1 - HRP - Introduction

1.1 Service Manual Disclaimer
1.2 Introduction
1.3 Documentation Guide

Service Manual - Disclaimer

You should not do mechanical or electrical machine repairs or service procedures unless you are qualified and knowledgeable about the processes.

Only authorized personnel with the proper training and certification should do many repair procedures.

WARNING: Some mechanical and electrical service procedures can be extremely dangerous or life-threatening. Know your skill level and abilities.

All information herein is provided as a courtesy for Haas machine owners for reference and illustrative purposes only. Haas Automation cannot be held responsible for repairs you perform. Only those services and repairs that are provided by authorized Haas Factory Outlet distributors are guaranteed.

Only an authorized Haas Factory Outlet distributor should service or repair a Haas machine that is protected by the original factory warranty. Servicing by any other party automatically voids the factory warranty.

Haas Robot Package - Introduction

Use this service manual to install and service the Haas Robot Package on Haas machines.

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

Robot is controlled by the CNC it is paired with. It does not respond to any external commands as it could cause hazardous conditions. Do not leave a network connection plugged into the robot controller. No remote control is permitted.

Run Mode

When in Run mode, unlocking the interlock and opening up the gate stops all motion, and no motion can be started until it is closed and locked.

Setup Mode

In Set up mode, 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 robot program will also be able to be run slowly to prove out the programmed path of the robot.

Note: The max robot speed in setup mode is 7.9 in/sec (200mm/sec).

Robot Motion

Manual motion is only permitted in set up mode and is recommended only with limited speed of motion. High speed is permitted but 500mm clearance for the safety of the operator is required. This requires the set up and verification of DCS/keep out zone(s).

Warning: Startup of automatic motion with someone in the fenced in area is controlled by the operator. The hazardous area is visible from the remote jog pendant outside of the fenced in area surrounding the robot. Verify nobody is in the fenced in area before starting an automatic operation.

Lighting

Level of task lighting required for the robot installation is to be provided by the end user. The robot does not require any lighting. But, light will be required for a user to load or unload parts or to perform maintenance, or service.

Haas Robot - FANUC Dual Check Safety (DCS)

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.

Note: Verify proper setup of the DCS zones at the time of robot installation and every 6 months. It should also be verified after a new job has been set up. Scan the code below with your mobile device to go directly to the procedure.

Operation

Recommendation of PPE including but not limited to gloves to protect from sharp edges and chips, eye glasses for eye protection, steel toed shoes etc. when handling parts or loading/unloading parts for the robot to handle.

Warning: Loss of air pressure may cause the gripper to allow a part being held to slip or be dropped. Users should review grippers that they purchase and determine how they will respond to a loss of power or air pressure, so they know how to minimize any potential hazard.

Robot Work Piece Limits

The operator is responsible for ensuring that the setup and operation of the robot is safe.

The robot has a maximum payload capacity of 7 kg (15.4 lbs). The weight of the workpiece and grippers must be less than the capacity.

Center the gripper fingers to the part. The part most securely gripped during robot motion. If the part is incorrectly gripped the part may be dropped.

The air regulator controls the gripper grip force. Adjust the regulator to the correct pressure for your setup.

If the speed of the robot is causing the part to be dropped,. Lower the speed or custom gripper fingers will be needed to secure the part.

Part Table Template Layout

The operator is responsible for ensuring that the setup and operation of the robot is safe.

The part table template provides the necessary alignment of the parts. If the parts are misaligned along a row or column, this can cause the gripper to crash into the part.

Center the parts against the edge of the lobes of the part table template to ensure correct alignment.

Handling

Requirement:

Where to Find:

Storage conditions for the individual machines.

Haas Operator’s Manuals section 1.1.3, Machine Environmental Limits:

Mill Operator's Manual

Lathe Operator's Manual

Fanuc Safety Handbook Section 3.2

FANUC Robot LR Mate 200iD Operator’s Manual Section 1.1

Dimensions, mass value(s), position of the center(s) of gravity;

Indications for handling (e.g. drawings indicating application points for lifting equipment).

See Robot Lifting section:

Haas Robot Package 1 – Lathe – Installation

Haas Robot Package 1 – Mill _ Installation

Installation

Requirement:	Where to Find:
Fixing/anchoring and vibration dampening requirements;	See Introduction section: Haas Robot Package 1 – Lathe – Installation Haas Robot Package 1 – Mill _ Installation
Assembly and mounting conditions;	See Robot Installation section: Haas Robot Package 1 – Lathe – Installation Haas Robot Package 1 – Mill _ Installation
Space needed for use and maintenance;	See Layout Drawing section: Haas Robot Package-1 product page.
Permissible environmental conditions (e.g. temperature, moisture, vibration, electromagnetic radiation);	Haas Operator’s Manual section 1.1.3, Machine Environmental Limits: Mill Operator's Manual Lathe Operator's Manual
Instructions for connecting the robot system to power supplies (particularly about protection against electrical overloading);	See Robot Electrical - Installation section: Haas Robot Package 1 – Lathe – Installation Haas Robot Package 1 – Mill _ Installation
Advice about waste removal/disposal;	Robot is a parts handeling device.
If necessary, recommendations about protective measures which have to be taken by the user; [e.g. additional or interim safeguards (see ISO 12100), safety distances, safety signs and signals];	No additional requirements or signs.
Instructions for how the initial test and examination of the robot system and its guarding system are to be carried out before first use and before being placed into production, including functional testing of reduced speed control.	See Verification section: Haas Robot Package 1 – Lathe – Installation Haas Robot Package 1 – Mill _ Installation

Initial Start-up Procedures

Requirement:	Where to Find:
Before applying power, verify that:
the robot has been properly mechanically mounted and is stable; the electrical connections are correct and the power (i.e. voltage, frequency, interference levels) is within the specified limits; the proper electrical earth (equalizing potential) is provided; the safety-related parts of the control system are properly installed; the other utilities (e.g. water, air, gas) are properly connected and within specified limits; the peripheral equipment including interlocks is properly connected; the limiting devices that establish the restricted space (when utilized) are installed; the appropriate safeguarding means are applied;	See Verification section: Haas Robot Package 1 – Lathe – Installation Haas Robot Package 1 – Mill _ Installation
The physical environment is as specified (e.g. lighting and noise levels, temperature, humidity, atmospheric contaminants);	Haas Operator’s Manual section 1.1.3, Machine Environmental Limits: Mill Operator's Manual Lathe Operator's Manual
The proper version of all programs – normal control and safety-related – have been validated and are the versions that are installed (engineering change management);	Requires Software version 100.20.000.1000 as a minimum. Haas Robot Package 1 – Lathe – Installation Haas Robot Package 1 – Mill _ Installation
After applying the power, verify that:
the start, stop and mode selection (including the key lock switches) control devices function as intended; each axis moves and is restricted as intended; emergency stop and protective stop (where included) circuits and devices are functional; it is possible to disconnect and isolate the external power sources; all safeguards, protective devices, enabling devices, and interlocks function as intended. all other safeguarding is in place (e.g. barriers, warning devices); in manual mode, the robot operates properly and can handle the product or workpiece;	See Verification section: Haas Robot Package 1 – Lathe – Installation Haas Robot Package 1 – Mill _ Installation Haas Robot - Fanuc Dual Check Safety (DSC) - Setup
The teach and playback capabilities function correctly;	Fanuc "Teach" and "Playback" Not Available
Environmental conditions are considered for compatibility [e.g. explosion, corrosiveness, humidity, dust, temperature, electromagnetic interference (EMI), radio frequency interference (RFI) and electrostatic discharge (ESD)];	Haas Robot Package-1 product page.
In automatic (normal) operation, the robot operates properly and can perform the intended task at the rated speed and load.	Haas Robot - Quick Start Guide

System Information

Requirement:	Where to Find:
Detailed description of the system, its fittings, its guards and/or protective devices;	Haas Robot Package 1 – Lathe – Installation Haas Robot Package 1 – Mill _ Installation
Comprehensive range of applications for which the robot system is intended, including prohibited usages, if any, taking into account variations of the original robot system, if appropriate;	Haas Robot Package-1 product page. Fanuc Safety Handbook Section 2.1
Safety requirements specification describing the safety functions performed by the control system and their safety integrity, discrete stopping circuits, safety controllers and safe communications;	Contact your Local Haas Factory Outlet.
Other controller functions, operator panels, teach pendants, enabling devices and awareness indicators;	Haas Robot Package 1 – Lathe – Installation Haas Robot Package 1 – Mill _ Installation
Diagrams (layout, control, electrical, hydraulic, pneumatic, etc.);	Interface wiring diagrams see Robot Electrical - Installation section: Haas Robot Package 1 – Lathe – Installation Haas Robot Package 1 – Mill _ Installation
Data concerning other hazards, for example, radiation, gases, vapors, dust and vibration generated with reference to the measuring methods used;	Depends on customer’s specific application, no flammable or explosive applications permitted, per Haas Operators Manual
Technical documentation about electrical equipment (see IEC 60204 series);	Fanuc Safety Handbook Section 4
Specifications for equipotential bonding requirements (grounding). Electrical ground (equalizing potential) shall be provided in accordance with IEC 60204-1;	Haas Robot Package 1 – Lathe – Installation Haas Robot Package 1 – Mill _ Installation
Documents attesting that the robot system complies with mandatory requirements;	Fanuc Safety Handbook Section 2.3 and Section 7. HAAS Declaration of Conformity. See Risk Assessment for HRP1
Modifications made to the protective measures that were originally provided with the component machines;	Haas machine and robot System is sold as a complete cell, changes or modifications are the responsibility of the user/integrator to verify compliance to applicable standards and safety requirements.
End-effector (end of arm tooling) load analysis, behavior in event of energy loss, human intervention considerations, maintenance and intended life;	FANUC Robot LR Mate 200iD Operator’s Manual Section 3.4 Haas Robot - Quick Start Guide
Interface requirements to other machines;	N/A Haas provides a complete work cell solution.
Location of dynamic limiting zones;	Haas Robot - Fanuc Dual Check Safety (DSC) - Setup Haas Robot Package-1 Layout Drawing.
Intended life of the system.	Depends on use and application.

Use of the System

Requirement:	Where to Find:
Residual risk, those risks that could not be eliminated by the protective measures taken by the designer;	Haas Operator’s Manuals Door Rules - Run/ Setup Mode section: Mill Operator's Manual Lathe Operator's Manual
Particular risks that may be generated by certain applications, by the use of certain fittings, and about specific safeguards that are necessary for such applications;	Haas Robot - Fanuc Dual Check Safety (DSC) - Setup
Reasonably foreseeable misuse and prohibited usages;	Haas Operator’s Manuals: Mill Operator's Manual Lathe Operator's Manual
Material flow;	See Layout Drawing section: Haas Robot Package-1 product page.
Intended use; (Parts Loader)	Haas Robot Package-1 product page. Haas Robot Interface
Task zones and associated residual risks (see ISO 11161); Operator tasks, locations and routes to perform the tasks;	Haas Operator’s Manuals: Mill Operator's Manual Lathe Operator's Manual Haas Robot - Quick Start Guide
Spans of control of the various control and protective devices (see ISO 11161) (e.g. protective devices, reset of protective devices, enabling devices, emergency stops, control stations, disconnecting means);	N/A Haas CNC Control is the master controller and controls the Fanuc Control, the slave controller.
Description of manual controls (actuators), enabling devices, protective stops;	Haas Operator’s Manuals: Mill Operator's Manual Lathe Operator's Manual Haas Robot - Quick Start Guide
Setting and adjustment;	Haas Robot - Quick Start Guide
Modes and means for stopping (especially emergency stop);	Haas Operator’s Manuals: Mill Operator's Manual Lathe Operator's Manual Haas Robot Package 1 – Lathe – Installation Haas Robot Package 1 – Mill _ Installation
Fault identification and location, repair, and re-starting after an intervention;	Haas Robot - Troubleshooting Guide Haas Robot - Quick Start Guide
Personal protective equipment that needs to be used and training required;	Haas Operator’s Manuals: Mill Operator's Manual Lathe Operator's Manual Haas Robot - Quick Start Guide
Instructions for any test or examination necessary after change of component parts or addition of optional equipment (both hardware and software) which can affect the safety functions; Service to be performed by the Haas Factory Outlet.	Haas Robot - Troubleshooting Guide Haas Robot - Quick Start Guide
Instructions that disconnected pendants shall be removed from access;	N/A Removing Remote Jog Handle renders the Robot and CNC inoperable.
Instructions for fault and emergency recovery of system equipment;	Haas Robot - Troubleshooting Guide Haas Robot - Quick Start Guide Fanuc R30IB Plus Maintenance Manual Appendix E.
Training requirements for remote control operations;	n/a no remote control permitted
Storage locations or design of unused cableless pendants to prevent use of an inactive emergency stop;	n/a no cables pendants
Requirements for periodic functional testing of safety-related equipment;	Haas Operator’s Manual (Lathe and Mill) Section 1.1.2 Mill Operator's Manual Lathe Operator's Manual Haas Robot - Quick Start Guide
Guidance on correct selection, preparation, application, and maintenance of process unique expendables.	Haas Operator’s Manuals: Mill Operator's Manual Lathe Operator's Manual Haas Robot - Quick Start Guide

Maintenance

Requirement:	Where to Find:
Nature and frequency of inspections for safety functions;	Haas Operator’s Manuals: Mill Operator's Manual Lathe Operator's Manual FANUC Robot LR Mate 200iD Operator’s Manual Section 7.1 & Appendix A
Instructions relating to maintenance operations which require a definite technical knowledge or particular skills and hence should be carried out exclusively by skilled persons (e.g. maintenance staff, specialists);	Haas Operator’s Manuals: Mill Operator's Manual Lathe Operator's Manual (No User Repairs, Contact the Haas Factory Outlet). FANUC I/O Unit Model A Connection and Maintenance Manual Section 2
Instructions relating to maintenance operations (e.g. replacement of consumable parts) which do not require specific skills and hence may be carried out by users (e.g. operators);	Haas Operator’s Manuals: Mill Operator's Manual Lathe Operator's Manual (No Consumable Parts) FANUC Robot LR Mate 200iD Operator’s Manual Section 7.1-4, 7.1-74
Drawings and diagrams enabling maintenance personnel to carry out their task rationally (especially fault-finding tasks);	Haas Operator’s Manuals: Mill Operator's Manual Lathe Operator's Manual (No Consumable parts) FANUC Robot LR Mate 200iD Operator’s Manual Section 7
Information to replace safety-related parts (e.g. manufacturer part number, specification of the parts);	FANUC Robot LR Mate 200iD Operator’s Manual Section 7.3 & Appendix A Haasparts.com or contact your local Haas Factory Outlet.
Contact information for the manufacturer(s) to allow for replacement of parts;	Haas Operator’s Manuals: Mill Operator's Manual Lathe Operator's Manual Haasparts.com or contact your local Haas Factory Outlet. FANUC Robot LR Mate 200iD Operator’s Manual Cover Page Fanuc Safety Handbook Section 8 Fanuc Robot LR Mate 200ID Maintenance Manual Appendix A.
Tasks that require energy control and isolation;	n/a, Service performed only by Haas certified service personnel, there are no user serviceable parts or functions beyond maintenance items noted in the Haas Operators Manual
Safe working practice for manual suspension of safeguards.	N/A No Suspension of Safegaurds.

Emergency Situations

Requirement:	Where to Find:
Type of fire-fighting equipment to be used;	No flammable materials or coolants permitted. Haas Operator’s Manuals: Mill Operator's Manual Lathe Operator's Manual
Warning about possible emission or leakage of harmful substance(s);	N/A
Means to fight their effects (if practicable).	N/A
Information in accordance with ISO 9946;	FANUC Robot LR Mate 200iD Operator’s Manual
Information in accordance with Part 1;	FANUC Robot LR Mate 200iD Operator’s Manual
Where applicable, information on manual high-speed control using the pendant;	No high speed in set up mode
Instruction on installation of limiting devices, including number, location and degree of adjustment of hard stop capability, including instructions on the number, location and implementation of any non-mechanical limiting devices, and capabilities of dynamic limiting, when included;	Haas Robot - Fanuc Dual Check Safety (DSC) - Setup
Information on the number and operation of enabling devices and instructions for installation of additional devices;	Haas Operator’s Manuals: Mill Operator's Manual Lathe Operator's Manual Haas Robot - Quick Start Guide
Information on the stopping time and distance or angle of the three axes with the greatest displacement and motion;	FANUC Robot LR Mate 200iD Operator’s Manual
The specification for any fluids or lubricants to be used in lubrication, braking, or transmission system internal to the robot;	Haas Operator’s Manuals: Mill Operator's Manual Lathe Operator's Manual Haas Robot - Quick Start Guide
Information defining the limits for the range of motion and load capacity, including maximum mass, position of the center of gravity of the workpiece and work holding fixture;	DNE in Haas Docs FANUC Robot LR Mate 200iD Operator’s Manual
Information on relevant standards the robot or robot system meets, including any that have been certified by a third party;	FANUC Robot LR Mate 200iD Operator’s Manual
When applicable, instructions on synchronized motion of robots and special training necessary for the programmers/operators;	FANUC Robot LR Mate 200iD Operator’s Manual
Instructions on emergency or abnormal movement of the robot without drive power;	FANUC R-30iB Plus Maintenance Manual Section E, Brake Release Unit
Programmed limits established by the use of safety-rated soft axis and space limiting features;	Haas Robot - Fanuc Dual Check Safety (DSC) - Setup
For robot systems designed for collaborative operation, declaration that the robot is suitable for integration as a collaborative robot, with a reference to 5.11 that identifies the requirements met and type of operations.	N/A No Collaborative Operation.

Marking

Requirement:	Where to Find:
The business name and full address of the manufacturer and, where applicable, his authorized representative,	Robot arm base, front of control box
Designation of the machinery,	Robot arm base, front of control box
Designation of series or type,	Table supporting robot arm
Serial number, if any,	Robot arm base, front of control box
The year of construction, that is the year in which the manufacturing process is completed,	Robot arm base, front of control box
If machinery is designed and constructed for use in a potentially explosive atmosphere, it shall be marked accordingly.	N/A No flammable or explosive parts, coolants or chips noted in operator's manual.

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