HPC-300/1K - How it Works and Troubleshooting Guide (Classic Haas Control)

How it Works

The High-Pressure Coolant (HPC-300/1K) with Auto-Clean filter uses a gear-driven pump that is mounted in the coolant tank to move pressurized coolant through the cutting tool. The coolant then returns to the coolant tank. The coolant continuously cycles through the coolant system.

  1. HPC Auto-Clean Coolant Pump: Pressurizes and pumps the coolant from the coolant tank through the HPC system. The auto-clean pneumatic cylinder eliminates the need for an inline filter. When the pump stops, the pneumatic cylinder activates, cleaning the filter and preventing chips from entering the HPC system. A vacuum sensor detects if the filter is clogged.
  2. Check Valve: A one-way valve that lets coolant flow through in one direction. It does not let the coolant flow back down into the tank when the pump is powered off.
  3. HPC Pressure Sensor: On newer models, the HPC pressure sensor connects to the check valve inside the rear enclosure panel, behind the coolant connector bracket. On some models, the HPC pressure sensor is located behind the tool changer.

HPC-300/1K Pump Diagram

Use M88 to activate HPC, and M89 to deactivate it.

Symptom Possible Cause(s) Corrective Action(s) Section

Alarm 151 HPC LOW PRESSURE

A short circuit in the pump motor or pump motor cable caused the circuit breaker to trip on the motor drive PCB.

Check the circuit breaker on the motor drive PCB.

Check for shorts in the HPC pump cable and on the motor leads.

1
Incorrect power phasing - the pump motor is running backward. Check the phasing indicators and change the incoming power cables, if necessary. 2
Damage to the motor shaft key, shaft collar, or wear in other parts of the pump head assembly Inspect the motor shaft / pump head assembly. 3
The HPC pressure sensor is defective. Some coolant flow may occur if this is the case. Troubleshoot the coolant pressure sensor. 4

Low coolant flow, no alarm.

Low coolant flow, the pump cavitates (cavitation sounds like heavy grit in the pump head, or a suction sound) or is otherwise noisy

The HPC pump filter or intake strainer is clogged. Clean the filters. Remove chips from the coolant system. 5
The Auto-clean coolant pump filter (if equipped) is clogged. Test and troubleshoot the Auto-clean pump filter. 6
The pressure relief spring in the pump head is damaged. Inspect the pressure relief spring. 7
Damage to the motor shaft key, shaft collar, or wear in other parts of the pump head assembly. Inspect the motor shaft / pump head assembly. 3

Section 1

Symptoms: Alarm 151 HPC LOW PRESSURE

Possible Cause: A short circuit in the pump motor or pump motor cable caused the circuit breaker to trip on the motor drive PCB located on the door of the I/O PCB.

Corrective Action:

1. On the motor drive PCB:
note: The PCB [2] on the HPC-1K has a fan. The HPC-300 PCB [1] does not.

Make sure that the circuit breaker is in the ON position.

If the circuit breaker has tripped, turn it back on. Test the HPC system. If the circuit breaker trips again, check for a short circuit in the HPC pump.

note: You must use water-based coolants with the HPC-1K system. Thicker fluids like cutting oil will overload the pump and trip the breaker.

2. Check the pump for shorts:

Measure the (3) leads [1] to ground [2] on the HPC power cable. If all leads test open to ground, the pump and cabledo not have a short.

If the motor lead test indicates a short, disconnect the cable from the motor. Measure the (3) cable leads [3] to ground. If any lead tests short, the pump is at fault. If none of the leads test short, the cable is at fault.

3. If all leads test OK:

Check the HPC motor for binding that could cause an over amperage condition.

Section 2

Symptoms: Alarm 151 HPC LOW PRESSURE

Possible Cause: Incorrect power phasing - the pump motor is running backward.

Corrective Action:

The power supply PCB has a phase detect with neon indicators on the top center portion of the board. Make sure that the electrical power is phased correctly:

  • Green Light: The incoming power is phased correctly.
  • Orange Light: The incoming power is incorrectly phased.
  • Both Lights: A phase is missing (there is a loose cable in the system).

If the electrical power is phased incorrectly:

Set the main circuit breaker to the OFF position.

Lock the main circuit breaker. Use an approved lock with an approved safety tag.

Swap the #74 and #75 incoming power cables at the main transformer.

Section 3

Symptom: Alarm 151 HPC LOW PRESSURE. Low coolant flow, no alarm. Low coolant flow, the pump cavitates (cavitation sounds like heavy grit in the pump head, or a suction sound) or is otherwise noisy.

Possible Cause: Damage to the motor shaft key, shaft collar, or wear in other parts of the pump head assembly.

Cutting abrasive materials causes premature wear on the coolant system, resulting in reduced pressure. Use additional filtration when you cut abrasive materials

Corrective Action:

Remove the pump from the tank. Rotate the pump motor fan [1] by hand clockwise. Make sure that the pump coupling [2] also turns.

If it does not turn, separate the pump from the motor. Check for a damaged key on the motor shaft.

Section 4

Symptoms: Alarm 151 HPC LOW PRESSURE

Possible Cause: The coolant pressure sensor does not work. Some coolant flow may occur if this is the case.

Corrective Action:

Press PARAM/DGNOS. Go to the I/O diagnostics page.

Short the sensor connector leads. The HPC Low Pressure bit state should change from 1 to 0.

If it does not change, then the cable or the I/O PCB is damaged. Measure for resistance at both ends of the cable. If the cable has resistance, go to diy.haascnc.com to troubleshoot the I/O PCB.

note: Depending on the year the machine was made, the HPC pressure sensor connects to the check valve inside the rear enclosure panel, behind the coolant connector bracket. On some models, the HPC pressure sensor is located behind the tool changer.

Replace the pressure switch if it is defective: If the bit changes, use an inline pressure gauge to verify the pressure is correct. If the pressure is over 40 psi, replace the switch.

Section 5

Symptoms: Low coolant flow, no alarm. Low coolant flow, the pump cavitates (cavitation sounds like heavy grit in the pump head, or a suction sound) or is otherwise noisy.

Possible Causes: The coolant filter or intake strainer is clogged. The filters are clogged.

Corrective Action:

  • Machines made before March, 2015: Remove the filter retaining ring [1] and filter screen [2] from the bottom of the TSC pump assembly. Clean the filter screen [2] with warm, soapy water and a soft brush.
  • Machines made after March, 2015: Remove the filter tray from the bottom of the TSC assembly. Remove the tray lid [3] from the filter [4]. Use a brush to clean the filter.

Remove the chip basket and polyester mesh strainer (if the strainer is installed) from the chip tray. Remove all chips from the chip strainer basket.

To replace the mesh strainer [5], pull it tightly over the top of the chip basket [7]. Make sure that the elastic band [6] goes over the edge of the chip basket [7].

Section 6

Symptoms: Low coolant flow, no alarm. Low coolant flow, the pump cavitates (cavitation sounds like heavy grit in the pump head, or a suction sound) or is otherwise noisy.

Possible Cause: The Auto-clean coolant pump filter (if equipped) is clogged.

Corrective Action:

Make sure that the auto-clean plunger activates when the HPC pump shuts off. If it does not shut off, go to diy.haascnc.com to troubleshoot the solenoid. Test the HPC purge solenoid.

If the solenoid operates and it outputs air, check the air tube for kinks or breaks.

Section 7

Symptoms: Low coolant flow, no alarm. Low coolant flow, the pump cavitates (cavitation sounds like heavy grit in the pump head, or a suction sound) or is otherwise noisy.

Possible Cause: The pressure relief spring is damaged.

Corrective Action:

  1. Remove the HPC pump from the tank.
  2. Remove the pressure relief plugs.
  3. Inspect the spring and valve pin. Replace the spring if it is broken and the pin if it is pitted or worn.

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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