Program Stops in HAAS and Doesnt Throw Alarm

[AustinMLab]

Program keeps freezing, ive had this issue with other programs before with fusion. Worked fine all day yesterday, started program up this morning and my faceing op freezes on the 6th part, no alarm. The only way ive been able to fix it in the past is by changing lead in position or in this case flipping the pass direction 180 and then it will run fine. Ive never had it do this with any of my mastercam programs but most of my large production fusion programs will do this at random. Machine is a 2011 HAAS VF3ss. Attached is a video of the issue and the program. Thank you to whoever takes the time to read this. Also apologies with the video cutting at the end, youll have to pause it to read the code, only way i could get the video short enough to attach it.

[AustinMLab]

Its now also doing it (same program) on my g154 p1 boring operation. Same thing just hits that line of code and freezes, no alarms.

[seth.madore]

So you're saying that you can run 5 parts of the same program and on the 6th part your machine will just stop?

[AustinMLab]

No its all depending on the operation and its all random, it just stops. Seems to be something with lead in lead out locations and whether there is a lead in radius or no lead in radius, or lead out radius. It also can be fine one run then a few runs later it randomly freezes.

[AustinMLab]

Every time ive had this happen the fixes include removing lead in and out radiuses and changing lead in location. Can be different jobs completely, this is just the job im running today thats giving me issues.

[seth.madore]

If it was doing it all the time at the same spot, I'd be looking at the output code. As it's doing it randomly, I'd be looking at something in the control itself. I appreciate that your MasterCAM code doesn't result in this gremlin..

[AustinMLab]

Yeah i was hoping mentiong mastercam would narrow the problem down, seeing as my machine plays nice with that post as opposed to fusions. Ill post to this thread in the future if i figure out where this gremlin is hiding as it seems to found a particularly good hiding spot. I want to figure this out because its killing my ability to quickly get lights out production programs onto my machine as i have to babysit it for a few days until it starts causing the issue.

[dwilliamsFM6K4]

Have you tried loading the program into memory and not running from USB?

[AustinMLab]

I have not, thats good idea. Ill give that a shot

[AustinMLab]

Not enough disk space on the machine memory 😕

[seth.madore]

For how many parts? Try one or two and see if the problem persists.

You may need to go with sub programs of one part, or write up an increment macro.

[dwilliamsFM6K4]

I mean that's probably the issue then, the machine has to cache the program even if its on a USB etc also would explain some of the intermittence

Can you drip feed it? That's what I do with my super old HAAS

[AustinMLab]

That all makes sense, thank you for the insight, I'll give it a shot and
let you know how it goes.

[davidM8MP]

I’m having a similar issue when it gets to the lead out on a 2d chamfer at the end. It just stops feeding and won’t go to the next line. No alarm, coolant and spindle continue not perpetuity. VF3, this is our first program with fusion, all others have been mastercam with no issue. 

[programming2C78B]

I've had this too. Just power cycle the machine. 

[john_jeffriesLPQEA]

Anyone ever figure this out?   I've got this problem now as well and a power cycle didn't help.

[heather_tracy]

Hi @john_jeffriesLPQEA,

I wanted to check in and see if you still needed assistance, or if you found a solution to your question already? Let us know if you need further assistance by providing an update or if you have found a solution, please share it with the community so other members who may have the same question could learn from your experience.

All the best,

Heather | Community Manager

[zeljnik2013]

First, Happy New Year.

I am user of several type HAAS machine and i will try to help from my expirience. I checked file and i can not see any problem in programing, but i will write few stuff : 

1. Older HAAS machines have problem with some "complex" strategies (for example, HSM/HSR SolidCAM, 2d/3d pocket HSMWorks) - problem is lead in or lead out. 10 years ago, i tested SolidCAM HSM/HSR strategies on 2000. year HAAS VF2. Machine gave me an error after 5 minutes of running and i did not understand what was happening. Later i realized where the problem was. 

2. I solved problem on HSMWorks 2d/3d pocket strategies on very easy way, picture under ... 

Lead in and lead out radiuses HAVE/MUST TO BE set on zero! In oposite, You have error on machine! 

3. Next, where i can see the problem - You can not use new postprocessor from Fusion librery on 14 years old machine. I have 2021 HAAS ST20Y machine and i am using postprocessor from 2018 - new pp gives me an alarm . I can not turn the thread, not even chance. I tried everything, but without success.

4. Please try with my postprocessor, i am working on all VF machines with this pp. I made few changes in pp, but do not ask me what, i do not know - a lot of time has passed. And, please, be careful.

p.s. Prt scr is from HSMWorks, but it is the same as the Fusion CAM modul. Same option(s) we have in Fusion.

Big greetings for all CNC operators/programmers and good luck in 2026.

[heather_tracy]

Hello, @john_jeffriesLPQEA,

Did the information provided by @zeljnik2013 help you and answer your question?

If yes, please click on the "Accept Solution" button on the post(s) that solved your problem. This will assist other community users in finding and benefiting from this information.

If not, please do not hesitate to give an update in this thread so all community members receive an update on the progression of your question, and can suggest next steps that may be helpful for you to achieve what you're looking for.

All the best,

Heather | Community Manager

[johnJBLZB]

I will try this next time we run the machine with a Fusion program.  

Thanks for the info.

JJ