Hi all. Just got a new-to-me 2010 SMM2 with a side mount tool changer. First real CNC machine for me, and first Haas. This machine will only be used for prototyping, no production.
Machine just got set up and I'm starting to learn the controller but I've been running into a "low air pressure" alarm at some tool changes. I've searched this forum and others, watched the Haas videos on this alarm, and tried to do some debugging but I still have an issue (I think) so I'm wondering if anyone here has input.
I'm using a model 10020DCAD air compressor by California Air Tools. The compressor is rated:
- 2HP
- 5.2 CFM at 90psi (I wrote CAT and they verified it would put out 4CFM at 100psi, per my machine's spec)
- 10 gallon tank
California Air Tools - The Largest Manufacture of Ultra Quiet, Oil-Free & Lightweight Air Compressors - CAT-10020DC
The compressor is located in an attic space just outside of my shop and there's about 40~50' of 1/2" Rapid Air line running from the compressor to the machine. The max tank pressure is about ~130psi at shutoff, and the line pressure is regulated to 100psi. I've got the machine regulator set at 85~90psi per spec.
Here's the issue. When I run a simple program of a series of eight changes one after the other (at 25% rapid) the machine gets through about 5~6 changes but then errors out with the low pressure alarm. On the last tool change before failure, the arm moves to the spindle and you hear an air venting sound but it just stays open. It hangs there like that for ~10 seconds and then alarms out. Will attach some pics of the various connections and video link below (note pic shows tank pressure only at 70psi - was during initial charge; it's set to fill to 130psi). It seems to get through 2~3 changes at 50% rapid.
I originally had quick disconnects at the compressor and machine but I read those can be choke points so I've removed all of those. So, there is no restriction smaller than what's on the compressor or the machine regulator (I think both are 3/8"). Again, the air line itself is 1/2". I checked the filter in the machine's water trap to see if that was clogged but it appears to have been removed entirely (yes, I'll get a replacement) so obviously that's not impeding air flow. In the video you can see that the initial pressure is ~90psi, then during tool changes it's just over 80psi and drops momentarily to ~70 psi during the change. After a few tool changes I can hear the compressor kick on (kicks on ~90psi tank pressure) and that's when the tool change fails. So, it seems like the tool changes work when the machine is pulling from the compressor tank, but when the compressor is actively refilling the tool change fails.
So, my questions are
- Is this really an issue? I'm not sure when I'd ever do 8 tool changes in rapid succession but what worries me is that this is a sign of an air supply issue that may bite me in the middle of a program. Like, maybe I'm using the air gun to blow something off, which drains the tank to the recharge point and then, at that moment, if the machine calls a tool change it'll fail. Or, is something like this pretty unlikely?
- If this is something to address is my issue the compressor or could it be a machine issue (pressure switch or something)? If the problem is the compressor, do I need something that can actively pump more air (more HP), something with a bigger tank, or both?
- I've read about others adding a second "accumulator" tank at the machine to address low pressure issues. Do you think this would do it? And if so, where should that accumulator tank go - before or after the machine regulator? How big an accumulator would you recommend?
I thought I'd read of others with mini mills that were using even smaller compressors successfully, so I'm a bit surprised but this issue. Thanks for any input! Looking forward to making chips with this machine.
[video]https://miks.smugmug.com/Haas-stuff/Haas-SMM2-stuff/i-r6Lh3QP[/video]
Machine just got set up and I'm starting to learn the controller but I've been running into a "low air pressure" alarm at some tool changes. I've searched this forum and others, watched the Haas videos on this alarm, and tried to do some debugging but I still have an issue (I think) so I'm wondering if anyone here has input.
I'm using a model 10020DCAD air compressor by California Air Tools. The compressor is rated:
- 2HP
- 5.2 CFM at 90psi (I wrote CAT and they verified it would put out 4CFM at 100psi, per my machine's spec)
- 10 gallon tank
California Air Tools - The Largest Manufacture of Ultra Quiet, Oil-Free & Lightweight Air Compressors - CAT-10020DC
The compressor is located in an attic space just outside of my shop and there's about 40~50' of 1/2" Rapid Air line running from the compressor to the machine. The max tank pressure is about ~130psi at shutoff, and the line pressure is regulated to 100psi. I've got the machine regulator set at 85~90psi per spec.
Here's the issue. When I run a simple program of a series of eight changes one after the other (at 25% rapid) the machine gets through about 5~6 changes but then errors out with the low pressure alarm. On the last tool change before failure, the arm moves to the spindle and you hear an air venting sound but it just stays open. It hangs there like that for ~10 seconds and then alarms out. Will attach some pics of the various connections and video link below (note pic shows tank pressure only at 70psi - was during initial charge; it's set to fill to 130psi). It seems to get through 2~3 changes at 50% rapid.
I originally had quick disconnects at the compressor and machine but I read those can be choke points so I've removed all of those. So, there is no restriction smaller than what's on the compressor or the machine regulator (I think both are 3/8"). Again, the air line itself is 1/2". I checked the filter in the machine's water trap to see if that was clogged but it appears to have been removed entirely (yes, I'll get a replacement) so obviously that's not impeding air flow. In the video you can see that the initial pressure is ~90psi, then during tool changes it's just over 80psi and drops momentarily to ~70 psi during the change. After a few tool changes I can hear the compressor kick on (kicks on ~90psi tank pressure) and that's when the tool change fails. So, it seems like the tool changes work when the machine is pulling from the compressor tank, but when the compressor is actively refilling the tool change fails.
So, my questions are
- Is this really an issue? I'm not sure when I'd ever do 8 tool changes in rapid succession but what worries me is that this is a sign of an air supply issue that may bite me in the middle of a program. Like, maybe I'm using the air gun to blow something off, which drains the tank to the recharge point and then, at that moment, if the machine calls a tool change it'll fail. Or, is something like this pretty unlikely?
- If this is something to address is my issue the compressor or could it be a machine issue (pressure switch or something)? If the problem is the compressor, do I need something that can actively pump more air (more HP), something with a bigger tank, or both?
- I've read about others adding a second "accumulator" tank at the machine to address low pressure issues. Do you think this would do it? And if so, where should that accumulator tank go - before or after the machine regulator? How big an accumulator would you recommend?
I thought I'd read of others with mini mills that were using even smaller compressors successfully, so I'm a bit surprised but this issue. Thanks for any input! Looking forward to making chips with this machine.
[video]https://miks.smugmug.com/Haas-stuff/Haas-SMM2-stuff/i-r6Lh3QP[/video]