2.2 Lathe - APL

This document explains how to assemble and install the Haas Automatic Parts Loader (APL) for a Lathe.

Machine Requirements:

• NGC/Software Version 100.19.000.1100 or greater
• ST-10/15/20/25 Reboot Sheet Metal (Flat Face)
• Autodoor
• RJH-T
• I/O PCB Hinge Door. 93-1000297 I/O DOOR ASSY HINGED
• Check the Layout Drawing document for Machine Specifications such as Turret and Y-Axis requirements 

NOTE: Before installing the APL make sure that the lathe is leveled and the distance from the floor to the casting is 3 inches.

Remove the auto door cover [1].

Use the provided drill guide [1] to drill the mounting holes for the DOOR FULLY OPEN status switch.

Align the right most hole on top of the drill guide that is marked with one slot [2] with the autodoor cover mounting hole to the left of the auto door motor and secure it with the BHCS.

ST-10/15:

• Drill the two Ø 3/16" (4.7mm) mounting holes through the drill guide holes that are marked with one slots [3].

ST-20/25:

• Drill the two Ø 3/16" (4.7mm) mounting holes through the drill guide holes that are marked with the slots on both sides [4].

Using the provided self tapping screws, install the DOOR FULLY OPEN switch assembly [5] and the DOOR FULLY OPEN trip flag [6].

ST-10/15:

• Align the right most drill guide hole [1] that marked with three slots next to it with the existing pemnut on top of the roof panel and secure it with the BHCS.
• Drill the four Ø 11/32" (8.7mm) mounting holes through the drill guide holes [2] that are also marked with the three slots.

ST-20/25:

• Place the drill guide up against the cable cover [3] flange as shown in the picture.
• Drill the four Ø 11/32" (8.7mm) mounting holes through the drill guide holes [4] that are marked with the three slots.

Install the support pillar [6] onto the machine (with the beam mounting flange [5] facing the front of the machine) using the BHCS and the nuts on the underside of the roof panel. 

For machines with a Light Curtain and Small Tooling Tray:

Remove the tooling tray bracket that is attached to the bottom of the pendant.

ST-10/15:

• Place the drill guide [1] against the front panel, 8 inches (203mm) away from the right corner of the enclosure.

ST-20/25:

• Place the drill guide [1] against the front panel, 17.75 inches (450mm) away from the right corner of the enclosure.

Drill the four Ø 3/16" (4.7mm) mounting holes through the drill guide holes [2] that are marked with two slots.

Remove the drill guide and attach the tooling tray [3] to the front panel using four self tapping screws [4].

For machines with a Light Curtain and Large Tooling Tray and Tooling Tray Bracket Adapter.

Remove the tooling tray bracket that is attached to the bottom of the pendant.

Place the Tooling Tray Bracket Adapter 10.25"[1] above the door rail cover and 10.5"[2] from the door opening.

Drill the four Ø3/16" (4.7mm) mounting holes through the Bracket Adapter holes and attach the Tooling Tray Bracket Adapter to the front panel using four self tapping screws.

Mount the Tooling Tray to the Tooling Tray Bracket Adapter with button head cap screws.

Turn the air supply OFF

Inside the CALM cabinet, remove the NPT plug [1] from one of the CALM manifold ports

Install the push to connect fitting [2]

This is where the air line from the APL solenoid rack will be routed to the CALM cabinet

• Remove table shipping brackets [1]
• Remove AW axis shipping bracket [2]

To set the AU axis square to the AW axis. The bridge may be shimmed with washers[1]. These will be placed between the bridge and the shipping pad when at its shipping position.

When installing an APL look carefully for these washers [1] as you unbolt and raise the bridge. If you find washers [1] then move them to the upper pad on the same column when reinstalling the bridge.

• Move the beam from its shipping position to the top of the columns [3] using the lift fixture [1]
• Leave the lifting brackets on so you can level the beam later after you power the APL and level the table

Remove the AU axis shipping brackets [1]  that are located on the back of the AW axis carriage.

Remove the AU axis servo motor cover to gain access to the W axis shipping brackets [3].

Remove the AW axis shipping brackets [3].

Reinstall the AU axis servo motor cover [2].

Air supply should be connected, if it is turn it off.

Remove the shipping brackets [1] from the rotator.

Reinstall the bolts.

 NOTE: The gripper assembly will rotate in position as soon as the air supply is turned back ON.

Route the AU and AW axes cables with the air lines down through the pillar [1].

Connect the air lines to the solenoids in accordance with the decal.

Install the provided conduit tube over the air lines to protect it from damage.

Connect each solenoid cable to the corresponding connection on the manifold bracket under the solenoids.

The cable carrier bracket [1] and its hardware can be found in a bag zip tied to the APL.

Install the cable carrier bracket [1] as shown with the provided hardware.

Verify that the bracket [2] is sitting on top of the APL edge [3] as shown, this will help ensure the cable carrier does not get caught on the edge.

Brake loose the bolts [1] that secure the right side hard stop block [2].

Position the hard stop block [2] 0.75 inches (19mm) away from the edge of the rack gear assembly [3].

Torque the hard stop mounting bolts to 25 ft-lbs (33.9 Nm).

Make sure that the front edge of the APL and the front of the machine are parallel. [1]

Use the provided measurements between spindle motor cover [2] and the right APL pillar [3] to place the APL on the left side of the machine.

NOTE: Dimensions are in inches.

Install the AU, AV and AW axes amplifiers in the respect with the decal labels on the amplifier fan bracket .

NOTE: AU axis amplifier [1] shown on the picture.

NOTE: Skip this step if the machine has Live Tooling, Y axis or the Sub-Spindle option. Machines that were built with the  Live Tooling, Y axis and the Sub-Spindle  will have an additional ammplifier bank to the left of the Vector Drive and  will come with the dual lead DC BUS cable installed from the factory.

If the machine was built with the single lead DC buss cable (33-04901B) you will need to replace it with the dual lead DC BUS cable (33-0052C) provided with the kit.

Before working on this cable, power the machine OFF and allow the Vector Drive capacitors to discharge until the red light [1] on the Vector Drive is OFF.

Remove the old cable that supplies DC voltage from the Vector Drive terminals 2 and 3 to the amplifiers.

Install the new dual lead DC BUS cable (33-0052C) as follows:

• Connect the end with the ring terminals [2] to the terminal 2 and 3 on the Vector Drive:
  • The white lead that is labeled TB2 "+" to the terminal 2
  • The black lead that is labeled TB3 "-" to the terminal 3
• Route the longer cable through the fan bracket under the amplifiers and connect it to the "+" H.V. and the "-" H.V. terminals on the left most servo amplifier [3] as labeled.
• Connect the remaining cable to the "+" H.V. and the "-" H.V. terminals on the right most servo amplifier [4] as labeled.

Route the AU, AV and AW axes power cables through the opening on the bottom of the control cabinet.

Connect the power cable leads to the high voltage terminals:

• red to RED [1]
• white to WHT [2]
• black to BLK [3]

 NOTE: The AV axis power cable leads are labeled PH-A, PH-B and PH-C due to a different color scheme. Connect as follows:

• PH-A to RED
• PH-B to WHT
• PH-C to BLK

Connect the ground wire [4] to the bracket for the amplifier fan.

Find the high-voltage terminals [5] on the nearest amplifier.

Find the high-voltage terminals [7] on the amplifier.

Install the jumpers [6] from the installation kit between these terminals.

Connect the black wire to -H.V. Connect the red wire to +H.V.

Connect the current command cables to the connector near the top of the each amplifier [1].

Connect the other ends of the cables to the AMPLIFIER COMMAND outputs on the NGC PCB [2] as follows:

• AU axis to the output 13.
• AV axis to the output 15.
• AW axis to the output 16.

Route the U, V and W axes encoder cables through the opening on the bottom of the control cabinet and connect them to the ENCODER inputs on the NGC PCB [3] as follows:

• AU axis to the input 13.
• AV axis to the input 15.
• AW axis to the input 16.

Route the AW axis brake cable into the control cabinet and connect it to P3/4/5 on the SIO.

Connect the DOOR FULLY OPEN switch as labeled:

• COM to the top terminal [1].
• NO to the middle terminal [2].

Route the cable into the control cabinet as shown on the picture.

 NOTE: Make sure to install the provided magnetic clip [3] and cable clamps [4] to keep the cable clear of the moving autodoor motor [5].

Connect the other end of the cable to the SIO P27 RRI Door Open input. 

Install the autodoor cover.

Install the SMTC PCB [1] onto the SIO door using the standoffs [2] and the screws [3].

Interconnect the SMTC PCB cables as shown on the diagram.

If the machine has a Smart CAN auto door, plug cable 33-1518 into P15 on the SIO board. 

Attach the APL E-Stop as shown and route the cable along the bottom so that it groups up with the other cables that route to the control cabinet.

Connect the APL E-Stop button wire to TB1 on the I/O Board.

Remove jumper from JP1 on the I/O PCB.

Change factory setting: 1278 [1278]: Robot Ready E-Stop Enabled to True

Level the APL base with the bubble level on top of the APL table.

Use the leveling screws at the bottom of the APL base to level the APL front to back [1] and side to side [2].

When done with leveling make sure that all four leveling screws make contact with the floor.

Place the bubble level [1] on top of the horizontal beam.

Loosen the bolts that secure the beam to the pillars.

Lift or lower the right side [2] of the horizontal beam until it leveled.

Tighten the bolts that secure the horizontal beam to the pillars.

Remove the lifting brackets. 

 NOTE: For Machines with light curtain perform this section. 

Place the light curtain mount [1] flush with the right door opening edge [2].

Mark and drill seven Ø 3/16" (4.7mm) mounting holes [3].

Attach the light curtain mount to the machine using the self tapping screws. 

NOTE: You can route the light curtain cable at this point to avoid reinstalling the self tapping screws. 

Assemble the light curtain mounting brackets as shown on the picture [1].

 NOTE: The light curtain kit contains the transmitter and the receiver. You can identify these by the sticker on the side of the housing. It is labeled "RECEIVER" [2] and "TRANSMITTER" [3]. 

When installing the light curtains make sure that the end with the cable connection is on the bottom.

Install the light curtain receiver [4] on the lathe side.

Install the light curtain transmitter [5] on the APL side.

Make sure that the transmitter and the receiver are pointed at each other before tightening the mounting bolts.

Route the Transmitter cable [6] and the Receiver [7] cable into the control cabinet as shown.

Use the provided velcro patch to attach the 24VDC power supply to the right wall inside the control cabinet.

Interconnect the light curtain cables as shown on the diagram.

If plugs P5/6/7 are not available on the PSUP PCB. Remove a fan power cable from P5/6/7 and plug in 33-7180 CBL FAN ADAPTER TO DUAL FAN. Plug in the fan power cable and light curtain power cable into 33-7180.

 Caution: The AW-Axis brake cable is disconnected during shipping as a safety precaution.  If the APL is not enabled in the control, the AW axis can drop on the table if powered on.  Make sure the APL is enabled before plugging in the brake cable.

Connect the AW Axis brake cable.

Power Up the machine with the E-STOP depressed.

Before releasing the E-STOP, navigate to the CURRENT COMMANDS screen and make sure that the AUTOMATIC PART LOADER tab is visible. 

Navigate to the ALARMS AND MESSAGES and make sure that there is no active alarms associated with the AU, AV and AW axes.

 NOTE:  If the APL is left disabled, and the E-STOP is released, the AW axis will fall.

Release the E-STOP and zero return the machine.

Set the GRID offsets for the AU, AV and the AW axes. Refer to the Axis Grid Offset - NGC.

• Set Grid Offsets for AU, AV, and AW axes:
• Zero Return AU, AV, and AW
• Go to the Diagnostics Tab> Parameters > Factory Settings
  • Press AU + F4
  • Press AV + F4
  • Press AW + F4

• Set Tool Change Offset
• Put small puck template on table.
• Place 2” diameter puck in front left position on template
• Align Gripper 1 in AU and AV to the puck
• Set Tool Change Offset
• Diagnostics -> Parameter -> Factory
  • AU + F2
  • AV + F2

With an indicator base clamped to the gripper [1] Jog the AU axis and measure if the dowel pins [2] on the APL table is inline with the AU axis motion. NTE 0.060" (1.5mm).

If your machine does not have the new linear rail kit please complete the retrofit procedure per APL Linear Rail Retrofit Kit Installation

Clamp the piece of round stock [1] in the APL gripper 1.

Note: Using machined jaws will increase accuracy

Jog AU and AW axes to place the gripper with the round stock in front of the spindle chuck [2].

Move the APL base [3] front to back with a pallet jack until the piece of round stock [1] align with the spindle.

 NOTE: When moving the APL base, make sure that the APL beam support [4] pillar moves the same amount and the front of the APL stays parallel to the front of the machine.

Jog the AU axis and place the stock into the chuck.

Open and close the chuck and check for deflection of the AW arm

Move the table back forth, and the AW axis up and down until there is minimal movement when the chuck clamps on the stock.

Check Gripper number 2 in the same way.

Once the APL grippers aligned with the spindle, tighten the bolts that secure the APL beam support to the roof panel [4].

Fine front-to-back adjustment of the gripper.

Remove the bolts that keep the rotator extrusion cover [1] in place.

Remove the rotator extrusion cover.

Break loose two bolts [2] that secure the rotator [3] to the bracket. This will allow you to move the gripper assembly front to back.

Once the gripper assembly is in desired position, torque the two mounting bolts [2] to 60 ft-lbs (81 Nm) and install the rotator extrusion cover.

Torque the four SHCS [4] to 20 ft-lbs (27 Nm) 

Set rotator limits. 

The rotator clockwise (CW) and counterclockwise (CCW) limits are set with the stop screws on top of the rotator unit. There is a stop screw for the CW limit [1] and the CCW limit [2]. 

To adjust the CW limit:

• Break loose the jam nut [3].
• Rotate the gripper assembly clockwise until it stops against the stop screw.
• Turn the CW stop screw in or out to manipulate the CW limit position.
• Once the rotator is in desired CW limit position, hold the CW stop screw with the wrench and tighten the jam nut [3].

Use the CCW stop screw [2] to set the CCW limit.

Use a magnetic base and indicator on the table to indicate the side of the gripper plate while moving the AW axis up and down.  Adjust rotator limits until this is relatively parallel with the AW axis.

• The APL spring pusher is made with a shank to fit either a 25mm or 1” tool holder
• This tool must take up a toolholder on the turret
• If the machine is a ST-10/15 you will need two empty toolholders to allow enough space for the gripper
• Program the following steps to the beginning of any Lathe APL program to make sure the part is properly seated into the chuck:
  • Locate the spring pusher in front of the part
  • Move the Z axis to compress the spring about 0.50 inches or 12.7 mm
  • Open the chuck with a dwell of one second
  • Close the chuck with a dwell of one second
  • Retract the turret to the safest position possible

• Use a pen [1] to put a mark on the floor at the location of each foot.
•  Note: Turn the feet to the sides of the APL to avoid a tripping hazard.
• Drill [2]  Ø 0.50" (13 mm) hole in each mark.
• Drill the hole to a depth of 2.0" (51 mm).

• Put the foot [3] over the hole [4].
• Put an anchor [2] into the hole.
• Use a hammer [1] to tap the anchor.
• Tap the anchor until it is at the bottom of the hole.
• Put a washer [6] and a nut [5] on the bolt.
• Torque each nut to 55 ft-lb (75 Nm).

 Warning: If you turn Setting 372 to None, the AW - axis will drop if not supported or disconnected. Do one of the following:

• Jog to a safe location
• Unplug all APL cables BERFORE releasing E-STOP
• Unplug AW brake BEFORE releasing E-STOP

To disable the APL to run the machine in stand-alone mode. Press [SETTING]. Change the following Settings:

• 372 Parts Loader Type to 0: None
• 376 Light Curtain Enabled to Off