is to be used.
Haas 5c Indexer Manual
The first controller's down (RS-232 out) line connector goes to the second controller's up (RS-232 in) line connector, etc. The RS-232 interface sends and receives seven data bits, even parity, and two stop bits. The data rate can be between 110 and bits per second. When using RS-232, it is important to make sure that Parameters 26 (RS-232 Speed) and 33 (X-on/X-off Enable) are set to the same value in the controller and PC. Parameter 12 must be set to 3 in order to coordinate mill and controller motion. This will prevent Aux. Axis position mismatch alarm (355) when in handle jog mode.
If Parameter 33 is set to on, the controller uses X-on and X-off codes to control reception, so be sure your computer is able to process these. It also drops CTS (pin 5) at the same time it sends X-off and restores CTS when is sends X-on.
The RTS line (pin 4) can be used to start/stop transmission by the controller or the X-on/Xoff codes can be used. The DSR line (pin 6) is activated at power-on of the controller and the DTR line (pin 20 from the PC) is not used. If Parameter 33 is 0, the CTS line can still be used to synchronize output. When more than one HAAS controller is daisy-chained, data sent from the PC goes to all of the controllers at the same time. That is why an axis selection code (Parameter 21) is required.
Data sent back to the PC from the controllers is OR ed together so that, if more than one box is transmitting, the data will be garbled. Because 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. 15 17 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 controller must also be in RUN mode to respond to the interface. Since the controller powers-on in RUN mode, remote unattended operation is thus possible. Commands are sent to the controller in ASCII code and terminated with a carriage return (CR). A line feed (LF) is optional and is ignored. Responses that occur for some commands are also in ASCII and terminated by a CR and LF. All but one command must be preceded by the axis select code (U, V, W, X, Y, Z) and this is replaced by an x in the following list.
Only the B command does not require the select code as it can be used to activate all axes simultaneously.