Haas Robot Package 2 - VMC - Installation

Introduction

This procedure will show you how to install the Haas Robot Arm Package-2.

Note: The Haas designed work cell made up of a CNC machine and a robot have been evaluated for compliance to CE requirements. Changes or variations to the Haas cell design should be evaluated for compliance to the applicable standards and are the responsibility of the user/integrator.

Machine Requirements:

  • 100.21.000.1120 version or higher
  • Built after 1/1/19 or I/O board updated to 34-349xB or later
  • VF/VM Reboot Sheet Metal
  • Haas Autodoor (See machine requirements for CAN Auto Door)
  • Remote Jog Handle - XL 93-1000610 REMOTE JOG HANDLE TOUCH LCD (RJH-XL)
  • I/O PCB HINGE DOOR 93-1000297 I/O DOOR ASSY HINGED
  • Requires separate 200-230V 3-Phase, 50/60 Hz, 3 kVA Power Supply[7]. See the Fanuc STARTUP GUIDE for more information.

Fixing / Anchoring Requirements

The Haas Robot Package 2 needs to be anchored to be sufficiently stable when used according to Haas defined part size and weight limits. See the Robot Anchoring section below.

The Haas Robot Package Includes the following Components:

  • 30-13008B  Robot PKG-2 Fence Kit (fencing with gate to enclose the operators station)
  • 32-0910    Gate Interlock
  • 32-8585B  Remote E-Stop Assembly (includes holster and 36' foot cable for remote handle jog)
  • 32-8584B  HRP-2 Electrical Interface Box Assembly (Includes robot signals and power cables)

 Note:  The parts above are subject to change and there will be some variation depending on build date. 

 Important: HE machines with an autodoor that are ordered with a robot or APL will not come with an edge sensor because these automation options come with a fence. If the machine is going to be ran without the automation option that has the fence, you will need to order and install an edge sensor for the machine. Reference the applicable edge sensor procedures for the correct part number to order:

Mill Setup

1

Complete the following on both doors:

Remove the autodoor motor cover [1] and the autodoor motor assembly [2].

Install the new proximity switch bracket [3] to the existing proximity switch block [5].

Install the door always open proximity switch [4] to the bracket [3].

Install the drill guide [7] for the door open flag [6] and drill and tap 2x 10-32 holes through the sheet metal of the door.

  • Drill size: #21 or 5/32"
  • Tap 10-32 NF

Remove the template and install the door open flag with 2x flat head cap screws. Re-install the autodoor motor assembly, bracket, and cover.

Use provided shims to set the height between the proximity switch and the door open flag.

2

Remove the tool tray and tool table from the machine.

Move the air gun hose mount [1] to the opposite side of the tool rack. Drill holes in the tool rack for the 1/4"-20 screws. Use a H (17/64") drill to make clearance holes.

Move the Remote Jog Handle (RJH) to the opposite side of the control pendant and route the cable.

3

Route the door fully open cables into the control cabinet as shown on the picture.

Connect to 32-0807 PROX NO LEFT DOOR FULLY OPEN to SIO P27.

Connect to 32-0856 PROX NO RIGHT DOOR FULLY OPEN to SIO P72.

4

  • 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 in the tool carousel.
  • Program the following steps to the beginning of any  program to make sure the part is properly seated into the chuck:
    • Locate the spring pusher above the part
    • Move the Z axis to compress the spring about 0.50 inches or 12.7 mm
    • Open the vise with a dwell of one second
    • Close the vise with a dwell of one second

Note: The Part Number for the spring pusher is: 

  • 30-12642 SPRING PUSHER APL.  The 25mm or 1.0” holder is sold separately.

Robot Lifting

Robot Lifting Requirements

Use this information for lifting/moving Robot Package 2.

The Haas Robot Package 2 needs to be lifted according to Fanuc's recommendation. See the Fanuc Robot M-20iD/25 Mechanical Unit Operator's Manual, Chapter 1, Section 1 Transportation starting on page 1 for lifting/moving information.

HRP-2 Fanuc Robot M-20iD/25 Mechanical Unit Operator's Manual

Robot Installation

1

Table 1[1]

Table 2[2] (optional)

Place the Fanuc Control Box on the right side of the machine next to the control panel[3]. 

Part Flip Station [4].

2

Robots with a Weldment Base

Measure these dimensions from the machine skirt to the robot mounting holes on the robot stand.

 Note: The following dimensions are recommended distances. The position may vary depending on the users application.

VF-1/2

Place the robot stand to the left front side of the machine. The the rear mounting hole of the robot should be 27.5 inches from the front of the machine[1]. The the right mounting hole of the robot should be 37.0 inches from the front of the machine[2]. The the rear mounting hole of the robot should be 25.0 inches from the left side of the machine[3].

Table 1 front table bracket should be 26.5 inches from the front of the machine[4]. The left mounting hole of the front table bracket should be 20.0 inches from the left side of the machine[5].

Table 2 left mounting hole of the front table bracket should be 53.0 inches from the front of the machine[6]. The right mounting hole of the front table bracket should be 62.0 inches from the front of the machine[7]. The left mounting hole of the front table bracket should be 59.0 inches from the right mounting hole of Table 1 front table bracket[8].

Part Flip Station should be 31.5 inches from the left side of the machine[9]. The front right anchoring hole should be 18.0 inches from the front of the machine[10]. 

VF-3/4

Place the robot stand to the left front side of the machine. The the rear mounting hole of the robot should be 23.0 inches from the front of the machine[1]. The the right mounting hole of the robot should be 32.5 inches from the front of the machine[2]. The the rear mounting hole of the robot should be 42.0 inches from the left side of the machine[3].

Table 1 front table bracket should be 22.5 inches from the front of the machine[4]. The left mounting hole of the front table bracket should be 1.0 inches from the left side of the machine[5].

Table 2 left mounting hole of the front table bracket should be 48.5 inches from the front of the machine[6]. The right mounting hole of the front table bracket should be 57.5 inches from the front of the machine[7]. The left mounting hole of the front table bracket should be 59.0 inches from the right mounting hole of Table 1 front table bracket[8]. 

Part Flip Station should be 14.5 inches from the left side of the machine[9]. The front right anchoring hole should be 13.5 inches from the front of the machine[10]. 

VF-5

Place the robot stand to the left front side of the machine. The the rear mounting hole of the robot should be 20.0 inches from the front of the machine[1]. The the right mounting hole of the robot should be 30.0 inches from the front of the machine[2]. The the rear mounting hole of the robot should be 49.5 inches from the left side of the machine[3].

Table 1 front table bracket should be 19.0 inches from the front of the machine[4]. The left mounting hole of the front table bracket should be 14.0 inches from the left side of the machine[5].

Table 2 left mounting hole of the front table bracket should be 45.0 inches from the front of the machine[6]. The right mounting hole of the front table bracket should be 54.5 inches from the front of the machine[7]. The left mounting hole of the front table bracket should be 59.0 inches from the right mounting hole of Table 1 front table bracket[8].

Part Flip Station should be 1.0 inches inside from the left side of the machine[9]. The front right anchoring hole should be 8.5 inches from the front of the machine[10]. 

3

Robots with a Cast Base

Measure these dimensions from the machine skirt to the anchor holes on the robot base.

 Note: The following dimensions are recommended distances. The position may vary depending on the users application.

VF-1/2

Place the robot stand to the left front side of the machine. The the rear mounting hole of the base should be 24.5 inches from the front of the machine[1]. The the right mounting hole of the robot should be 37.0 inches from the front of the machine[2]. The the rear mounting hole of the robot should be 25.0 inches from the left side of the machine[3].

Table 1 front table bracket should be 26.5 inches from the front of the machine[4]. The left mounting hole of the front table bracket should be 20.0 inches from the left side of the machine[5].

Table 2 left mounting hole of the front table bracket should be 53.0 inches from the front of the machine[6]. The right mounting hole of the front table bracket should be 62.0 inches from the front of the machine[7]. The left mounting hole of the front table bracket should be 59.0 inches from the right mounting hole of Table 1 front table bracket[8].

Part Flip Station should be 31.5 inches from the left side of the machine[9]. The front right anchoring hole should be 18.0 inches from the front of the machine[10]. 

VF-3/4

Place the robot stand to the left front side of the machine. The the rear mounting hole of the robot should be 20.0 inches from the front of the machine[1]. The the right mounting hole of the robot should be 32.5 inches from the front of the machine[2]. The the rear mounting hole of the robot should be 42.0 inches from the left side of the machine[3].

Table 1 front table bracket should be 22.5 inches from the front of the machine[4]. The left mounting hole of the front table bracket should be 1.0 inches from the left side of the machine[5].

Table 2 left mounting hole of the front table bracket should be 48.5 inches from the front of the machine[6]. The right mounting hole of the front table bracket should be 57.5 inches from the front of the machine[7]. The left mounting hole of the front table bracket should be 59.0 inches from the right mounting hole of Table 1 front table bracket[8]. 

Part Flip Station should be 14.5 inches from the left side of the machine[9]. The front right anchoring hole should be 13.5 inches from the front of the machine[10]. 

VF-5

Place the robot stand to the left front side of the machine. The the rear right mounting hole of the robot should be 17.0 inches from the front of the machine[1]. The the front right mounting hole of the robot should be 30.0 inches from the front of the machine[2]. The the rear right mounting hole of the robot should be 49.5 inches from the left side of the machine[3].

Table 1 front table bracket should be 19.0 inches from the front of the machine[4]. The left mounting hole of the front table bracket should be 14.0 inches from the left side of the machine[5].

Table 2 left mounting hole of the front table bracket should be 45.0 inches from the front of the machine[6]. The right mounting hole of the front table bracket should be 54.5 inches from the front of the machine[7]. The left mounting hole of the front table bracket should be 59.0 inches from the right mounting hole of Table 1 front table bracket[8].

Part Flip Station should be 1.0 inches inside from the left side of the machine[9]. The front right anchoring hole should be 8.5 inches from the front of the machine[10]. 

4

Robot Anchoring Requirements

The Haas Robot Package 2, Part Table, and Part Flip Station needs to be anchored to be sufficiently stable when used according to Haas defined part size and weight limits. See the Anchoring Instructions (Drop-In Expansion) for anchoring information.

Anchoring Instructions (Drop-In Expansion)

5

Turn the machine air supply OFF.

Inside the CALM cabinet, remove a NPT plug from one of the CALM manifold ports.

The Robot Gripper Air Regulator has magnetic mounts to attach to the robot stand

Mount the Robot Gripper Air Regulator to the robot stand.

Route the air line from the left side of the regulator along the front skirt of the machine to the CALM cabinet and install the push to connect fitting.

Route the air line from the right side of the regulator to the Air 1 port on the robot and install to the push-to-connect fitting.

Turn the machine air supply ON.

Parts Table Assembly

1

The Parts Table needs to be assembled. Follow the procedure below for installation.

Haas Robot - Parts Table Assembly

Shaft Loading Kit Installation

1

To install the HRP-2 Shaft Loading Kit. Follow the procedure below for installation.

HRP-2 - Shaft Loading Kit - Installation

Fence Installation

1

The robot fence, door interlock assembly, and Remote E-Stop needs to be installed with the robot and machine. Follow the procedure below for installation.

Robot Fence Installation
HRP-2 VMC Fence Layout

Attention: The fence anchors will use a 3/8th drill bit, they are NOT the same size as the robot anchors.

2

Install the fence panels together.

Install the fence panel assembly to the fence post with the self tapping screws. The top of the fence panel assembly should be 22.5 inches from the top of the fence post. 

Install the fence panel assembly to the front of the machine with the self tapping screws. The location installed will depend on the machine and fence location

Robot Electrical - Installation

 Caution: When you do maintenance or repair on CNC machines and their components, you must always follow basic safety precautions. This decreases the risk of injury and mechanical damage.

  • Set the main circuit breaker to the [OFF] position.

 Danger: Before beginning any work inside the control cabinet the High Voltage indicator light on the 320V Power Supply / Vector Drive must have been off for at least 5 minutes.

Some service procedures can be dangerous or life-threatening. DO NOT attempt a procedure that you do not fully understand. If you have any doubts about doing a procedure contact your Haas Factory Outlet (HFO) and schedule a service visit.

1

VMC Robot Interface Mounting Location

The Robot electrical interface box has magnetic mounts to attach to the machine sheet metal.

Mount the Robot electrical interface box [1] as shown in the picture.

Route the Robot interface electrical cables through the bottom of the electrical cabinet.

2

Perform the following steps to connect the robot to the Haas machine.

Robot Power

Requires separate 200-230V 3-Phase, 50/60 Hz, 3 kVA Power Supply[7]. See the Fanuc Startup Guide for more information.

 Note: It is recommended to install a strain relief cable grip to remove stress on the power cable connections and isolate the power cable from the controller cabinet.

Cable P/N 33-8562C has multiple connections:

I/O PCB

  • Connect the E-STOP terminal block connections to SIO PCB TB-1B (see diagram)[1].
  • Verify the jumper is installed on the SIO PCB at JP1.
  • Connect the Setup mode terminal block connections to SIO PCB TB-3B (see diagram)[1].
  • Plug the User Relays into K9 and K10.  (see diagram)[11].
  • Connect the cable labeled P1 SIO to the SIO PCB at P1[2].

Note: Do not plug anything into the connector FILTER OV FAULT.

Maincon PCB

  • Connect the RJ-45 cable [3] to Ethernet to USB adapter [4] (P/N 33-0636). Connect the USB connector end to the Maincon PCB J8 top port (see diagram). Add a ferrite filter 64-1252 to the USB adapter.
PSUP PCB
  • Mount the 24VDC Power Supply[10] to the left side of the control cabinet and plug into connector labled 24V PS on cable 33-8562C. Connect cable 33-1910A[9] to the 24VDC Power Supply[10] and plug into P3 on the PSUP PCB.

SKBIF to Remote Jog Handle

  • Connect the RJ12 cable 33-8550C[5] from the Remote E-stop box to cable 33-0713 and plug into the SKIBF PCB P9.
  • Remove the jumpers JP2 and JP3 on the SKBIF from the horizontal position and replace them in the vertical position.
  • Plug the RJH-XL cable into the cradle.

 Warning: By not putting the jumpers in the vertical position, E-STOP functionality on the RJH-XL is disabled and the machine is considered unsafe. Jumpers MUST be inserted vertically.

Robot Electrical Box to Robot Control

  • Connect the Robot Control Signal Cables [6] P/N 33-8592A to the Robot Electrical Interface Box. Add a ferrite filter 64-1252 to the RJ-45 cable.

Note: If cable 33-8591A or 33-8592A is not installed to the Fanuc Control box, see the HRP Troubleshooting Guide Robot Control Wiring HRP-2/3 step for wiring instructions.

Fence Interlock

  • Connect the fence door interlock cable [8] to the electrical interface box.

First Power-UP

1

Locate the Mode Switch on the Controller Operator Panel. The keu should be set to Auto Mode[2].

Make sure the [E-STOP] button[3] is not pressed.

Turn on the Robot Control box by rotating the Breaker clockwise to On[1].

2

Turn on the Haas CNC.

Zero Return all Axes.

Insert Service USB key.  Go into Service mode.

Go to Parameters> Factory tab.  Change the following:

  • 1278 [1278:] Robot Ready E-Stop Enabled to TRUE
  • 2191 [694:] LIGHT CUTAIN TYPE to LC_TYPE_1
  • 2195 [:] Enable Right Door Fully Open Switch to TRUE
  • 2196 [:] Enable Left Door Fully Open Switch to TRUE

Note: Machines with Software Version 100.20.000.1010 or higher will need to change the following parameter:

  • 2192 [:] Light Curtain Trigger Threshold to 0

Press [SETTING].

Set the Settings:

  • 372 Parts Loader Type to 3: Robot.
  • 376 Light Curtain Enabled to On

 

3

Press [CURRENT COMMANDS].

Go to Devices>Robot>Jogging tab. Change the following:

  • Maximum Jogging Speed to 7.9 in/sec (200 mm/sec).

Go to the Setup tab. Change the following:

  • Max Robot Speed to 78 in/sec (1981 mm/sec). 
  • Gripper Net Mass to 7.0 lbs.
  • Number of Grippers to the number of grippers.
  • Raw Gripper Clamp Output to 1.
  • Raw Gripper Unclamp Output to 2.
  • Raw Gripper Clamp Delay to the clamp/unclamp duration in sec.
  • Raw Gripper Clamp Type to OD/ID.

4

Press [CURRENT COMMANDS].

Go to Devices>Robot>Setup tab[1].

Press [E-Stop].

Press [F1] to connect the robot[2].

The first time connecting a robot to a machine, a Robot Activation window will pop-up. This pop-up shows the Software Version of the machine[3], the MAC address of the robot[4], and the Machine Generated Code[5] used for Machine Time Extension on the portal.

To activate the robot, enter the F Number[6] and Unlock Code[7].

The F Number is found on the robot ID tag that is on the control panel door or on the robot arm.

The Unlock Code is generated after completing the Robot Installation on the Haas Business Center.

For Service Activation. In Service Mode, Press [INSERT] to connect the robot. This will be disabled after a Cycle Power.

Note: This step can only be completed by a HFO Service Technician.

Note: The green button on the control box will light up.

5

Press the [HANDLE JOG] button. 

Press the [CURRENT COMMANDS]  and go to Devices > Robot > Jogging tab.

On the Remote Handle Jog Touch press the Joint button to go into the Joints Coordinates.

Jog the robot from its shipping position to a safe position.

Note: Press [Emergency Stop] before working on the robot.

Note: Turn off the machine air by turning the valve in the Air/Lube cabinet and pull the pressure relief valve to release the air in the system.

Gripper Installation

1

Install the gripper to the robot end effector mounting face.

2

Install the gripper to the robot end effector mounting face.

3

Install the gripper to the robot end effector mounting face.

4

Install the shaft gripper assembly to the robot end effector mounting face.

5

See the HRP-2 Dual Gripper - Installation instructions for install the dual gripper on the HRP-2.

6

Route the air lines between the solenoid on robot arm and the gripper. Connecting the airlines to the corresponding color coded fittings. Install conduit to each pair of air lines. 

 Note: Turn on the machine air by turning the valve in the CALM cabinet.

Verification

Test the E-stop:

  • Press the Pendant and External E-STOP buttons and make sure the machine generates 107 EMERGENCY STOP alarm.  If the E-STOP button does not generate a 107 EMERGENCY STOP alarm verify the wiring. Load the latest configuration files to enable the RJH-XL.

Test the Gate Interlock on the Fence:

  • With the key inserted in the interlock, the two red LED lights in the front of the interlock should be off. 
  • On the Haas pendant, there should not be any E-stop or light curtain/fence alarms or icon triggered.
  • Remove the key from the interlock. The two red LED lights should turn on and a warning should appear on the Haas pendant for light curtain/fence.
  • Check the light curtain/fence icon show on the screen.  If the icon does not show, verify wiring, alingment and factory setting: 2191 [694:] LIGHT CUTAIN TYPE is set to LC_TYPE_1.

Test the operation of the grippers:

  • Verify the gripper clamps and unclamps correctly.
  • Press the [CURRENT COMMANDS]  and go to Devices > Robot > Jogging tab.
  • Press [F3] to clamp/unclamp the Raw Gripper.

Test the Remote Jog Handle:

  • Undock the Remote Jog Handle
  • Press the [HANDLE JOG] button. 
  • Press the [CURRENT COMMANDS]  and go to Devices > Robot > Jogging tab.
  • On the Remote Handle Jog press the Joint button to go into the Joints Coordinates.
  • Move the robot to a safe location.

Verify Safe / Run Mode Operation

All Haas CNC machines are equipped with a key switch on the side of the control pendant to lock and unlock setup mode. The robot will have the following behaviors depending on what mode is selected. 

  • When the Haas control is in Run mode, mode 1, unlocking the interlock and opening up the gate stops all motion, and no motion can be started until it is closed and locked.
  • When the Haas control is in Set up mode, mode 2, speed limited motion such as jogging an axis of the robot can be performed in order to program a robot's path of motion, pick up position, set a robot's tool center point, (an offset), load and pick up parts from the spindle or part holder in the machine, etc. The programmed path will also be able to be run slowly to prove out the programmed path of the robot.

FANUC Dual Check Safety (DCS) – Setup

Each Haas Robot is provided with FANUC's DCS System. This allows the user to define speed and positional limits to the robot. If the robot goes outside of these limits, DCS will stop the robot and remove power to the motors.

This procedure will show you how to set up a Fanuc Dual Check Safety (DCS) zone.

FANUC Dual Check Safety (DCS) – Setup

Haas Robot - Quick Start Guide

After installing the robot, set up a job following the procedure below.

Haas Robot - Quick Start Guide

Disable the Robot

To disable the robot 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

Haas Robot Package 2 - Lathe - Installation

Introduction

This procedure will show you how to install the Haas Robot Arm Package-2.

Note: The Haas designed work cell made up of a CNC machine and a robot have been evaluated for compliance to CE requirements. Changes or variations to the Haas cell design should be evaluated for compliance to the applicable standards and are the responsibility of the user/integrator.

Machine Requirements:

  • 100.21.000.1120 version or higher
  • ST-20/25/20L/25L/30/35/30L/35L & DS-30Y Reboot Sheet Metal (Flat Face)
  • ST-30L/35L machines must have Right Door Assembly 30-12628B or later. Machines built 10/08/2020 and later. If the machine does not have assembly, upgrade the door assembly with Door Trolley Plate 25-13911B or later.
  • Haas Autodoor (See machine requirements for CAN Auto Door)
  • Remote Jog Handle - XL 93-1000610 REMOTE JOG HANDLE TOUCH LCD (RJH-XL)
  • I/O PCB HINGE DOOR 93-1000297 I/O DOOR ASSY HINGED
  • Requires separate 200-230V 3-Phase, 50/60 Hz, 3 kVA Power Supply[7]. See the Fanuc STARTUP GUIDE for more information.

Note: If the machine has the Parts Catcher option installed. The catch tray will interfere with the robot and will need to be removed. A custom sheet metal panel will need to be made to cover and seal the opening.

Fixing / Anchoring Requirements

  • The Haas Robot Package 2 needs to be anchored to be sufficiently stable when used according to Haas defined part size and weight limits. See the Robot Anchoring section below.

The Haas Robot Package Includes the following Components:

  • 30-13008B  Robot PKG-2 Fence Kit (fencing with gate to enclose the operators station)
  • 32-0910    Gate Interlock
  • 32-8585B  Remote E-Stop Assembly (includes holster and 36' foot cable for remote handle jog)
  • 32-8584B  HRP-2 Electrical Interface Box Assembly (Includes robot signals and power cables)

 Note:  The parts above are subject to change and there will be some variation depending on build date. 

 Important: HE machines with an autodoor that are ordered with a robot or APL will not come with an edge sensor because these automation options come with a fence. If the machine is going to be ran without the automation option that has the fence, you will need to order and install an edge sensor for the machine. Reference the applicable edge sensor procedures for the correct part number to order:

Lathe Setup

1

Remove the auto door cover [1].

2

ST-20/25/30/35 & DS-30Y:

For machines with the switch bracket holes on the roof panel. Install the switch bracket to the right pair of holes[1] for ST-20/25 and the left pair of holes[2] for ST-30/35 & DS-30Y.

3

ST-20/25/30/35/30L/35L & DS-30Y:

For machines without the switch bracket holes on the roof panel. Use the provided drill guide to drill the mounting holes for the Left Door Fully Open Switch.

With the door fully open, place the drill template against the door roller adjustment plate. 

Drill the two Ø3/16" (4.7mm) mounting holes through the drill guide holes that are marked with two slots[1].

Using the provided self tapping screws, install the Door Fully Open Switch assembly and the Door Fully Open Switch Flag.

4

ST-30L/35L:

Use the provided drill guide to drill the mounting holes for the Right Door Fully Open Switch.

Place the drill template on the top enclosure and against the Door Track Mount.

Drill the two Ø3/16" (4.7mm) mounting holes through the drill guide holes that are marked with one slot[1].

Using the provided self tapping screws, install the Door Fully Open Switch assembly and the Door Fully Open Switch Flag.

5

Connect the Door Fully Open Switches as labeled:

  • BLK <COM> to the top terminal [1].
  • RED <NO> to the middle terminal [2].

Route the cables 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].

If a single door machine, connect the other end of the cable to the SIO P27 RRI Door Open input.

If the a dual door machine, connect the left door cable to SIO P27 RRI Door Open input and the right door cable to SIO P72 RRI Door Open input.

Install the autodoor cover.

6

  • 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  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

Robot Lifting

Robot Lifting Requirements

Use this information for lifting/moving Robot Package 2.

The Haas Robot Package 2 needs to be lifted according to Fanuc's recommendation. See the Fanuc Robot M-20iD/25 Mechanical Unit Operator's Manual, Chapter 1, Section 1 Transportation starting on page 1 for lifting/moving information.

HRP-2 Fanuc Robot M-20iD/25 Mechanical Unit Operator's Manual

Robot Installation

1

Table 1[1]

Table 2[2] (optional)

Place the Fanuc Control Box behind the machine next to the control panel[3].

Part Flip Station [4].

2

Robots with a Weldment Base

Measure these dimensions from the machine skirt to the robot mounting holes on the robot stand.

 Note: The following dimensions are recommended distances. The position may vary depending on the users application.

ST-20/25

Place the robot stand to the left front side of the machine. The the rear mounting hole of the robot should be 29.0 inches from the front of the machine[1]. The the right mounting hole of the robot should be 39.0 inches from the front of the machine[2]. The the rear mounting hole of the robot should be 27.0 inches from the left side of the machine[3].

Table 1 front table bracket should be 28.0 inches from the front of the machine[4]. The left mounting hole of the front table bracket should be 21.5 inches from the left side of the machine[5].

Table 2 left mounting hole of the front table bracket should be 54.5 inches from the front of the machine[6]. The right mounting hole of the front table bracket should be 63.5 inches from the front of the machine[7]. The left mounting hole of the front table bracket should be 59.0 inches from the right mounting hole of Table 1 front table bracket[8]. 

Part Flip Station should be 24.5 inches from the left side of the machine[9]. The front right anchoring hole should be 17.5 inches from the front of the machine[10]. 

ST-20L/25L

Place the robot stand to the left front side of the machine. The the rear mounting hole of the robot should be 29.5 inches from the front of the machine[1]. The the right mounting hole of the robot should be 39.0 inches from the front of the machine[2]. The the rear mounting hole of the robot should be 42.5 inches from the left side of the machine[3].

Table 1 front table bracket should be 28.5 inches from the front of the machine[4]. The left mounting hole of the front table bracket should be 5.5 inches from the left side of the machine[5].

Table 2 left mounting hole of the front table bracket should be 55.5 inches from the front of the machine[6]. The right mounting hole of the front table bracket should be 65.0 inches from the front of the machine[7]. The left mounting hole of the front table bracket should be 59.0 inches from the right mounting hole of Table 1 front table bracket[8]. 

Part Flip Station should be 9.0 inches from the left side of the machine[9]. The front right anchoring hole should be 18.0 inches from the front of the machine[10]. 

ST-30/35 & DS-30Y

Place the robot stand to the left front side of the machine. The the rear mounting hole of the robot should be 29.5 inches from the front of the machine[1]. The the right mounting hole of the robot should be 38.5 inches from the front of the machine[2]. The the rear mounting hole of the robot should be 27.0 inches from the left side of the machine[3].

Table 1 front table bracket should be 28.5 inches from the front of the machine[4]. The left mounting hole of the front table bracket should be 21.0 inches from the left side of the machine[5].

Table 2 left mounting hole of the front table bracket should be 54.5 inches from the front of the machine[6]. The right mounting hole of the front table bracket should be 63.5 inches from the front of the machine[7]. The left mounting hole of the front table bracket should be 60.0 inches from the right mounting hole of Table 1 front table bracket[8].

Part Flip Station should be 24.5 inches from the left side of the machine[9]. The front right anchoring hole should be 18.0 inches from the front of the machine[10]. 

ST-30L/35L

Place the robot stand to the left front side of the machine. The the rear mounting hole of the robot should be 29.0 inches from the front of the machine[1]. The the right mounting hole of the robot should be 38.5 inches from the front of the machine[2]. The the rear mounting hole of the robot should be 49.5 inches from the left side of the machine[3].

Table 1 front table bracket should be 28.5 inches from the front of the machine[4]. The left mounting hole of the front table bracket should be 1.5 inches from the left side of the machine[5].

Table 2 left mounting hole of the front table bracket should be 54.5 inches from the front of the machine[6]. The right mounting hole of the front table bracket should be 63.5 inches from the front of the machine[7]. The left mounting hole of the front table bracket should be 60.0 inches from the right mounting hole of Table 1 front table bracket[8].

Part Flip Station should be 2.0 inches from the left side of the machine[9]. The front right anchoring hole should be 17.5 inches from the front of the machine[10]. 

3

Robots with a Cast Base

Measure these dimensions from the machine skirt to the anchor holes on the robot base.

 Note: The following dimensions are recommended distances. The position may vary depending on the users application.

ST-20/25

Place the robot stand to the left front side of the machine. The the rear mounting hole of the robot should be 26.0 inches from the front of the machine[1]. The the right mounting hole of the robot should be 39.0 inches from the front of the machine[2]. The the rear mounting hole of the robot should be 27.0 inches from the left side of the machine[3].

Table 1 front table bracket should be 28.0 inches from the front of the machine[4]. The left mounting hole of the front table bracket should be 21.5 inches from the left side of the machine[5].

Table 2 left mounting hole of the front table bracket should be 54.5 inches from the front of the machine[6]. The right mounting hole of the front table bracket should be 63.5 inches from the front of the machine[7]. The left mounting hole of the front table bracket should be 59.0 inches from the right mounting hole of Table 1 front table bracket[8]. 

Part Flip Station should be 24.5 inches from the left side of the machine[9]. The front right anchoring hole should be 17.5 inches from the front of the machine[10]. 

ST-20L/25L

Place the robot stand to the left front side of the machine. The the rear mounting hole of the robot should be 26.5 inches from the front of the machine[1]. The the right mounting hole of the robot should be 39.0 inches from the front of the machine[2]. The the rear mounting hole of the robot should be 42.5 inches from the left side of the machine[3].

Table 1 front table bracket should be 28.5 inches from the front of the machine[4]. The left mounting hole of the front table bracket should be 5.5 inches from the left side of the machine[5].

Table 2 left mounting hole of the front table bracket should be 55.5 inches from the front of the machine[6]. The right mounting hole of the front table bracket should be 65.0 inches from the front of the machine[7]. The left mounting hole of the front table bracket should be 59.0 inches from the right mounting hole of Table 1 front table bracket[8]. 

Part Flip Station should be 9.0 inches from the left side of the machine[9]. The front right anchoring hole should be 18.0 inches from the front of the machine[10]. 

ST-30/35 & DS-30Y

Place the robot stand to the left front side of the machine. The the rear mounting hole of the robot should be 26.5 inches from the front of the machine[1]. The the  right mounting hole of the robot should be 38.5 inches from the front of the machine[2]. The the rear mounting hole of the robot should be 27.0 inches from the left side of the machine[3].

Table 1 front table bracket should be 28.5 inches from the front of the machine[4]. The left mounting hole of the front table bracket should be 21.0 inches from the left side of the machine[5].

Table 2 left mounting hole of the front table bracket should be 54.5 inches from the front of the machine[6]. The right mounting hole of the front table bracket should be 63.5 inches from the front of the machine[7]. The left mounting hole of the front table bracket should be 60.0 inches from the right mounting hole of Table 1 front table bracket[8].

Part Flip Station should be 24.5 inches from the left side of the machine[9]. The front right anchoring hole should be 18.0 inches from the front of the machine[10]. 

ST-30L/35L

Place the robot stand to the left front side of the machine. The the rear mounting hole of the robot should be 26.0 inches from the front of the machine[1]. The the right mounting hole of the robot should be 38.5 inches from the front of the machine[2]. The the rear mounting hole of the robot should be 49.5 inches from the left side of the machine[3].

Table 1 front table bracket should be 28.5 inches from the front of the machine[4]. The left mounting hole of the front table bracket should be 1.5 inches from the left side of the machine[5].

Table 2 left mounting hole of the front table bracket should be 54.5 inches from the front of the machine[6]. The right mounting hole of the front table bracket should be 63.5 inches from the front of the machine[7]. The left mounting hole of the front table bracket should be 60.0 inches from the right mounting hole of Table 1 front table bracket[8].

Part Flip Station should be 2.0 inches from the left side of the machine[9]. The front right anchoring hole should be 17.5 inches from the front of the machine[10]. 

4

Robot Anchoring Requirements

The Haas Robot Package 2, Part Table, and Part Flip Station needs to be anchored to be sufficiently stable when used according to Haas defined part size and weight limits. See the Anchoring Instructions (Drop-In Expansion) for anchoring information.

Anchoring Instructions (Drop-In Expansion)

5

Turn the machine air supply OFF.

Inside the CALM cabinet, remove a NPT plug from one of the CALM manifold ports.

The Robot Gripper Air Regulator has magnetic mounts to attach to the robot stand

Mount the Robot Gripper Air Regulator to the robot stand.

Route the air line from the left side of the regulator along the front skirt of the machine to the CALM cabinet and install the push to connect fitting.

Route the air line from the right side of the regulator to the Air 1 port on the robot and install to the push-to-connect fitting.

Turn the machine air supply ON.

Parts Table Assembly

1

The Parts Table needs to be assembled. Follow the procedure below for installation.

Haas Robot - Parts Table Assembly

Shaft Loading Kit Installation

1

To install the HRP-2 Shaft Loading Kit. Follow the procedure below for installation.

HRP-2 - Shaft Loading Kit - Installation

Fence Installation

1

The robot fence, door interlock assembly, and Remote E-Stop needs to be installed with the robot and machine. Follow the procedure below for installation.

Robot Fence Installation
HRP-2 Lathe Fence Layout

Attention: The fence anchors will use a 3/8th drill bit, they are NOT the same size as the robot anchors.

2

Install the fence panel sheet metal to the coolant collector sheet metal and secure the robot fence to the fence panel sheet metal.

Robot Electrical - Installation

 Caution: When you do maintenance or repair on CNC machines and their components, you must always follow basic safety precautions. This decreases the risk of injury and mechanical damage.

  • Set the main circuit breaker to the [OFF] position.

 Danger: Before beginning any work inside the control cabinet the High Voltage indicator light on the 320V Power Supply / Vector Drive must have been off for at least 5 minutes.

Some service procedures can be dangerous or life-threatening. DO NOT attempt a procedure that you do not fully understand. If you have any doubts about doing a procedure contact your Haas Factory Outlet (HFO) and schedule a service visit.

1

ST Robot Interface Mounting Location

The Robot electrical interface box has magnetic mounts to attach to the machine sheet metal.

Mount the Robot electrical interface box [1] as shown in the picture.

Route the Robot interface electrical cables [2] through the bottom of the electrical cabinet.

2

Perform the following steps to connect the robot to the Haas machine.

Robot Power

Requires separate 200-230V 3-Phase, 50/60 Hz, 3 kVA Power Supply[7]. See the Fanuc Startup Guide for more information.

 Note: It is recommended to install a strain relief cable grip to remove stress on the power cable connections and isolate the power cable from the controller cabinet.

Cable P/N 33-8562C has multiple connections:

I/O PCB

  • Connect the E-STOP terminal block connections to SIO PCB TB-1B (see diagram)[1].
  • Verify the jumper is installed on the SIO PCB at JP1.
  • Connect the Setup mode terminal block connections to SIO PCB TB-3B (see diagram)[1].
  • Plug the User Relays into K9 and K10.  (see diagram)[11].
  • Connect the cable labeled P1 SIO to the SIO PCB at P1[2].

Note: Do not plug anything into the connector FILTER OV FAULT.

Maincon PCB

  • Connect the RJ-45 cable [3] to Ethernet to USB adapter [4] (P/N 33-0636). Connect the USB connector end to the Maincon PCB J8 top port (see diagram). Add a ferrite filter 64-1252 to the USB adapter.

PSUP PCB

  • Mount the 24VDC Power Supply[10] to the left side of the control cabinet and plug into connector labled 24V PS on cable 33-8562C. Connect cable 33-1910A[9] to the 24VDC Power Supply[10] and plug into P3 on the PSUP PCB.

SKBIF to Remote Jog Handle

  • Connect the RJ12 cable 33-8550C[5] from the Remote E-stop box to cable 33-0713 and plug into the SKIBF PCB P9.
  • Remove the jumpers JP2 and JP3 on the SKBIF from the horizontal position and replace them in the vertical position.
  • Plug the RJH-XL cable into the cradle.

 Warning: By not putting the jumpers in the vertical position, E-STOP functionality on the RJH-XL is disabled and the machine is considered unsafe. Jumpers MUST be inserted vertically.

Robot Electrical Box to Robot Control

  • Connect the Robot Control Signal Cables [6] P/N 33-8592A to the Robot Electrical Interface Box. Add a ferrite filter 64-1252 to the RJ-45 cable.

 Note: If cable 33-8591A or 33-8592A is not installed to the Fanuc Control box, see the HRP Troubleshooting Guide Robot Control Wiring HRP-2/3 step for wiring instructions.

Fence Interlock

  • Connect the fence door interlock cable [8] to the electrical interface box.

First Power-UP

1

Locate the Mode Switch on the Controller Operator Panel. The keu should be set to Auto Mode[2].

Make sure the [E-STOP] button[3] is not pressed.

Turn on the Robot Control box by rotating the Breaker clockwise to On[1].

2

Turn on the Haas CNC.

Zero Return all Axes.

Insert Service USB key.  Go into Service mode.

Go to Parameters> Factory tab.  Change the following:

  • 1278 [1278:] Robot Ready E-Stop Enabled to TRUE
  • 2191 [694:] LIGHT CUTAIN TYPE to LC_TYPE_1
  • 2194 [:] Enable Front Door Fully Open Switch to TRUE

Note: Machines with Software Version 100.20.000.1010 or higher will need to change the following parameter:

  • 2192 [:] Light Curtain Trigger Threshold to 0

Press [SETTING].

Set the Settings:

  • 372 Parts Loader Type to 3: Robot.
  • 376 Light Curtain Enabled to On

3

Press [CURRENT COMMANDS].

Go to Devices>Robot>Jogging tab. Change the following:

  • Maximum Jogging Speed to 7.9 in/sec (200 mm/sec).

Go to the Setup tab. Change the following:

  • Max Robot Speed to 78 in/sec (1981 mm/sec). 
  • Gripper Net Mass to 7.0 lbs.
  • Number of Grippers to the number of grippers.
  • Raw Gripper Clamp Output to 1.
  • Raw Gripper Unclamp Output to 2.
  • Raw Gripper Clamp Delay to the clamp/unclamp duration in sec.
  • Raw Gripper Clamp Type to OD/ID.

4

Press [CURRENT COMMANDS].

Go to Devices>Robot>Setup tab[1].

Press [E-Stop].

Press [F1] to connect the robot[2].

The first time connecting a robot to a machine, a Robot Activation window will pop-up. This pop-up shows the Software Version of the machine[3], the MAC address of the robot[4], and the Machine Generated Code[5] used for Machine Time Extension on the portal.

To activate the robot, enter the F Number[6] and Unlock Code[7].

The F Number is found on the robot ID tag that is on the control panel door or on the robot arm.

The Unlock Code is generated after completing the Robot Installation on the Haas Business Center.

For Service Activation. In Service Mode, Press [INSERT] to connect the robot. This will be disabled after a Cycle Power.

Note: This step can only be completed by a HFO Service Technician.

Note: The green button on the control box will light up.

5

Press the [HANDLE JOG] button. 

Press the [CURRENT COMMANDS]  and go to Devices > Robot > Jogging tab.

On the Remote Handle Jog Touch press the Joint button to go into the Joints Coordinates.

Jog the robot from its shipping position to a safe position.

Note: Press [Emergency Stop] before working on the robot.

Note: Turn off the machine air by turning the valve in the Air/Lube cabinet and pull the pressure relief valve to release the air in the system.

Gripper Installation

1

Install the gripper to the robot end effector mounting face.

2

Install the gripper to the robot end effector mounting face.

3

Install the shaft gripper assembly to the robot end effector mounting face.

4

See the HRP-2 Dual Gripper - Installation instructions for install the dual gripper on the HRP-2.

5

Route the air lines between the solenoid on robot arm and the gripper. Connecting the airlines to the corresponding color coded fittings. Install conduit to each pair of air lines. 

 Note: Turn on the machine air by turning the valve in the CALM cabinet.

Verification

Test the E-stop:

  • Press the Pendant and External E-STOP buttons and make sure the machine generates 107 EMERGENCY STOP alarm.  If the E-STOP button does not generate a 107 EMERGENCY STOP alarm verify the wiring. Load the latest configuration files to enable the RJH-XL.

Test the Gate Interlock on the Fence:

  • With the key inserted in the interlock, the two red LED lights in the front of the interlock should be off. 
  • On the Haas pendant, there should not be any E-stop or light curtain/fence alarms or icon triggered.
  • Remove the key from the interlock. The two red LED lights should turn on and a warning should appear on the Haas pendant for light curtain/fence.
  • Check the light curtain/fence icon show on the screen.  If the icon does not show, verify wiring, alingment and factory setting: 2191 [694:] LIGHT CUTAIN TYPE is set to LC_TYPE_1.

Test the operation of the grippers:

  • Verify the gripper clamps and unclamps correctly.
  • Press the [CURRENT COMMANDS]  and go to Devices > Robot > Jogging tab.
  • Press [F3] to clamp/unclamp the Raw Gripper.

Test the Remote Jog Handle:

  • Undock the Remote Jog Handle
  • Press the [HANDLE JOG] button. 
  • Press the [CURRENT COMMANDS]  and go to Devices > Robot > Jogging tab.
  • On the Remote Handle Jog press the Joint button to go into the Joints Coordinates.
  • Move the robot to a safe location.

Verify Safe / Run Mode Operation

All Haas CNC machines are equipped with a key switch on the side of the control pendant to lock and unlock setup mode. The robot will have the following behaviors depending on what mode is selected. 

  • When the Haas control is in Run mode, mode 1, unlocking the interlock and opening up the gate stops all motion, and no motion can be started until it is closed and locked.
  • When the Haas control is in Set up mode, mode 2, speed limited motion such as jogging an axis of the robot can be performed in order to program a robot's path of motion, pick up position, set a robot's tool center point, (an offset), load and pick up parts from the spindle or part holder in the machine, etc. The programmed path will also be able to be run slowly to prove out the programmed path of the robot.

FANUC Dual Check Safety (DCS) – Setup

Each Haas Robot is provided with FANUC's DCS System. This allows the user to define speed and positional limits to the robot. If the robot goes outside of these limits, DCS will stop the robot and remove power to the motors.

This procedure will show you how to set up a Fanuc Dual Check Safety (DCS) zone.

FANUC Dual Check Safety (DCS) – Setup

Haas Robot - Quick Start Guide

After installing the robot, set up a job following the procedure below.

Haas Robot - Quick Start Guide

Disable the Robot

To disable the robot 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

 

Haas Robot Package 2 - UMC - Installation

Introduction

This procedure will show you how to install the Haas Robot Arm Package-2.

Note: The Haas designed work cell made up of a CNC machine and a robot have been evaluated for compliance to CE requirements. Changes or variations to the Haas cell design should be evaluated for compliance to the applicable standards and are the responsibility of the user/integrator.

Machine Requirements:

  • 100.21.000.1120 version or higher
  • UMC-500 Built 3/18/2022 and later with Auto Window Option, 90 Degree Control Cabinet, Haas Workholding Ready.
  • UMC-750 Built 4/16/2022 and later with Auto Window Option, 90 Degree Control Cabinet, Haas Workholding Ready.
  • UMC-1000 Built 1/19/2022 and later with Auto Window Option, 90 Degree Control Cabinet, Haas Workholding Ready.
  • Remote Jog Handle - XL 93-1000610 REMOTE JOG HANDLE TOUCH LCD (RJH-XL)
  • I/O PCB HINGE DOOR 93-1000297 I/O DOOR ASSY HINGED
  • Requires separate 200-230V 3-Phase, 50/60 Hz, 3 kVA Power Supply[7]. See the Fanuc STARTUP GUIDE for more information.

Fixing / Anchoring Requirements

The Haas Robot Package 2 needs to be anchored according to Fanuc's recommendation to be sufficiently stable when used according to Haas defined part size and weight limits. See the Robot Anchoring section below.

The Haas Robot Package Includes the following Components:

  • 30-13419 Robot PKG-2 UMC Safety Guard (fencing with gate to enclose the operators station)
  • 32-09942 Gate Interlock
  • 32-0995 RJH Holster Assembly (includes holster and 36' foot cable for remote handle jog with Emergency Stop)
  • 32-8582B  HRP-2 Electrical Interface Box Assembly (Includes robot signals and power cables)

 Note: The parts above are subject to change and there will be some variation depending on build date. 

Robot Lifting

Robot Lifting Requirements

Use this information for lifting/moving Robot Package 2.

The Haas Robot Package 2 needs to be lifted according to Fanuc's recommendation. See the Fanuc Robot M-20iD/25 Mechanical Unit Operator's Manual, Chapter 1, Section 1 Transportation starting on page 1 for lifting/moving information.

HRP-2 Fanuc Robot M-20iD/25 Mechanical Unit Operator's Manual

Robot Installation

1

Table 1[1]

Table 2[2] (optional)

Place the Fanuc Control Box on the back side of the machine next to the control panel[3]. 

Part Flip Station [4].

2

Measure these dimensions from the machine skirt to the edge of the robot base plate.

 Note: The following dimensions are recommended distances. The position may vary depending on the users application.

UMC-500

Place the robot stand in front of the Auto Side Window. The front of the robot base plate should be 17.0 inches from the side of the machine[1]. The left side of the robot base plate should be 9.5 inches from the front of the machine[2].

Table 1 front table bracket should be 13.0 inches from the side of the machine[3]. The left mounting hole of the front table bracket should be 22.0 inches from the front of the machine[4].

Table 2 left mounting hole of the front table bracket should be 37.5 inches from the front of the machine[5]. The right mounting hole of the front table bracket should be 46.5 inches from the front of the machine[6]. The left mounting hole of the front table bracket should be 59.0 inches from the right mounting hole of Table 1 front table bracket[82].

Part Flip Station should be 28.0 inches from the left side of the robot base plate[8]. The front right anchoring hole should be 22.0 inches from the side of the machine[9].

UMC-750

Place the robot stand in front of the Auto Side Window. The front of the robot base plate should be 17.0 inches from the side of the machine[1]. The left side of the robot base plate should be 14.5 inches from the front of the machine[2].

Table 1 front table bracket should be 17.0 inches from the side of the machine[3]. The left mounting hole of the front table bracket should be 13.0 inches from the front of the machine[4].

Table 2 left mounting hole of the front table bracket should be 37.5 inches from the front of the machine[5]. The right mounting hole of the front table bracket should be 46.5 inches from the front of the machine[6]. The left mounting hole of the front table bracket should be 82.0 inches from the right mounting hole of Table 1 front table bracket[7].

Part Flip Station should be 28.0 inches from the left side of the robot base plate[8]. The front right anchoring hole should be 22.0 inches from the side of the machine[9].

UMC-1000

Place the robot stand in front of the Auto Side Window. The front of the robot base plate should be 17.0 inches from the side of the machine[1]. The left side of the robot base plate should be 16.5 inches from the front of the machine[2].

Table 1 front table bracket should be 15.0 inches from the side of the machine[3]. The left mounting hole of the front table bracket should be 15.0 inches from the front of the machine[4].

Table 2 left mounting hole of the front table bracket should be 37.5 inches from the front of the machine[5]. The right mounting hole of the front table bracket should be 46.5 inches from the front of the machine[6]. The left mounting hole of the front table bracket should be 80.0 inches from the right mounting hole of Table 1 front table bracket[7].

Part Flip Station should be 28.0 inches from the left side of the robot base plate[8]. The front right anchoring hole should be 22.0 inches from the side of the machine[9].

3

Robot Anchoring Requirements

The Haas Robot Package 2 Base Plate, Part Table, Fence, and Part Flip Station needs to be anchored to be sufficiently stable when used according to Haas defined part size and weight limits. See the Anchoring Instructions (Drop-In Expansion) for anchoring information.

Anchoring Instructions (Drop-In Expansion)

4

  • 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 in the tool carousel.
  • Program the following steps to the beginning of any  program to make sure the part is properly seated into the chuck:
    • Locate the spring pusher above the part
    • Move the Z axis to compress the spring about 0.50 inches or 12.7 mm
    • Open the vise with a dwell of one second
    • Close the vise with a dwell of one second

Note: The Part Number for the spring pusher is: 

  • 30-12642 SPRING PUSHER APL.  The 25mm or 1.0” holder is sold separately.

Parts Table Assembly

1

The Parts Table needs to be assembled. Follow the procedure below for installation.

Haas Robot - Parts Table Assembly

Shaft Loading Kit Installation

1

To install the HRP-2 Shaft Loading Kit. Follow the procedure below for installation.

HRP-2 - Shaft Loading Kit - Installation

Fence Installation

1

The robot fence, door interlock assembly, and Remote E-Stop needs to be installed with the robot and machine. Follow the procedure below for installation.

Robot Fence Installation
HRP-2 UMC Fence Layout

Attention: The fence anchors will use a 3/8th drill bit, they are NOT the same size as the robot anchors.

2

Install the machine fence panels together.

Install the fence panel assembly to the fence post with the self tapping screws. The top of the fence panel assembly should be 14.5 inches from the top of the fence post. 

Install the fence panel assembly to the side of the machine with the self tapping screws. The location installed will depend on the machine and fence location

3

Install the control panel fence panels together. Install the fence panel assembly to the 90 degree control panel channel.

Install the fence panel assembly to the fence post and side of the machine with the self tapping screws. The location installed will depend on the machine and fence location

Robot Electrical - Installation

 Caution: When you do maintenance or repair on CNC machines and their components, you must always follow basic safety precautions. This decreases the risk of injury and mechanical damage.

  • Set the main circuit breaker to the [OFF] position.

 Danger: Before beginning any work inside the control cabinet the High Voltage indicator light on the 320V Power Supply / Vector Drive must have been off for at least 5 minutes.

Some service procedures can be dangerous or life-threatening. DO NOT attempt a procedure that you do not fully understand. If you have any doubts about doing a procedure contact your Haas Factory Outlet (HFO) and schedule a service visit.

1

UMC Robot Interface Mounting Location

The Robot electrical interface box has magnetic mounts to attach to the machine sheet metal.

Mount the Robot electrical interface box [1] as shown.

Route the Robot interface electrical cables through the bottom of the electrical cabinet.

2

Pendant Access Cover

Remove the plug installed on the Pendant Access Cover and install the rubber grommet.

If the Pendant Access Cover does not have the access hole, drill a 0.75" hole in the end of the cover.

3

UMC Robot Electrical & Air Routing

Route cable 33-1134 [1] from the RJH Holster along the fence to the Pendant Access Cover grommet to the SKBIF PCB.

Route cable 33-1135 [2] from the Interlock along the fence and machine skirt with the magnet mounts to the Electrical Interface Box.

Route cable 33-8561C [3] from the Electrical Interface Box along the 90 Degree Control Panel channel to Control Panel.

Route air hose [4] from the Air Regulator along the machine skirt to the Calm Cabinet.

Coil the extra cable from the Fanuc Control Box to the Robot and zip tie the coil to the magnet mounts to attach to the back of the machine off the ground.

4

Turn the machine air supply OFF.

Inside the CALM cabinet, remove a NPT plug from one of the CALM manifold ports.

The Robot Gripper Air Regulator has magnetic mounts to attach to the machine sheet metal.

Mount the Robot Gripper Air Regulator to the machine skirt below the pendant.

Route the air line from the right side of the regulator along the side skirt of the machine to the CALM cabinet and install the push to connect fitting.

Route the air line from the left side of the regulator to the Air 1 port on the robot and install to the push-to-connect fitting.

Turn the machine air supply ON.

5

Perform the following steps to connect the robot to the Haas machine.

Robot Power

Requires separate 200-230V 3-Phase, 50/60 Hz, 3 kVA Power Supply[7]. See the Fanuc Startup Guide for more information.

 Note: It is recommended to install a strain relief cable grip to remove stress on the power cable connections and isolate the power cable from the controller cabinet.

Cable P/N 33-8561C has multiple connections:

I/O PCB

  • Connect the E-STOP terminal block connections to SIO PCB TB-1B (see diagram)[1].
  • Verify the jumper is installed on the SIO PCB at JP1.
  • Connect the Setup mode terminal block connections to SIO PCB TB-3B (see diagram)[1].
  • Plug the User Relays into K9 and K10.  (see diagram)[11].
  • Connect the cable labeled P1 SIO to the SIO PCB at P1[2].

Note: Do not plug anything into the connector FILTER OV FAULT.

Maincon PCB

  • Connect the RJ-45 cable [3] to Ethernet to USB adapter [4] (P/N 33-0636). Connect the USB connector end to the Maincon PCB J8 top port (see diagram). Add a ferrite filter 64-1252 to the USB adapter.
PSUP PCB
  • Mount the 24VDC Power Supply[10] to the left side of the control cabinet and plug into connector labled 24V PS on cable 33-8561C. Connect cable 33-1910A[9] to the 24VDC Power Supply[10] and plug into P3 on the PSUP PCB.

SKBIF to Remote Jog Handle

  • Connect the RJ12 cable 33-1134[5] from the Remote E-stop box to cable 33-0713 and plug into the SKIBF PCB P9.
  • Remove the jumpers JP2 and JP3 on the SKBIF from the horizontal position and replace them in the vertical position.
  • Plug the RJH-XL cable into the cradle.

 Warning: By not putting the jumpers in the vertical position, E-STOP functionality on the RJH-XL is disabled and the machine is considered unsafe. Jumpers MUST be inserted vertically.

Robot Electrical Box to Robot Control

  • Connect the Robot Control Signal Cables [6] P/N 33-8592A to the Robot Electrical Interface Box. Add a ferrite filter 64-1252 to the RJ-45 cable.

 Note: If cable 33-8591A or 33-8592A is not installed to the Fanuc Control box, see the HRP Troubleshooting Guide Robot Control Wiring HRP-2/3 step for wiring instructions.

Fence Interlock

  • Connect the fence door interlock cable [8] to the electrical interface box.

First Power-UP

1

Locate the Mode Switch on the Controller Operator Panel. The keu should be set to Auto Mode[2].

Make sure the [E-STOP] button[3] is not pressed.

Turn on the Robot Control box by rotating the Breaker clockwise to On[1].

2

Turn on the Haas CNC.

Zero Return all Axes.

Insert Service USB key.  Go into Service mode.

Go to Parameters> Factory tab.  Change the following:

  • 1278 [1278:] Robot Ready E-Stop Enabled to TRUE
  • 2191 [694:] LIGHT CUTAIN TYPE to LC_TYPE_1

Note: Machines with Software Version 100.20.000.1010 or higher will need to change the following parameter:

  • 2192 [:] Light Curtain Trigger Threshold to 0

Press [SETTING].

Set the Settings:

  • 372 Parts Loader Type to 3: Robot.
  • 376 Light Curtain Enabled to On

 

3

Press [CURRENT COMMANDS].

Go to Devices>Robot>Jogging tab. Change the following:

  • Maximum Jogging Speed to 7.9 in/sec (200 mm/sec).

Go to the Setup tab. Change the following:

  • Max Robot Speed to 78 in/sec (1981 mm/sec). 
  • Gripper Net Mass to 7.0 lbs.
  • Number of Grippers to the number of grippers.
  • Raw Gripper Clamp Output to 1.
  • Raw Gripper Unclamp Output to 2.
  • Raw Gripper Clamp Delay to the clamp/unclamp duration in sec.
  • Raw Gripper Clamp Type to OD/ID.

4

Press [CURRENT COMMANDS].

Go to Devices>Robot>Setup tab[1].

Press [E-Stop].

Press [F1] to connect the robot[2].

The first time connecting a robot to a machine, a Robot Activation window will pop-up. This pop-up shows the Software Version of the machine[3], the MAC address of the robot[4], and the Machine Generated Code[5] used for Machine Time Extension on the portal.

To activate the robot, enter the F Number[6] and Unlock Code[7].

The F Number is found on the robot ID tag that is on the control panel door or on the robot arm.

The Unlock Code is generated after completing the Robot Installation on the Haas Business Center.

For Service Activation. In Service Mode, Press [INSERT] to connect the robot. This will be disabled after a Cycle Power.

Note: This step can only be completed by a HFO Service Technician.

Note: The green button on the control box will light up.

5

Press the [HANDLE JOG] button. 

Press the [CURRENT COMMANDS]  and go to Devices > Robot > Jogging tab.

On the Remote Handle Jog Touch press the Joint button to go into the Joints Coordinates.

Jog the robot from its shipping position to a safe position.

Note: Press [Emergency Stop] before working on the robot.

Note: Turn off the machine air by turning the valve in the Air/Lube cabinet and pull the pressure relief valve to release the air in the system.

Gripper Assembly

1

Install the gripper to the robot end effector mounting face.

2

Route the air lines between the solenoid on robot arm and the gripper. Connecting the airlines to the corresponding color coded fittings. Install conduit to each pair of air lines. 

 Note: Turn on the machine air by turning the valve in the CALM cabinet.

Verification

Test the E-stop:

  • Press the Pendant and External E-STOP buttons and make sure the machine generates 107 EMERGENCY STOP alarm.  If the E-STOP button does not generate a 107 EMERGENCY STOP alarm verify the wiring. Load the latest configuration files to enable the RJH-XL.

Test the Gate Interlock on the Fence:

  • With the key inserted in the interlock, the two red LED lights in the front of the interlock should be off. 
  • On the Haas pendant, there should not be any E-stop or light curtain/fence alarms or icon triggered.
  • Remove the key from the interlock. The two red LED lights should turn on and a warning should appear on the Haas pendant for light curtain/fence.
  • Check the light curtain/fence icon show on the screen.  If the icon does not show, verify wiring, alingment and factory setting: 2191 [694:] LIGHT CUTAIN TYPE is set to LC_TYPE_1.

Test the operation of the grippers:

  • Verify the gripper clamps and unclamps correctly.
  • Press the [CURRENT COMMANDS]  and go to Devices > Robot > Jogging tab.
  • Press [F3] to clamp/unclamp the Raw Gripper.

Test the Remote Jog Handle:

  • Undock the Remote Jog Handle
  • Press the [HANDLE JOG] button. 
  • Press the [CURRENT COMMANDS]  and go to Devices > Robot > Jogging tab.
  • On the Remote Handle Jog press the Joint button to go into the Joints Coordinates.
  • Move the robot to a safe location.

Verify Safe / Run Mode Operation

All Haas CNC machines are equipped with a key switch on the side of the control pendant to lock and unlock setup mode. The robot will have the following behaviors depending on what mode is selected. 

  • When the Haas control is in Run mode, mode 1, unlocking the interlock and opening up the gate stops all motion, and no motion can be started until it is closed and locked.
  • When the Haas control is in Set up mode, mode 2, speed limited motion such as jogging an axis of the robot can be performed in order to program a robot's path of motion, pick up position, set a robot's tool center point, (an offset), load and pick up parts from the spindle or part holder in the machine, etc. The programmed path will also be able to be run slowly to prove out the programmed path of the robot.

FANUC Dual Check Safety (DCS) – Setup

Each Haas Robot is provided with FANUC's DCS System. This allows the user to define speed and positional limits to the robot. If the robot goes outside of these limits, DCS will stop the robot and remove power to the motors.

This procedure will show you how to set up a Fanuc Dual Check Safety (DCS) zone.

FANUC Dual Check Safety (DCS) – Setup

Haas Robot - Quick Start Guide

After installing the robot, set up a job following the procedure below.

Haas Robot - Quick Start Guide

Disable the Robot

To disable the robot 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
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