haas liquid grease - troubleshooting guide · grease manifold depending on the machine type and...

LAST UPDATED: 02/17/2020

Haas Liquid Grease - Troubleshooting Guide

HLG - Purge Clogged Lines - How To Video

Introduction

1. Axis-Lube Air Solenoid2. Metal Canister Grease Reservoir3. Plastic Canister Grease Reservoir4. Air Pressure Gauge5. Grease Manifold6. Ballnut7. Linear Guide Truck8. Axis Grease Manifold9. Orifice Fitting - grease flows in a helical

shape around a set screw and oversizedrilled thread. Do not remove the setscrew from the orifice fitting.

10. Pressure Sensor: 4 PSI switch, normallyopen (not shown, located behind (5) )


of 11 pages

http://www.haascnc.com/content/haascnc/en.html

System Operation Overview


of 11 pages


When a lubrication cycle is commanded, the solenoid applies air pressure to the grease reservoir for 3 seconds(specified in Parameter 2027), which forces the grease to move up the grease pick-up tube [5] and into the greasemanifold. The grease flows through the lubrication lines to the lubrication points where it gets pushed through therestrictors into the components that require the lubrication (ballscrew, linear guides pads, etc). Once the cycle ends,the pressure from the grease reservoir is vented to the atmosphere, the check valve [1] traps the pressurized greasein the manifold and the grease will start to flow through the snubber and the check valve [2] back to the greasecanister until the pressure in the manifold drops to 0 PSI.

During the lubrication cycle the control monitors the pressure in the lubrication manifold in order to detect a failureof the lubrication system.

When the solenoid is commanded to turn on, the control begins to monitor the status of the pressure switch [3]. Theswitch is expected to close within 3 seconds (specified in Parameter 1374) from the moment that the solenoid wascommanded ON. Once the pressure is detected it is expected to stay for at least 15 seconds (specified in Parameter1375). If all of the above statements were satisfied during the cycle then the lubrication cycle is considered successful.

If pressure in the system was not detected within 3 seconds (specified in the Parameter 1374) the control will stopmonitoring the pressure and display the “Low Lube” warning icon until the next lube cycle. If such a condition wasdetected for 5 consecutive lube cycles, then the control will generate the Alarm 2073 AXIS LUBRICATION PRESSURENOT DETECTED. The alarm will not be generated during a program execution, it will only be generated after theprogram execution ends or after pressing a [RESET] button.

If the pressure in the system drops below 4 PSI before 15 seconds (specified in Parameter 1375), the control willdisplay “Low Lube” warning icon until the next lube cycle. If such a condition is detected for the next 4 consecutivelube cycles (5 total cycles) the control will generate the Alarm 2075 AXIS LUBRICATION RESERVOIR IS EMPTY. Thealarm will not be generated during a program execution. It will be generated after the program execution ends orafter pressing a [RESET] button.

The Haas Liquid Grease (HLG) system utilizesshop air pressure to pressurize the HLG reservoirvia a 120VAC solenoid. Both components arelocated inside the air/lube cabinet

The lubrication cycle will be initiated when:

1. The axes have been in motion for thetime specified in Setting 277 (6 hours bydefault).

2. The machine has been idle for 24 hours(specified in Parameter 1401).

3. If the user presses [F2] while in theLUBE MAINTENANCE section of theDIAGNOSTIC display.

The HLG manifold has two internal check valves[1] and [2]; internal snubber before the checkvalve [2]; the pressure gauge and the 4 PSInormally open pressure switch [3]. There aremultiple lubrication lines coming out of thegrease manifold depending on the machine typeand configuration. The lubrication lines that arerouted above the air/grease pump will have acheck valve [4] at the grease manifold to preventthe grease from draining from the lines back tothe reservoir between the lubrication cycles.


of 11 pages


Symptom Table

Symptom Possible Cause Corrective Action

Alarm 2082 RESIDUALPRESSURE DETECTEDPRIOR TO AXISLUBRICATION CYCLE

Cloggedorifices, lubelines, ormanifolds.

Inspect all orifices, lube lines, manifolds for clogs/debris. Refer to HaasLiquid Grease - Purge Clogged Lines procedure.

The grease islow or empty.

Refill the grease. Refer to Axis Lubrication System - Grease Reservoir -Haas Liquid Grease - Refill procedure.Always make sure you replace the grease with Haas Liquid Greaseor an approved alternative. The emergency substitute can stillgenerate alarms.

There is nocheck valve onthe vertical axisgrease tube.

Make sure there is a check valve on the grease tube of the vertical axis ifthere was any air in the tube.

There is aproblem withthe greasemanifold.

Inspect the grease manifold.

There is aproblem withthe pressureswitch for theaxis grease.

Inspect the pressure switch for the axis grease and check the softwareversion.

Alarm 2073 AXISLUBRICATIONPRESSURE NOTDETECTED

Alarm 2075 AXISLUBRICATIONRESERVOIR EMPTY

There is aproblem withthe axis-lube airsolenoid.

Inspect the axis-lube air solenoid.

Grease canister is emptybut no alarms aregenerated and thepressure gauge is holdingpressure

Machine does not appearto be using grease asmuch as expected

Cloggedorifices, lubelines, ormanifolds.

Inspect all orifices, lube lines, manifolds for clogs/debris. Blow out withair, flush with Syngear 1150, replace parts that cannot be unclogged asnecessary. Upgrade the mesh filter in the pick-up tube from the previous40 mesh filter to the new 80 mesh filter.


of 11 pages

http://www.haascnc.com/content/haascnc/en/service/troubleshooting-and-how-to/how-to/haas-liquid-grease---purge-clogged-lines.html


http://www.haascnc.com/content/haascnc/en/service/troubleshooting-and-how-to/how-to/Minimum-Lubrication-Axis-Grease-Reservoir-Haas-Liquid-Grease-Refill-AD0121.html

http://www.haascnc.com/content/haascnc/en/service/troubleshooting-and-how-to/how-to/Minimum-Lubrication-Axis-Grease-Reservoir-Haas-Liquid-Grease-Refill-AD0121.html


Vertical Axis Check Valve

Corrective Action: Check for the presence of acheck valve on the grease tube of the verticalaxis.

If there is air in this tube or no grease, install thecheck valve (P/N: 58-2754) to this port on themanifold. Make sure the arrow is pointing downas shown in the image.

The machine does an Axis Lubrication cycle every24 hours of axis feed time. In some cases it ispossible that the machine can go a prolongedperiod of time without an Axis Lubrication cycle. Ifthis happens and the machine's Z-Axis greasetube does not have a check valve, the grease maycome back down the tube. When the machinedoes its next lubrication cycle, only air getspushed through the tube. The horizontal axes getlubricated correctly while the vertical axis onlygets air. Over time this damages the vertical axisballscrew, linear guides, and trucks.

The check valve on the grease tube of the verticalaxis prevents the grease from coming back downthe tube. Install a check valve if the machine doesnot have one.


of 11 pages


Grease Manifold

Corrective Action: Inspect the grease manifold.

Follow these steps to make sure the greasemanifold operates correctly.

Disconnect all of the axis-grease tubes [1] fromthe grease-pressure manifold and connect a plug[2] to each connector on the manifold.

Do the Axis Lubrication Test. If the Check-Lubeicon shows, the grease manifold is faulty. Replacethe grease manifold.

If the Check-Lube icon does not show followthese steps.

Disconnect the plug [1] from the grease manifoldand connect the axis-grease tube [2].

Do the Axis Lubrication Test. If the Check-Lubeicon shows, there is a leak in that axis. Examinethe entire length of tube and associated fittingsand manifolds and fix the leak.

Repeat this test with the other axes.


of 11 pages


Pressure Switch

Corrective Action: Inspect the pressureswitch for the axis grease.

Machines with the Next GenerationControl:

Check the software version on themachine. The machine must have softwareversion 100.16.000.1020 or higher. Updatethe machine software if necessary.

Do the Axis Lubrication Test andmonitor INPUT 68,LOW_AXIS_GREASE_PRESSURE in the I/Otab in Diagnostics.

Machines with the Classic Haas Control:

Do the Axis Lubrication Test and monitorthe Ax Grease Press. input in the I/O tab.

If the input changes from a 1 to a 0, thepressure switch operates correctly.

If it does not, disconnect the cables fromthe pressure switch and use a jumper toconnect them as shown. The pressureswitch is behind the grease manifold. If theinput changes from a 1 to a 0, the pressureswitch is faulty. Replace the pressureswitch.

Note: If the grease reservoir is empty orhas been recently refilled, warnings/alarms 2073 and 2075 can occur until theaxis lubrication system purges some airfrom the system.


of 11 pages


Axis-Lube Air Solenoid

Corrective Action: Inspect the axis-lube airsolenoid.

Do the Axis Lubrication Test and make sure thevoltage to the min. lube solenoid is 120 VAC.

Note: Do not measure the voltage with themin. lube grease solenoid disconnected from theconnector.

Refer to the I/O PCB - TROUBLESHOOTING GUIDE(CLASSIC HAAS CONTROL) to troubleshoot the I/OPCB.

Refer to the SOLENOID TROUBLESHOOTINGGUIDE to troubleshoot the solenoid.

If the solenoid is not activating whencommanded, check for:

• the connector being in the correctlocation.

• loose or broken wires.• air coming out of the solenoid without

the tube connected.• firm solenoid cable connection at the I/

O board.


of 11 pages

http://www.haascnc.com/content/haascnc/en/service/troubleshooting-and-how-to/troubleshooting/classic-haas-control---i-o-pcb---troubleshooting-guide.html

http://www.haascnc.com/content/haascnc/en/service/troubleshooting-and-how-to/troubleshooting/classic-haas-control---i-o-pcb---troubleshooting-guide.html

http://www.haascnc.com/content/haascnc/en/service/troubleshooting-and-how-to/troubleshooting/solenoid---troubleshooting-guide.html

http://www.haascnc.com/content/haascnc/en/service/troubleshooting-and-how-to/troubleshooting/solenoid---troubleshooting-guide.html


Clogging and Contamination


of 11 pages


Clearing A Clog• Inspect linear guides and ball screws for

fresh grease• If there doesn't appear to be grease,

move to the orifices• Ensure there is enough grease in the

canister to run a test• Disconnect the orifices from the linear

guide pads and manually &continuously fire the solenoid

• If no grease comes out of the orificethey are likely clogged

• Remove the orifices from the copperlines and inspect the copper lines forclogs

• Fire the solenoid again with the orificesremoved

• If no grease exits the lines there couldbe a clog in one of the manifolds

• Go to the lube cabinet and disconnectthe plastic tube for the axis you aretesting

• Blow pressurized shop air into the tubeand see if this will clear the clog

• If the clog does not clear refer to theHAAS LIQUID GREASE - PURGECLOGGED LINES procedure.


of 11 pages




Eliminating Contamination

• If you were able to clear a clog just byusing air pressure and did not replaceany copper lines or manifolds, you mayhave contamination in the lines thatcould cause a new clog in the future.

• Check for contamination in the pick-uptube within the canister assembly [1]

◦ Un-screw the grease canister[4]

◦ Remove the brass fitting [3]that holds the mesh screen [2]in the pick-up tube and cleanwith a rag and alcohol

◦ Dry with compressed air◦ REPLACE THE MESH SCREEN

WITH A NEW FINER 80 MESHSCREEN PROVIDED IN OURSERVICE KIT (P/N 58-1993A)[2]

◦ Re-install the fitting andscreen

• To ensure a new clog does not occur,flush the lines without the orificesinstalled with Syngear SH1150 oil(93-2626)

• Install new orifices• Re-fill can with Haas Liquid Grease or

Syngear SH1150 oil• Prime the lines and run as usual


of 11 pages

http://www.haascnc.com/content/haascnc/en/service/troubleshooting-and-how-to/how-to/haas-liquid-grease-filter-kit.html





haas liquid grease - troubleshooting guide · grease manifold depending on the machine type and...

Documents