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UMC -500 - Pallet Pool Installation

3.3 UMC PP - 16/20 Station - Version 2

Last updated: 01/19/2023

UMC PP - 16/20 Station - Version 2 - Installation

Pallet Pool Installation Video

Introduction

The following procedure will show you how to install a 16/20 staion Pallet Pool on the following machines:

  • UMC-500/SS

The Next Generation software on the machine must be version 100.20.000.1110 or higher.

The Pallet Pool option is currently not field installable.

Important: To ensure that the Pallet Pool does not become mis-aligned, it is recommended that the machine and Pallet Pool be anchored. Refer to the following link: Anchoring Instructions.

The Pallet Pool option has a room for a total of 17 pallets that can be installed on a UMC-500 with the Pallet Pool option.

The Pallet Pool has 2 servo axes. The PR axis rotates the Pallet Pool ram and the PS axis extends and retracts the Pallet Pool ram to load/unload the pallets.

The UMC-500 must be level before the Pallet Pool can be installed. Refer to the UMC-500 Installation procedure.

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.

Caution: When you handle a PCB, you must wear an Electrostatic Discharge (ESD) strap.

To level the machine without the Pallet Pool connected to the machine, do the following: 

Make sure that there is a shorting block [1] installed on the top two pins of the P12 connector on the I/O PCB 

Make sure there is a jumper (P/N 33-0527) [2] connected to I/O PCB at P14.
 Note: These jumpers are needed to operate the machine without the Pallet Pool.

Disable the pallet pool, change setting 382 Disable Pallet Changer to Pallet Pool.


Note: The above step will disabled the Pallet Pool to allow you to zero return the machine so it can be leveled.

Refer to the UMC-500 Installation procedure.

Leveling Screws Hardware

Note: The washers [1] and nuts [2] are installed during shipping and should be saved for installation and not be discarded.

Note: The washer orientation [3] is important.  The conical part of the washer should be against the casting,  see illustration.

Mating the Pallet Pool

   

1

Remove the loading station door blocking bolt [1].

Make sure to raise all of the pallet shelf supporting screws [2] before placing the pallet pool on the floor. 

2

Remove cross bracing [1] from the pallet pool before mating the pallet pool.

3

Install the drip tray [1] on the bottom of the auto window, this component should slide right on the window. 

4

Install the Pallet Pool alignment blocks onto the host machine's base.

Note: The alignment block with the radius [2] must be installed towards the back of the UMC and the alignment block with the flat side [1] must be installed towards the front of the machine. Use the three SHCS 3/8-16 X 2 and the one SHCS 3/8-16 X 1 3/8 [4].

Install the alignment bars [3] onto the pallet pool base.

 NOTE: Use the CABCOOL as a height reference in relation to the pallet pool enclosure opening.

Move the pallet pool assembly so the alignment arms are 3 - 6” (76 - 152 mm) away from the alignment blocks. 

Install the leveling pads under the pallet pool and lower the pallet pool. 

5

Use a pallet jack or forklift to move the pallet pool close to the machine.

A decal has been placed on the rear of the machine to indicate where the pallet forks [2] should lift the machine from [1].

NOTE: Have the pallet jack pick up the pallet pool from the opposite side of where the slide window would be.

6

Install the turnbuckles [3] with the provided hardware (SHCS, washer, and bushings [1]) onto the alignment arms [2] and the base casting [4].

NOTE: The side of the turnbuckle with the two bushings should be installed on the side of the pallet pool.

Evenly tighten the turnbuckles until the alignment arms are almost tight against the alignment bars, STOP once the alignment bars areapproximately 1-2" away from the alignment blocks.

Adjust the height of the pallet pool so that the height of the alignment bars are to the center of the blocks before tightening the turnbuckles flush to the alignment blocks. Raise or lower the pallet pool leveling screws evenly when doing so.

Continue to evenly tighten the turnbuckles until the alignment arms are tight against the alignment blocks.

Once the alignment bars and blocks are evenly flush to each other loosen up the turn buckles.

7

Make sure the main circuit breaker is in the [OFF] position and wait until the Vector Drive High-Voltage light turns off.

 Note: The PR (Pallet Rotate) and PS (Pallet Slide) amps are already installed at the factory.

Knock out the pre-cut access panel [1].

Route the pallet pool cables [2] into the control cabinet as shown in the illustration.

Connect the PR motor encoder cable to Maincon PCB channel 15
Connect the PS motor encoder cable to Maincon PCB channel 16.

Connect the PR motor power cable to the amplifier labeled PR. Install the ferrite filter bead on the motor power cable.

Connect the PS motor power cable to the amplifier labeled PS. Install the ferrite filter bead on the motor power cable.

8

Connect the air gun hose [1] to the air line under the pallet pool [2]. 

Route the air hose from the pallet pool to line coming from the the lube cabinet [3].

Connect the air line from the pallet pool to the to the T-fitting [4] connecting the machine air gun line to the lube cabinet.

Follow the line from the lube cabinet [5] to help locate the T-fitting.

9

Connect the hydrualic lines to the bulkhead. The pallet clamp [1] is marked with a green zip tie and pallet unclamp [2] is marked with a red zip tie. The hydraulic lines should run through the conduit neatly.

NOTE: The bulkhead uses quick disconnects  for the hydraulic hoses. The clamp side has the male side quick disconnect [3] and the unclamp has the female side [4], this is to avoid installing the hoses backwards..

Route the HPU oil level sensor cable 32-0423 from the HPU to the connector bracket [5].

10

Connect HPU UP/ DWN SOL [1] to P38.

Connect HPU THRML PROBE [3] to P46.

Connect HPU PALLET CLMP SOL  [4] to P35.

Connect HPU PRESSURE SNSR [5] to P48.

Remove the jumper connection from the P14 [6] connector on the I/O PCB.

Connect PP STATUS SWITCHES  [7] to P14

Remove the shorting block from the P12 [8] connector on the I/O PCB

Connect PALLET CHNGR STATION [9] to P12

Connect PALLET ALRAM cable [10]  to P50.

Make sure all the Pallet Pool status bracket connectors are plugged into the correct location.

 NOTE: Store the Pallet Pool jumpers in a safe location, these will be used by the service personnel to move or service the machine.

11

Route the HPU PUMP PWR cable  to P1 on the TMD card located on the I/O PCB hinged door. 

The rest of the components in this image are already connected but this diagram can be used as reference. 

12

Remove the bolts [2] that attach the RAM forks to the shipping bracket [1].

13

Set the main circuit breaker to the ON position.

Push [POWER ON].

Zero Return all the Axis'

Do the following to enable the pallet pool option on a UMC-500.  

Important:  You will need to do this step if you perform a option 5 clean install option on a UMC-500 with a pallet pool.

Set setting 382 Disable Pallet Changer to None.

Find the Haas Pallet Pool Parameters decal on the E-Stop on the Pallet Pool machine.  Write down the values.

Use the USB Service key to go into Service Mode.

Press [DIAGNOSTIC] Go to the PARAMETERS> Factory setting tab.

Set the following factory settings values:

  1. 2128 [:] Pallet Pool Type = HPU Lift
  2. 40.011 (HPU 1 Type ) = On Demand
  3. 15.019 [:] PR-Axis Invisible = False
  4. 16.019 [:] PS-Axis Invisible = False
  5. 15.004 [:] PR-Axis Disable = False
  6. 16.004 [16:3] PS-Axis Disabled = False
  7. Turn TMD card on
Set the Grid and TC offsets for PR and PS axis
 
  1. 15.078 PR-Axis Tool Change Offset = Use the decal value.
  2. 15.140 PR-Axis Grid Offset = Use the decal value.
  3. 16.078 PS-Axis Tool Change Offset = Use the decal value.
  4. 16.140 PS-Axis Grid Offset = Use the decal value.
  5. Zero Return after the grid offset is adjusted

14

Remove the shipping brackets [1] by removing the hardware [2] attaching the shipping bracket to the loading station .

Base Level Pallet Pool

1

Verify all outer supports legs are NOT touching the floor.

Make sure the pallet pool sit on 3 points, the leveling foot that is not touching the puck is the one closest to the machine control cabinet [1].

2

Move the ram to its home position if it is not already, place the bubble level on ram and rough level with respect to X & Y. 

NOTE: Rough level by adjusting the 3 leveling feet without adjusting the 4th in the air.

Assigning Missing Pallets on Scheduler

1

It is a possible to enter a condition where the shelves in the pallet scheduling page are not assigned [1]. This will not allow the PR and PS to zero return or recover the machine. 

This section will explain how to assign the missing shelves, if your machine is not in this condition please skip to the next section. 

First, press [CURRENT COMMANDS] and navigate to the Pallet Schedule Table tab.

2

Press [EMERGENCY STOP] [1] and highlight the shelf tab on pallet number one.

With [EMERGENCY STOP] pressed, type the letter A and press [ENTER]. This will assign shelf A to pallet number 1 [2].

3

Repeat the previous step for the remaining pallet numbers in alphabetical number [1].

NOTE: The shelves can be re-assigned at any point  however the user chooses by repeating the same process (e.g. pallet number 3 can be assigned shelf B).

 

Align Pallet Drop Off Station

1

Insert the Service Key USB and put the machine in Service Mode.

Make sure there are no obstructions inside the machine or inside the pallet pool area. Pull out all the [E-STOPS] and [RESET] the alarms.

Press [ZERO RETURN] and then press [ALL]. The machine will zero return all the axes.

Once all the axis are zero returned press [RECOVER]. A pop up box will appear, select [2] for Pallet Changer Recovery.

2

The Pallet Changer Recovery screen shows the Pallet Pool Status. Make sure the Pallet Lifter is Down [1]. If not press [ALTER] to bring the Pallet Lifter down.

Press [R] and then the [DELETE] button. This will rotate the pallet lifter towards station R.

Press [F1] to open the auto window [3].

 

3

Still on the pallet recovery page press [R] then [DELETE]  to rotate the RAM towards the inside of the machine then press [+Z] to select the Pallet Slide Axis to send the RAM in the machine.

Make sure the bottom of the forks clear the receiver casting. Raise the pallet pool leveling screws evenly if they do not.

Then press [-Z] to select the Pallet Rotate Axis and manually rotate the RAM  adjust the PR axis until the forks are aligned side to side to the locating pins on the receiver. 

Press [Recovery] to get out of pallet recovery and go to Factory Settings 2321 [:] Shelf R Rotary Offset, set this offset to the current PR axis position.

Jog the PS axis to send the RAM back into the pallet pool area and zero return the PR axis.

4

Re-enter pallet recovery page and press [R] then [DELETE] to rotate pallet pool to R position.

Then press [F1] to open the window and then press [+Z] to select the Pallet Slide Axis and jog the RAM into the machine. 

Press [F2]  to unclamp the clamp cylinder and place a pallet onto the receiver with the arrows pointing towards the slide window.

 WARNING: The air blast on the receiver makes a loud noise ear plugs are recommended.

Press [F2] to clamp the pallet. 

With the Pallet Pool in the down position, use the Gap Gauge [1] 25-14354 to set the gap by adjusting the height of the Pallet Pool. Evenly raise or lower the pallet pool leveling screws in accordance to the gap gauge.

NOTE: The pallet pool should still be only on 3 points while adjusting the gap.

 

 

5

While in the same position adjust the Pallet Slide Offset.

Use the provided shim 25-14354 [2] as a straight edge to align the pallet to the fork [1] as shown in the image.

Press [Recovery] to get out of pallet recovery and go to Factory Settings 2313 [:] Shelf R Slide Offset and set the current PS axis position as the offset.

Jog the RAM back into the machine and zero return the pallet pool.

Re-enter the pallet recovery page and press [R] then [DELETE]  to send the RAM to the shelf R rotate position. Then press [R ] then [UNDO]  to send the RAM to the shelf R slide position.

Verify the pins are aligned to the holes on the pallet. Unclamp the pallet and raise and lower the pallet to verify it does so smoothly. If it does not adjust Parameters 2321 and 2313 accordingly. 

Manually remove the pallet from the machine. 

Finally, drop the fourth leveling screw onto the puck.

6

Make sure the RAM is in the down position and press [INSERT] to return the RAM to the pallet pool area.

Press [A] then [DELETE] to rotate the RAM to its home position.

Press [A] and [UNDO] to slide the RAM to its home position.

Verify that the level is still acceptable in the X & Y direction [1].

Once verified, zero return the PR and PS axis.

 

Align Pallet Loading Station

1

Load a pallet onto the loading station, and with the RAM in the loading station use the shipping bracket [1] to set the gap between the bottom of the RAM forks and the loading station.

Adjust the two loading station leveling feet [2] until the gap is set. Raise and lower the pallet to ensure it does so smoothly. 

NOTE: The gap should be set evenly on both side. 

Setting Up Pallet Stations

1

Lower all outer leveling feet [1] to the ground by hand then rotate each leveling foot by another 1/2 turn [2]. 

2

Please refer to the PALLET POOL OPERATORS MANUAL for how to load the pallets onto the machine using the Pallet Scheduling Table.

3

Place the provided tote under the Pallet Pool coolant discharge tray to catch the coolant and chips that drains from the pallets.

Empty the tote as needed. 

Test the pick up / drop off operation on the remaining stations by using the pallet pool recovery functions.  

Install the anchors.

Install the Pallet Pool guard panels.

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