ST-20-35, DS-30/35 - Parts Catcher - Installation

Applies to machines built from: 
March, 2012
AD0096 Rev C

ST-20-35, DS-30/35 - Parts Catcher - Introduction

This procedure tells you how to install a parts catcher on ST/DS series lathes. The images in this procedure show an ST-20.
note: The Parts Included list does not include all of the parts in the kit 93-2201, FIELD INSTALL PCAT ST20/30. The parts listed are only used in specific configurations. Refer to the Parts Included list to see which parts are necessary for each machine model.
Safety Notes
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.
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.

Prerequisites

 

Steps 6-8 tell you the locations of the electrical and pneumatic connections necessary to install the parts catcher. The steps are different for CALM (Consolidated Air/Lubrication Manifold) and Pre-CALM machines.

Machines with CALM have a cabinet at the rear of the machine. This is where the air connects to your machine. The cabinet contains the solenoids that operate all of the pneumatic devices.

Before CALM, the solenoids were near the pneumatic devices.

For CALM machines, do Step 6. Refer to Parts Included for CALM-only parts.

For Pre-CALM machines, do Steps 7-8. Refer to Parts Included for Pre-CALM-only parts.

 

If the lathe has a Servo Auto Door, you must remove the servo auto door drive assembly before you do this procedure. Refer to the Lathe Servo Auto Door Diagram for more information.

Machine Compatibility

Machine Models:

  1. ST-20/25/30/35
  2. DS-30/35
Do not do this procedure for ST-10/15/40/45/50/55 lathes.

Parts Included

KIT PN: 93-2201, FIELD INSTALL PCAT ST20/30. QTY: 1
CALM
30-11054
QTY: 1
SOLENOID, 4-WAY VALVE ASSEMBLY
Pre-CALM
30-8056
QTY: 1
SOLENOID, 5-WAY VALVE ASSEMBLY
Pre-CALM
33-1316
QTY: 1
CABLE, 310 PART CATCHER SOLENOID 10.0 FT
Pre-CALM
40-1644
QTY: 2
BOLT, SHCS 10-32 X 1 1/2
Pre-CALM
58-1238
QTY: 1
TUBE, 1/4 OD POLYETHYLENE (CLEAR) 6.0 FT
Pre-CALM
58-1256
9.0 ft.
TUBE, 1/4 OD POLYETHYLENE (CLEAR) 9.0 FT
CALM
58-1521
QTY: 1
FITTING, COMP3/8F NPT1/4M STR BRASS
CALM
58-2010
QTY: 20
HOSE, 5/32 OD NYLON
ST-20
25-11110A
QTY: 1
PANEL, DOOR LINER PARTS CATCHER (ST-20)
ST-30
25-11111A
QTY: 1
PANEL, DOOR LINER PARTS CATCHER (ST-30)

Tools Required

Red-I Grease

ST-20-35, DS-30/35 - Parts Catcher - Installation

Step 1

Push POWER OFF. Set the main circuit breaker to the OFF position. Lock the main circuit breaker. Use an approved lock with an approved safety tag.

Step 2

[1] Remove the door wiper and bumper assembly from the top of the bulkhead.

[2] Remove the door keeper from the inner side of the door.

[3] Remove the door roller guide from the top of the door.

[4] Lift the bottom of the door up from the bottom door track. Pull the door away and out of the machine.

Warning: The door is heavy. Get a second person to help you lift the door.

Step 3

Remove the liner [1] from the bottom of the door.

Use a heat gun on the adhesive until it becomes soft. Remove and discard the door filler [2] panel.

Apply adhesive sealant along each of the (4) edges [3] at the bottom of the door. Install the parts-catcher-compatible door liner [4].

Install the discharge guide [5]. Put the threaded posts through the holes in the door liner [4]. Attach the retention knobs [6] to the threaded posts.

Use (4) 1/4-20 x 1/2" button head cap screws (BHCS) [7] to attach the parts bin [8] to the front of the door.

Step 4

[1] Remove the left front panel.

[2] Remove the left side panel.

[3] Remove the rear panel.

Step 5

Remove the plug [1] from the bulkhead.

Install the air-cylinder assembly [2]. Put the pivot shaft through the hole in the bulkhead.

Attach the air cylinder assembly to the spindle head casting. Use (2) 5/16-18 x 3/4" socket head cap screws (SHCS) [3] and flat washers [4] in the top bracket. Use (2) 3/8-16 x 3-1/2" SHCS [5] in the bottom block.

Install the rubber seal [6] over the pivot shaft. Make sure the flat part of the seal is against the bulkhead sheet-metal.

Use snap rings [7] to attach the collar [8] over the pivot shaft.

Step 6

Install the parts catcher shaft [1] into the pivot shaft [2].

Attach the parts catcher [3] to the parts catcher shaft [4]. Use the (3) 1/4-20 x .5" button head cap screws (BHCS) [5] and flat washers [6].

Adjust the parts catcher until it is 0.50" (13 mm) from the chuck jaws. Tighten the shaft collar to 15 ft-lb (20 Nm).

Step 7

Do this step for CALM machines.

Install the air tubes [1 and 2] to the cylinder assembly.

Remove the plug [3] from the second-to-bottom hole in the air-distribution manifold. Install the compression fitting [4] into the second-to-bottom hole.

Install the cable ties to the solenoid. Put the yellow cable-tie on the A side [5] of the solenoid. Put the green cable-tie on the B side [6] of the solenoid.

Install the solenoid into the air distribution manifold. Tighten the nut on the compression fitting [4]. Make sure the solenoid aligns with the other solenoids.

Connect the other end of the air tube [1] from the top of the cylinder assembly to the B side [6] of the solenoid (green cable tie). Connect the other end of the air tube [2] from the bottom of the cylinder assembly to the A side [5] of the solenoid (yellow cable tie).

Connect the solenoid cable to the PARTS CATCHER connector.

Step 8

Do this step for Pre-CALM machines.

Use (2) 10-32 x 1-1/4" SHCS [1] to install the parts catcher solenoid [2] in an available set of pemnuts in the left rear panel.

note: The location of the pemnuts is different on some machines.

Put the signal cable for the parts catcher through the rear of the enclosure and connect it to the solenoid cable [3].

Install the cable through the bottom of the control cabinet. Connect the signal cable to P68 (parts catcher) on the I/O PCB.

Step 9

Do this step for Pre-CALM machines.

Make these connections:

  • Connect the 5/32" air tube from the bottom solenoid output fitting [1] for the solenoid output to the bottom fitting [2] for the air cyliner.
  • Connect the second 5/32" air tube from the top fitting [3] for the solenoid output to the top fitting [4] for the air cylinder.
  • Connect the 1/4" air tube to the 1/4" fitting on the solenoid [5]. Install the tube as shown [6].

Remove one of the plugs [7]. Install the fitting [9] and tube [8] to the manifold for the primary air regulator. Connect the 1/4" air tube [8] to the 90 degree fitting [9].

Step 10

Put the door into the lower track, then turn the door into position.

Warning: The door is heavy. Get a second person to help you lift the door.

Install the top roller guide. Refer to Step 1.

Set the main circuit breaker to the ON position. Push POWER ON.
Push PARAM/DGNOS one or two times to go to the diagnostics display. Go to the I/O tab.

Open and close the door while you monitor the value of Door Switch.

During the correct operation, Door Switch changes to 1 when the door is open and 0 when it is closed.

Step 11

Push POWER OFF. Set the main circuit breaker to the OFF position. Lock the main circuit breaker. Use an approved lock with an approved safety tag.

Install these components. Refer to the correct step:

  • Step 1: Install the door keeper to the inside of the door.
  • Step 1: Clean the felt parts of the door wiper and bumper assembly, then apply Red-I general-purpose grease. Install the inner door wiper and bumper assembly. Push the assembly up to seal the door wiper to the enclosure.
  • Step 2: Install the left front panel. Install the left panel. Install the rear panel.

Be aware: Many service and repair procedures should be done only by authorized personnel. The service technicians at your Haas Factory Outlet (HFO) have the training, experience, and are certified to do these tasks safely and correctly. You should not do machine repair or service procedures unless you are qualified and knowledgeable about the processes.

Danger: Some service procedures can be dangerous or life-threatening. DO NOT attempt a procedure that you do not completely understand. Contact your Haas Factory Outlet (HFO) and schedule a service technician visit if you have any doubts about doing a procedure.

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