Haas Technical Documentation Coolant Refill - Installation AD0171 Rev I Applies to machines built from: March, 2015 Scan code to get the latest version of this document Translation Available Coolant Refill - Introduction The Coolant Refill option features include: Automatically monitors the machine coolant level. Mixes shop water supply with coolant concentrate at user controlled ratios. Adds correctly mixed coolant at a specified concentration as necessary. Saves time by keeping the machine operator in front of the machine producing parts and not behind the machine mixing coolant. 1. Coolant Tank Mount 2. Stand Alone Mount Copyright 2018 by Haas Automation, Inc. No unauthorized reproduction Last Published On July 08, 2016 1/11
Caution: When you do maintenance or repair on CNC machines and their components, you must always follow basic safety precautions. This decreases the risk of injury and mechanical damage. Do these steps before you do work in the machine or in the control cabinet: Set the main circuit breaker to the [OFF] position. Use an approved lock with an approved safety tag. Always follow lock-out procedures in accordance to local government rules. After turning off the machine, wait at least 5 minutes before working in the control cabinet, to allow power to dissipate. Wait for the voltage indicator LED on the vector drive to go off completely. Always turn off the main air supply when you work on any part of the pneumatic system. Make sure to rest the spindle head on a block of wood when work is done on a vertical axis. This will prevent any unintended movement that could result in the axis falling. Never alter any safety circuits on the machine. Never change any parameter while in DEBUG mode (Classic Haas Control) and the servos ON. Put the machine in Emergency Stop mode to change any parameters. Never operate the machine in DEBUG mode (Classic Haas Control). You should not do machine repair or service procedures unless you are qualified and knowledgeable about the processes. Serious damage to the machine components can result in costly repairs. The service technicians at your Haas Factory Outlet (HFO) have the training and experience, and are certified to do these tasks safely and correctly. The repair and service work performed by your HFO is protected with a limited warranty. Danger: Some service procedures can be dangerous or life-threatening. DO NOT attempt a procedure that you do not fully understand. If you have any doubts about doing a procedure contact your Haas Factory Outlet (HFO) and schedule a service visit. Machine Compatibility The Coolant Refill is compatible with machines that have the following software version: Mill software 18.22A or higher. Lathe software 11.18A or higher. Next Generation Control software 100.16.000.1010 or higher. The CRO option is not compatible with EC-400/500 machines Copyright 2018 by Haas Automation, Inc. No unauthorized reproduction Last Published On July 08, 2016 2/11
Parts Included KIT PN: 93-2359, COOLANT REFILL FIELD INSTALL KIT. QTY: 1 [A] 30-11778 QTY: 1 COOLANT REFILL CRO [B] 59-1508 QTY: 1 HOSE, COMPRESION3/8" FEMALE X COMPRESION3/8" FEMALE [C] 58-1350 QTY: 1 NIPPLE, 90 DEGREES NPT3/8" MALE X NPT3/8" MALE GALVANIZED [D] 40-1981 QTY: 4 SCREW,FBHCS 1/4"-20 X 1/2" SELF- TAP W/LOCTITE [E] 58-1844 QTY: 1 FITTING, COMP 3/8 X COMP 3/8 BRASS STR [F] 58-1818 QTY: 1 HOSE, PVC BRAIDED 5/8" ID X 1.0"OD [G] 32-0411 QTY: 1 CABLE, COOLANT REFILL SOLENOID 21.50FT [H] 33-1240 QTY: 1 CRO NGC-CF ADAPTER CBL 6" [I] 57-0591 QTY: 1 FILTER SCREEN 1.0 OD GARDEN HOSE [J] 93-2360 QTY: 1 (OPTIONAL) COOLANT REFILL STAND [K] 33-0483 QTY: 1 CABLE, COOLANT REFIL ADAPTER FOR NGC LATHE Tools Required Refractometer Bucket - 2 Gallon Clamp Pliers (Stand Alone Mount Installation only) Copyright 2018 by Haas Automation, Inc. No unauthorized reproduction Last Published On July 08, 2016 3/11
Electrical Schematic Coolant Refill - Tank Handle - Installation This procedure tells you how to install the COOLANT REFILL [A] on a coolant tank with a handle. STEP 1 Install the COOLANT REFILL [A] onto the handle [1] of the coolant tank as shown. Put the HOSE [B] through the handle. Install the (2) SCREWS [D] as shown. Copyright 2018 by Haas Automation, Inc. No unauthorized reproduction Last Published On July 08, 2016 4/11
STEP 2 Connect the HOSE [B] to the water supply [1]. Make sure the screen filter [2] is installed in the hose fitting for the water supply. Note: The Cone Side Of The Screen Filter [2] Must Point Toward The Water Supply. Order additional supply HOSES [B] (comes with fitting [E]) from www.haasparts.com or from any hardware store - 3/8" appliance supply line. Start the water supply. Check for leaks. Note: The water supply must have a pressure of 40-100 psi (2.8-6.9 bar) to correctly produce the desired coolant concentration. STEP 3 Important: To prevent damage to the solenoid valve, make sure the screen filter is installed to clean the incoming water. Debris in the solenoid valve causes it to stay open. This causes inconsistent coolant mixing, and it could also overfill the coolant tank. Your water supply may require additional filtration. Add an aftermarket water filter [1] with a pressure regulator [2] if your water supply has high mineral content or other debris. The water filter and pressure regulator in the picture are not included. STEP 4 Install the NIPPLE [C] into the outlet port [1] as shown. Note: Move the coolant pumps so that the hole on the tank cover is under the NIPPLE [C]. Copyright 2018 by Haas Automation, Inc. No unauthorized reproduction Last Published On July 08, 2016 5/11
Coolant Refill - Stand Alone Mount - Installation This procedure tells you how to install the COOLANT REFILL [A] on a STAND ALONE MOUNT. This is for coolant tanks that do not have a handle or will not fit on the handle. Parts Included KIT PN: 93-2360, STAND ALONE MOUNT KIT. QTY: 1 [K] 59-1559 QTY: 1 COOLANT REFILL OPT STEP STOOL 24X13X13H [L] 40-0180 QTY: 2 SCREW, BHCS 1/4"-20 X 2 3/4" [M] 46-1750 QTY: 2 NUT, 1/4-20 WING [N] 57-22201 QTY: 2 ORING, 2-010 [O] 28-0269 QTY: 2 WASHER, NYLON 0.38"ID X 2.5"OD X0.215"THICK [P] 58-1842 QTY: 1 UOM: 2 ft HOSE, NYLON BRAIDED 1/2"ID [Q] 58-3048 QTY: 1 FITTING, HOSE BARB1/2 NPT3/8M STR BRASS [R] 59-1525 QTY: 1 HOSE CLAMP, EAR 15.7 MM - 18.5 MM [S] 28-0313 QTY: 1 FITTING, HOSE CAP 3/4"OD STEP 1 Put the ORINGS [N] over the SCREWS [L] as shown. Put the COOLANT REFILL [A] onto the STAND [K] so the SCREWS [L] pass through the slots [1] as shown. Install the WASHERS [O] and WING NUTS [M] to secure the COOLANT REFILL [A]. Copyright 2018 by Haas Automation, Inc. No unauthorized reproduction Last Published On July 08, 2016 6/11
STEP 2 Connect the HOSE [P]. Install the parts listed as shown onto the COOLANT REFILL [A]. HOSE BARB [Q] 1X HOSE [P] 1X CAP [S] 1X CLAMP [R] 1X STEP 3 Install the COOLANT REFILL [A] near the coolant tank and coolant connector bracket. Put the HOSE [P] in the coolant tank [2]. Caution: The HOSE [P] must be above the tank coolant mixture. Cut the HOSE [P] as necessary. Secure the hose. Coolant Refill - Electrical - Installation STEP 1 Do this step on a machine with the Classic Haas Control. Connect the ADAPTER CABLE [H] to the CABLE [G]. Connect the ADAPTER CABLE [H] to the P52 connector on the I/O PCB. Route the cable to the coolant connector bracket. Note: The coolant connector bracket is always located near the coolant tank. Find the location on the coolant connector bracket that has the label COOLANT REFILL [1]. Install the other end of the CABLE [G] at this location. Note: Drill a hole on the coolant connector bracket if it does not have this location. Copyright 2018 by Haas Automation, Inc. No unauthorized reproduction Last Published On July 08, 2016 7/11
STEP 2 Do this step on a machine with the Next Generation Control. Mill: Connect the CABLE [G] to the P36 connector on the I/O PCB. Lathe: Use the ADAPTER CABLE [K] on CABLE [G] and plug it into P16 and P17 on the I/O PCB. Route the cable to the coolant connector bracket. Note: The coolant connector bracket is always located near the coolant tank. Find the location on the coolant connector bracket that has the label COOLANT REFILL [1]. Install the other end of the CABLE [G] to this location. STEP 3 Connect the power cable [1] for the COOLANT REFILL [A] to the CABLE [G] in the coolant connector bracket.. Fill the COOLANT REFILL [A] with 5 gallons of coolant concentrate. Push [POWER ON]. STEP 4 Do this step on a machine with the Classic Haas Control. Change Setting 7 to OFF. Push [EMERGENCY STOP]. Set Parameter 1385 to 250. Change Setting 7 to ON. Push [CURNT COMDS]. Push [PAGE DOWN] until the COOLANT REFILL display shows. Push [F4] to set the Max gal. coolant added before repleshing concentrate. Push [Y]. Copyright 2018 by Haas Automation, Inc. No unauthorized reproduction Last Published On July 08, 2016 8/11
STEP 5 Do this step on a machine with the Next Generation Control. Push [DIAGNOSTIC]. Push the [RIGHT] CURSOR arrows to select the Maintenance tab [1]. Push the [DOWN] and [RIGHT] CURSOR arrows to select the Coolant Refill tab [2]. Push the [DOWN] CURSOR arrow to select Coolant Refill [3]. Push the [RIGHT] CURSOR arrow. Select ON. Push [ENTER]. Push [F4] [4] to set the Maximum Coolant From Remaining Concentrate. Push [Y]. Coolant Refill - Calibration STEP 1 Put an empty bucket [2] under the NIPPLE [C]. From the Coolant Refill page, [F3] starts the coolant flow and [F3] stops the coolant flow. Push [F3] to fill the bucket [1]. Push [F3] again to stop when coolant mixture fills the bucket. Measure the concentration of the coolant. Refer to the Maintaining Your Coolant Mixture video. Go to http://diy.haascnc.com for more information. Copyright 2018 by Haas Automation, Inc. No unauthorized reproduction Last Published On July 08, 2016 9/11
STEP 2 Do this step on a machine with the Classic Haas Control. If the measured concentration is lower than the value for the Coolant Concentration Percent [1], increase the value for the Coolant Concentration Adjust [2]. If the concentration is higher than the value for the Coolant Concentration Percent, decrease the value for the Coolant Concentration Adjust. Do steps 1 and 2 until the concentration is the same as the value for Coolant Concentration Percent. STEP 3 Do this step on a machine with the Next Generation Control. If the measured concentration is lower than the value for the Coolant Concentrate [1], increase the value for the Concentrate Adjustment [2]. If the concentration is higher than the value for the Coolant Concentrate, decrease the value for the Concentrate Adjustment. Do steps 1 and 2 until the concentration is the same as the value for Coolant Concentrate. STEP 4 Remove the bucket from the coolant tank. Put the HOSE [F] over the NIPPLE [C]. Caution: The HOSE [F] must be above the tank coolant mixture [1]. Cut the HOSE [F] as necessary. For maintenance and operation instructions refer to the Coolant Refill - Operation instructions. Go to http://diy.haascnc.com for more information. ASCO Air Purge Solenoid - Maintenance If your valve does not function correctly, it is most likely because debris got inside the ASCO air purge solenoid. This procedure tells you how to clean an ASCO brand air purge solenoid. Copyright 2018 by Haas Automation, Inc. No unauthorized reproduction Last Published On July 08, 2016 10/11
Push [POWER OFF]. Close the primary air valve. This stops the air supply to the machine. Remove the red cap [1]. Push the solenoid coil assembly [2] down to compress the spring inside. Remove the specification plate [3]. Remove the split spring [4] and valve subassembly [5] from the coil assembly [2]. Disassembly the valve subassembly [5]. Clean the parts with compressed air. Be sure to remove all debris from inside the valve. Apply a thin coat of high-grade silicone grease to the body gasket [6]. Assemble the components in the opposite order they were removed. Open the primary air valve. Make sure there are no leaks. Copyright 2018 by Haas Automation, Inc. No unauthorized reproduction Last Published On July 08, 2016 11/11